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REFERENCE TO PRIOR PROVISIONAL APPLICATION
This application claims the benefit of Provisional Application No. 60/051,770 filed Jul. 7, 1997.
BACKGROUND OF THE INVENTION
The tower guillotine cigar and cutter of this invention is used to cut off the end of a cigar, or the burning end of a cigar, so the smoker can either light or relight the cigar at a later time. There are many ways in which the end of a cigar may be removed, which go all the way from biting off the end of the cigar to using a knife to cut off the cigar end, or to use hand-operated cutters, or to even use a guillotine cigar-end cutter, such as illustrated in the French patent to George Lalanne, No. 2,390,115, issued on Aug. 12, 1978. However, the operation of these known cutters are different from this invention, and are often very dangerous to use. Cutting off the end of a cigar when the cigar is lit, requires some dexterity. Using a knife to cut off the end of a cigar as well as using the hand-operated cutters, or even the known guillotine cutter, can damage and sometimes ruin the cigar, by excessively spreading the end of the cigar more than desired.
The use of the known guillotine-type cutters as disclosed in the French patent, are also dangerous in use because in such cutters, the guillotine blade is normally positioned in the upper suspended location and is ready for release by merely moving a lever. This can cause the cutting blade to be inadvertently dropped, with the blade then passing through the upper and lower block members that are positioned at the bottom of the guillotine. These blocks further form a fixed horizontal hole through which the cigar end is projected. It can be easily understood that when the blade is in the upper position, that any inadvertent release of the blade may remove a users fingers. This inadvertent problem particularly could affect an inexperienced user such as children, who might be enticed as an attractive nuisance, to insert their fingers into the continuous hole through which the end of the cigar is inserted for cutting. Further, the known guillotine cigar end cutters do not have any effective means of locking the guillotine blade from inadvertent operation, and especially when the cutting blade is in the raised position.
SUMMARY OF THE INVENTION
This invention provides a new and unique tower guillotine cigar end cutter which uses a pair of twin towers positioned on a base with a moveable cutting block and blade that moves vertically up and down between the towers. A crossbeam on the upper ends of the towers supports a pulley which is used to raise and lower the moveable cutting blade and block. The rope is connected to the cutting block and blade by a release mechanism that is easily connected and disconnected to the cutting block, and is automatically released when the release mechanism, raising the cutting block and blade, reaches the upper crossbeam member. This operation allows the cutting block and blade to be maintained in normal operation in the non-raised position. Further, an easily operated lock is used to lock the cutting block in the non-operating position. So when it is desired to use the cutter to cut the end off of a cigar, the cutting block is unlocked, and is then raised or pulled by the rope to the point where the releaseable mechanism contacts the crossbeam, releasing the cutting block and blade, and allowing the cutting blade to drop and cut off the end of the cigar. This provides an easy to use, safe release mechanism, that is easily locked so the cutting block cannot be raised or lowered.
It is therefore the object of this invention to provide a new and improved cutting mechanism for cutting off the end of a cigar.
It is another object of this invention to provide an improved guillotine-type cigar end cutter that is easy to use, operates in a new and distinctive manner, and provides safety features in use.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view from the left front of the guillotine cutter;
FIG. 2 is an enlarged sectional view taken on line 2--2 of FIG. 1;
FIG. 3 is a sectional view taken on line 3--3 of FIG. 2;
FIG. 4 is a further enlarged view of a portion of FIG. 2, showing the release of the cutting block;
FIG. 5 is a sectional view taken on line 5--5 of FIG. 3;
FIG. 6 is a front view of the lower portion of the structure, showing the cutting block down, with a security lock engaged;
FIG. 7 is an enlarged view of the security locking pin and key; and
FIG. 8 is a side view, on a reduced scale, showing a storage box or humador incorporated into the base.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, the preferred embodiment of the present invention 10 comprises a base 12 on which is secured in vertical orientation, support columns or towers 14 and 15, with a bridging crossbeam 36. A landing block 24 is positioned between the two columns 14 and 15 and rests on base 12. Each of the columns 14 and 15 have vertical guide slots 26, which receive end guide projections that are at each end of the landing block 24. It is noted that the upper surface of the landing block 24 is flat, and has a slot 42 therein for receiving the cutting blade 22, and further has a curved semi-circular recess 64 on which the cigar rests.
A cutter block 20 has a flat lower surface that conforms with and rests on the upper surface of block 24. The guillotine cutting blade 22 is secured in the block 20, see FIGS. 2 and 3, and is held in position by rivet 21. The cutting block 20 has guide ends 27 which fit in the grooves 26 in columns 14 and 15. See FIG. 5. This provides aligned, vertical movement of block 20 so that when the cutting block 20 is dropped, blade 22 passes into slot 42 in the lower flat surface of block 24, cutting off the end of a cigar. Block 20 then rests on the upper flat surface of the landing block 24. The underside of the cutting block 20 has an arcuate opening 62 to accommodate the cut end of the cigar. A plate 51 is secured by screws to the upper surface of the cutter block 20, and bail 50 is secured or fastened to plate 51. A claw or tong-type releaseable connector 46 is secured to the end of the rope or line 32. Rope 32 is used to raise the cutting block 20 and cutting blade 22, to the crossbeam 36, where the releaseable connector 46 contacts a curved surface 60 in the manner to be described hereinafter, releasing the cutter block 20 and blade 115.
Crossbeam 36 has ends 35 and 38, with a circular outer configuration and a longitudinal slot as illustrated in FIGS. 2 and 3 with pulleys or sheaves 40 and 41 located at opposite ends for receiving, passing and supporting the rope or line 32. Also, a pair of pulleys or sheaves 52, are positioned adjacent opening 54 through the crossbeam, to provide aligned positioning of the end of the rope that is fixed to the releaseable connector 46. The end of line 32 can then be directed through either pulley 40 or 41, and its free end will then be connected to either sides of columns 14 or 15, and is secured by wrapping the end of the line around a wing cleat 34.
The releaseable connector 46, has a pair of tongs 56 and 58 and rotatably connects the tongs to the U-shaped bail 50, see FIGS. 2 and 4. The L-shaped tongs 56, 58 each has a claw shaped configuration with the mid part of the upper portion having an intersecting connection that allows rotational movement in the manner of tongs, and rotatably connects the tongs to the U-shaped bracket. The upper arm portions 61 and 63 of the tongs can move towards each other in adjacent planes. The rotational clockwise and counterclockwise movement of the lower L-shaped tongs 56, 58 is limited by the upper U-shaped bracket end of connector 46 as shown in FIG. 2. When line 32 is pulled over the respective pulleys 52 and 40, see FIG. 3, the releaseable connector 46 is moved upwardly, where the upper arms 61 and 63 contact the arcuate lower surface 60 of the crossbeam 36. This forces arms 61 and 63 apart, and thus rotates the tong ends 56 and 58 outwardly, removing the tongs from bail 50 and the block 20 thus falls, causing the cutter blade 22 to pass through slot 42, cutting the cigar that may be positioned in the cigar holder 16, with the end projecting through the circular opening in the landing block 24 formed by the adjacent circular openings 62 and 64 of the cutting block 20. The dish 18 receives the cut end of the cigar. The cutting block 20 may have an inset weight 68 to ensure clean cutting.
A lock device 44, releaseably locks the cutting block 20 in the lower, rest position. Respective holes 74 and 76 in columns 14 and 15, interconnect with holes 84 in the sides of the cutting block 20. The locking pin 44 connects and disconnects by a known slot and groove rotating connection 81. Pin 44 is inserted for example in hole 76, and thus moves the extended, locking pin 80 into hole 84 of the block 20, thus locking block 20 from vertical movement. Then the housing end 45 of the locking pin 44, is rotated in a manner to disconnect from pin 80, leaving the locking pin 80 in position. This forms a lock and key arrangement for selectively locking and unlocking cutting block 20 in the normal, safe, resting position.
In Operation
In operation of the guillotine cutter for cutting tips off the ends of cigars, the locking key is rotated to remove the extension lock pin 80 from hole 84 in the cutting block 20. The operator of the cutter will then engage the lifting claw or tongs connector by slipping the two tongs 56, 58 under the loop of the bail 50. This is accomplished by hooking one of the tongs of the claw while keeping tension on the line attached to the connector 46. The other tong will then easily slide into the loop, at which time the operator will be able to lift the cutter block from the landing block 24 to the height where the operator may insert a cigar into the cutting area, locating the end of the cigar to wherever the desire is to cut the end off of the cigar. The operator may secure the end of the line 32 to one of the bits 34 on either side of the guillotine for convenience, if the cutting block 20 is to be left in the open position while selecting a cigar, for example. A cigar is laid in the support 16 with the end to be cut extending over the opening 64 in the landing block 24.
When the operator is ready to drop the cutting block 20, a gentle pull on the rope 32 is made until the lifting release connector 46, namely arms 61 and 63, hits the curved under surface 60 of the crossbeam 36, which will cause the arms 61 and 63 to separate, disengaging the tongs 56, 58 from the cutter block 20 and allowing it to fall, cutting the cigar at the point of the user's decision. It is noted that each of the openings 62 and 64 have outwardly widened surfaces to allow the end of the cigar to fall easily into the dish 18, and also not to damage the remaining part of the cigar adjacent the cut end.
When not in use, the locking pin 80 is inserted into the respective locking holes 84 with the end 44 of the tubular housing 45 abutting the shoulder of hole 76 locking the cutting block 20 in the lower position. The key end of the locking device 44 is then rotated, and removed from the hole, thereby preventing use by others of the guillotine cutting blade in a manner that might injure someone.
FIG. 8, illustrates the entire guillotine cutting device as supported by base 12, with base 12 forming the lid of a cigar box 86, which lid is pivoted on a normal piano hinge 88.
Having described a preferred embodiment of this inventions, it should be apparent to those skilled in the art that my invention may be modified in both arrangement and detail. Therefore the protection afforded my invention should be limited only in accordance with the scope of the following claims:
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A tower guillotine cigar end cutter has spaced twin towers with an upper crossbeam on a base, with a moveable cutter block and blade that is raised vertically by a rope, between the towers. Upon release, the cutting blade and block falls on a lower block having a channel for the blade, thereby cutting the end off a cigar. The cutter block has adjacent half-circle openings for receiving a cigar end. The moveable cutter block when raised by a rope is released when a release mechanism on the rope, contacts the crossbeam. A locking device locks the cutter block from being vertically moved from the lower block, when not in use.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This patent application claims benefit of U.S. provisional patent application serial number 60/194,443 filed Apr. 4, 2000.
FIELD OF THE INVENTION
[0002] The invention relates to a method and dual reactor system for hydrotreating a wide cut cat naphtha stream comprising heavy cat naphtha (HCN) and intermediate cat naphtha (ICN). Accordingly, a HCN fraction is hydrotreated under non-selective hydrotreating conditions and an ICN fraction is hydrotreated under selective hydrotreating conditions. The hydrotreated HCN and ICN effluents may be conducted to heat exchangers to pre-heat the ICN feed, obviating the need for a furnace.
BACKGROUND OF THE INVENTION
[0003] The need for low-emissions, high-octane fuels has led to a need for fuels processes that diminish the concentration of sulfur-containing species in the fuel without substantially changing the fuel's octane number.
[0004] Conventional fuel processes for sulfur removal include contacting a naphtha with a catalyst in the presence of hydrogen under catalytic conversion conditions. One such technique, called catalytic hydrodesulfurization (HDS), involves reacting hydrogen with the sulfur compounds in the presence of a catalyst. HDS is one process within a class of processes called hydrotreating, or hydroprocessing, involving the introduction and reaction of hydrogen with various hydrocarbonaceous compounds. Hydrotreatment has been used to remove sulfur, nitrogen, and other materials such as metals.
[0005] Cracked naphtha obtained as a product of, for example, fluid catalytic cracking, steam cracking, thermal cracking, or coking may contain a significant concentration of sulfur up to as much as 13,000 ppm. Although the cracked naphtha streams constitute approximately half of the total gasoline pool, cracked naphtha contributes a substantially higher percentage of undesired sulfur to the gasoline pool. The remainder of the pool typically contains much lower quantities of sulfur.
[0006] Hydroprocessing cracked naphtha typically results in a product having a diminished concentration of olefinic species and non-hydrocarbyl species such as sulfur-containing species, and an augmented concentration of saturated species. Relatively severe hydroprocessing conditions are generally required to substantially remove sulfur-containing species, and such severe hydroprocessing conditions are known to result in a substantial octane number reduction in the hydroprocessed product.
[0007] Some conventional sulfur removal processes attempt to overcome the octane number reduction problem by making use of the non-uniform distribution of olefins and sulfur-containing species across the naphtha boiling range. In a typical naphtha, olefins are most concentrated and the sulfur concentration is relatively low in the fraction boiling between about 90° F. and 1 50° F., i.e., the light cat naphtha or “LCN” fraction. Sulfur species are most concentrated and the olefin concentration is relatively low in the heavy cat naphtha or “HCN” boiling range, typically about 350° F. to about 430° F. Intermediate cat naphtha (“ICN”) typically boils in the range of about 150° F. to about 350° F. and may contain significant amounts of both sulfur species and olefins. Sulfur species in the LCN fraction may be removed by caustic extraction without undesirable olefin saturation, while the ICN and HCN fractions generally require hydrotreating to remove the sulfur.
[0008] In one conventional process, the ICN fraction is hydrotreated under relatively mild conditions in order to lessen the amount of olefin saturation, while the HCN fraction is hydrotreated under more severe conditions. One disadvantage of this approach relates to the complexity and costs associated with operating two independent hydrotreating units and their associated feed pre-heating equipment.
[0009] There remains a need, therefore, for new processes for forming naphtha having a diminished concentration of sulfur-containing species, while maintaining a sufficient olefin concentration to provide a relatively high octane number.
SUMMARY OF THE INVENTION
[0010] In an embodiment, the invention relates to a method for hydrotreating heavy cat naphtha and intermediate cat naphtha streams. The method comprises hydrotreating a heavy cat naphtha feedstream having a HCN initial sulfur content and a HCN initial olefin content under HCN hydrotreating conditions effective to produce an HCN effluent at an elevated temperature having a HCN effluent sulfur content and a HCN effluent olefin content. An intermediate cat naphtha stream at an initial temperature is heated with the HCN effluent, via a heat exchanger for example, and thereby heated from the initial temperature to an increased temperature. The increased temperature ICN stream is hydrotreated under ICN hydrotreating conditions which are less severe than the HCN hydrotreating conditions to produce an ICN effluent having an ICN effluent sulfur content and an ICN effluent olefin content. In a preferred embodiment, the HCN effluent and the ICN effluent are combined, and the combined stream may be subjected to product separation procedures or conducted away from the process for storage or further processing. It is also preferred that HCN hydrotreating conditions be controlled to provide an HCN effluent having a temperature at least about 25° F. higher than the ICN hydrotreater's inlet temperature. More preferably, HCN and ICN hydrotreating conditions are controlled so that the HCN and ICN are both in the vapor phase (i.e., always above the dew point) during the hydrotreating operation.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] [0011]Figure 1A is a dual reaction system used in conventional sulfur removal processes.
[0012] [0012]FIG. 1B is a staged hydrotreater system suitable for use in the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0013] The invention is based on the discovery that ICN and HCN hydrotreating may be integrated in a staged reactor system to provide a low sulfur naphtha without substantially reducing the naphtha's octane number. More specifically, it has been discovered that regulating the HCN hydrotreating reactor conditions to saturate more than about 50 wt. % of the olefins in the HCN results in a HCN effluent temperature in the range of about 525° F. to about 700° F. Further such conditions would result in an effectively desulfurized HCN having a higher effluent temperature than would be achieved at lower levels of olefin saturation. Consequently, when operating under such HCN hydrotreating conditions, heat from the HCN effluent is useful for preheating ICN conducted to the ICN hydrotreater for selective sulfur removal without olefin saturation. Although the ICN and HCN effluent could be treated using two separate trains of separation equipment, the two effluents preferably are combined and treated together using common separation equipment and techniques.
[0014] Preferred naphtha boiling range feed streams are typically those having a boiling range from about 65° F. to about 430° F., preferably from about 150° F. to about 430° F. The naphtha can be any stream predominantly boiling in the naphtha boiling range and containing olefin, such as a thermally cracked or a catalytically cracked naphtha. Such streams can be derived from any appropriate source, for example, they can be derived from the fluid catalytic cracking (“FCC”) of gas oils and resids in a FCC unit (“FCCU”), or they can be derived from delayed or fluid coking of resids, or from steam cracking and related processes. It is preferred that the naphtha feed streams be derived from the fluid catalytic cracking of gas oils and resids. Such naphthas are typically rich in olefins and in some cases diolefins and relatively lean in paraffins.
[0015] The naphtha, preferably a cracked naphtha from a FCCU, generally contains not only paraffins, naphthenes, and aromatics, but also unsaturates, such as open-chain and cyclic olefins, dienes, and cyclic hydrocarbons with olefinic side chains. The cracked naphtha generally comprises an overall olefins concentration ranging as high as about 60 wt. %, more typically as high as about 50 wt. % and most typically from about 5 wt. % to about 40 wt. %. The cracked naphtha sulfur content will generally range from about 0.05 wt. % to about 0.7 wt. %, and more typically from about 0.07 wt. % to about 0.5 wt. % based on the total weight of the feedstock. Nitrogen content will generally range from about 5 wppm to about 500 wppm, and more typically from about 20 wppm to about 200 wppm.
[0016] Preferably, an ICN and a HCN fraction are separated from the naphtha feed stream, for example, by fractionation. Typically, FCCU main fractionators either are designed or can be modified to produce an about 350° F. to about 430° F. HCN side stream and an initial to about 350° F. raw gasoline cut which is debutanized to produce C 5 to about 350° F. FCC light gasoline. The C 5 to about 350° F. FCC light gasoline stream can be fractionated to produce a C 5 to about 150° F. LCN cut and an about 150° F. to about 350° F. ICN cut. The LCN cut may be desulphurized via conventional caustic extraction. Alternately, topping of the debutanized C 5 to about 350° F. gasoline may employ other conventional desulfurizing technology to produce a desulphurized LCN product and a sulfur bearing ICN cut as the feed for the ICN reactor. Preferably the feed to the HCN reactor is the about 350° F. to about 430° F. (or about 325° F. to about 430° F.) cut from the fractionator. The cut point between the LCN and ICN streams can be as low as about 11° F. and as high as about 200° F. The cut point between the ICN and HCN streams can be as low as about 300° F. and high as about 400° F.
[0017] The system of the present invention will be better understood with reference to FIG. 1B. Referring to FIG. 1B, a HCN fraction at a temperature below about 430° F. ( 10 ) preferably is conducted from a FCCU separation zone, such as a fractionater (not shown), to a heater ( 12 ), preferably a fired heater, where the HCN fraction is mixed with hydrogen gas and heated to the desired reaction temperature. The heated HCN fraction then is conducted to the HCN reactor ( 14 ) where the conditions are sufficiently severe to result in more than about 95% HCN desulfurization and more than about 50 wt. % olefin saturation.
[0018] HCN hydrotreating may be conducted under conditions that result in significant olefin saturation during desulfurization, i.e., non-selective hydrotreating conditions. HCN hydrotreater inlet temperature ranges from about 500° F. to about 650° F. HCN hydrotreater operating pressures are maintained at from about 80 psig to about 2000 psig, preferably at from about 200 psig to about 500 psig. Hydrogen treat rates range from about 200 standard cubic feet/barrel (SCF/B) to about 4000 SCF/B, preferably from about 500 to about 2000 SCF/B. The feed rate may vary from about 0.2 LHSV to about 20 aLHSV (liquid hourly space velocity), preferably from about 1 LHSV to about 5 LHSV. Such conditions, result in a HCN effluent having
[0019] (i) more than about 95 wt. % desulfurization and more than about 50 wt. % olefin saturation, the amount of desulfurization and olefin saturation being based, respectively, on the weight of the sulfur and the weight of olefins in the heated HCN fraction;
[0020] (ii) an HCN effluent temperature ranging from about 525° F. to about 700° F.; and
[0021] (iii) a sufficient quantity of HCN effluent that upon heating the ICN hydrotreater feed with the HCN and ICN effluents, the ICN hydrotreater inlet temperature is attained, obviating the need for an ICN preheat furnace.
[0022] HCN hydrotreating may be conducted in one or more hydrotreating reactors in the presence of hydrogen and a catalytically effective amount of a hydrotreating catalyst. As discussed, the HCN may contact or be mixed with hydrogen before heating in heater ( 12 ). Additional hydrogen may also be added directly to the HCN reactor. Hydrogen may be obtained from a hydrogencontaining stream that can be pure hydrogen or can be in a mixture with other components found in refinery hydrogen streams. It is preferred that the hydrogencontaining stream have little, if any, hydrogen sulfide. The hydrogen stream purity should be a least about 50% by volume hydrogen, preferably at least about 65% by volume hydrogen, and more preferably at least about 75% by volume hydrogen for best results.
[0023] The HCN hydrotreating reaction zone can consist of one or more fixed bed reactors, each of which can comprise a plurality of catalyst beds. Some olefin saturation will take place, and olefin saturation and the desulfurization reaction are generally exothermic, consequently interstage cooling between fixed bed reactors, or between catalyst beds in the same reactor shell, can be employed. However, generally it is preferred to retain all of the heat generated from these reactions for use in heating the ICN feed stream.
[0024] Preferred catalysts for HCN hydrotreating include conventional hydrodesulfurization catalysts. Generally, these catalysts comprise a hydrogenation component such as a metal, metal oxide or metal sulfide of a Group VIB and a Group VIII non-noble metal of the Periodic Table of Elements on a suitable support, such as, for example cobalt-molybdenum or nickel-molybdenum on a predominantly alumina support which may further comprise minor amounts of silica or other refractory oxides. The Periodic Table referred to herein is given in Handbook of Chemistry and Physics, published by the Chemical Rubber Publishing Company, Cleveland, Ohio, 45th Edition, 1964. The oxide catalysts are preferably sulfided prior to use.
[0025] The second hydrotreater stage, relating to ICN hydrotreating, will also be described with reference to FIG. 1B. As shown in the figure, an ICN fraction ( 20 ) at a temperature below 400° F. is conducted from the FCCU fractionator (not shown) to a heat exchanger ( 18 b ) where the ICN is heated by effluent from the ICN hydrotreater ( 22 ). As discussed, ICN hydrotreater effluent is used to heat, via a heat exchanger for example, the ICN feed to form a heated ICN. A sufficient amount of HCN effluent at a temperature higher than that of the heated ICN is conducted to a second heat exchanger ( 18 c ) to heat the heated ICN feed to an ICN inlet temperature ranging from about 475° F. to about 550° F., obviating the need for an external heat source such as an ICN pre-heat furnace.
[0026] Preferably, the HCN hydrotreater is operated so that the temperature of the HCN effluent exceeds the ICN hydrotreater inlet temperature by at least about 25° F. Consequently, the amount of heat transferred from the HCN effluent to the ICN may be controlled to provide the appropriate ICN hydrotreater inlet temperature. It should be clear to those skilled in the art that the HCN effluent's effectiveness for preheating the ICN feed is related to the relative temperatures and relative amounts of HCN effluent and ICN feed. Consequently, it is within the scope of this invention to adjust the cut points between the ICN and HCN as well as between the LCN and ICN to regulate the relative amounts, temperatures, and combinations thereof of the HCN and ICN feeds to provide sufficient heat to the ICN feed to reach the desired ICN hydrotreater inlet temperature
[0027] ICN hydrotreating is conducted under selective hydrotreating conditions in order to lessen the amount of olefin saturation during desulfurization. This has the benefit of minimizing the loss of octane number. However, it also reduces the amount of heat generated from olefin saturation lowering the amount of heat available in heat exchanger 18 b . An additional heat from the HCN effluent is added through exchanger 18 c . Selective hydrotreating conditions are generally less severe than the HCN hydrotreating conditions in the first stage of the invention. The use of a selective HDS catalyst is the preferred means by which olefin saturation in the ICN reactor is minimized. Preferably, fewer than 50 wt. % of the olefins, based on the weight of the ICN feed, are saturated in the ICN reactor. More preferably, the inlet temperature of the ICN reactor ranges from about 47° F. to about 600° F., and is at least 25° F. lower than the inlet temperature of the HCN reactor.
[0028] The ICN hydrotreater is preferably operated in the vapor phase at an inlet temperature ranging from about 475° F. to about 600° F., and with an effluent temperature ranging from about 525° F. to about 675° F. Reactor pressures preferably range from about 100 psig to about 300 psig, hydrogen treat rates range from about 1000 SCF/B to about 2500 SCF/B, and ICN feed rates range from about 1 LHSV to about 5 LHSV. Such conditions result in an ICN effluent having a temperature ranging from about 525° F. to about 675° F.
[0029] As in the HCN stage, the ICN hydrotreating may be conducted in one or more hydrotreating reactors in the presence of hydrogen and a catalytically effective amount of a hydrotreating catalyst. The hydrogen may be obtained from sources described in the description of the HCN stage. And as in the HCN stage, the hydrotreater reactor zone may consist of one or more fixed bed reactors, each of which may comprise a plurality of catalyst beds, and interstage cooling between reactors or beds may be employed.
[0030] Preferred hydrotreating catalysts for use in the ICN stage have a relatively high level of activity for hydrodesulfurization in combination with a relatively low tendency to saturate olefins. For example, some conventional hydrosulfurization catalysts typically contain MoO 3 and CoO levels within the ranges of those in the catalyst described herein. Other hydrodesulfurization catalysts have surface areas and pore diameters similar to those of the preferred catalysts.
[0031] One preferred catalyst has the following properties: (a) a MoO 3 concentration of about 1 to 10 wt. %, preferably about 2 to 8 wt. %, and more preferably about 4 to 6 wt. %, based on the total weight of the catalyst; (b) CoO concentration of about 0.1 to 5 wt. %, preferably about 0.5 to 4 wt. %, and more preferably about 1 to 3 wt. %, also based on the total weight of the catalyst; (c) a Co/Mo atomic ratio of about 0.1 to about 1.0, preferably from about 0.20 to about 0.80, more preferably from about 0.25 to about 0.72; (d) a median pore diameter of about 60 Å to about 200 Å, preferably from about 75 Å to about 175 Å, and more preferably from about 80 Å to about 150 Å; (e) a MoO 3 surface concentration of about 0.5×10 −4 to about 3×10 −4 g MoO 3 /m 2 , preferably about 0.75×10 −4 to about 2.5×10 −4 , more preferably from about 1×10 −4 to about 2×10 −4 ; and (f) an average particle size diameter of less than 2.0 mm, preferably less than about 1.6 mm, more preferably less than about 1.4 mm, and most preferably as small as practical for commercial hydrodesulfarization process unit. Most preferred catalysts also have a high degree of metal sulfide edge plane area as measured by the Oxygen Chemisorption Test described in “Structure and Properties of Molybdenum Sulfide: Correlation of O 2 Chemisorption with Hydrodesulfurization Activity,” S. J. Tauster et al., Journal of Catalysis 63, pp. 515-519(1980), which is incorporated herein by reference. The Oxygen Chemisorption Test involves edge-plane area measurements made wherein pulses of oxygen are added to a carrier gas stream and thus rapidly traverse the catalyst bed. For example, the oxygen chemisorption will be from about 800 to 2,800 preferably from about 1,000 to 2,200, and more preferably from about 1,200 to 2,000 μmol oxygen/gram MoO 3 . The terms hydrotreating and hydrodesulfurization are sometimes used interchangeably in this document.
[0032] The catalyst preferably is supported catalyst. Any suitable inorganic oxide support material may be used. Non-limiting examples of suitable support materials include: alumina, silica, titania, calcium oxide, strontium oxide, barium oxide, carbons, zirconia, diatomaceous earth, lanthanide oxides including cerium oxide, lanthanum oxide, neodymium oxide, yttrium oxide, and praseodymium oxide; chromia, thorium oxide, urania, niobia, tantala, tin oxide, zinc oxide, and aluminum phosphate. Preferred supports are alumina, silica and silica-alumina. A most preferred support is alumina. For the catalyst with a high degree of metal sulfide edge plane area, magnesia can also be used.
[0033] The support material may contain a small amount of contaminants, such as Fe sulfates, silica and various metal oxides, which can be present during the preparation of the support material. These contaminants are present in the raw materials used to prepare the support and preferably will be present in amounts less than about 1 wt. %, based on total weight of the support. It is more preferred that the support material be substantially free of such contaminants.
[0034] In one embodiment, the support comprises about 0 to 5 wt. %, preferably from about 0.5 to 4 wt. %, and more preferably from about 1 to 3 wt. %, of one or more additives selected from phosphorous and metals or metal oxides from Group IA (alkali metals) of the Periodic Table of the Elements.
[0035] The metals of the catalyst of the present invention can be deposited or incorporated upon the support by any suitable conventional means, such as by impregnation employing heat-decomposable salts of Group VIB and VIII metals or other methods know to those skilled in the art such as ion-exchange, with impregnation methods being preferred. Suitable aqueous impregnation solutions include, but are not limited to cobalt nitrate, ammonium molybdate, nickel nitrate, and ammonium metatungstate.
[0036] Impregnation of the hydrogenation metals on the catalyst support using the above aqueous impregnation solutions can be performed using incipient wetness techniques. The catalyst support is precalcinized and the amount of water to be added to just wet all of the support is determined. The aqueous impregnation solutions are added such that the aqueous solution contains the total amount of hydrogenation component metal(s) to be deposited on the given mass support. Impregnation can be performed for each metal separately, including an intervening drying step between impregnations, or as a simple co-impregnation step. The saturated support can then be separated, drained, and dried in preparations for calcination. Calcination generally is preformed at a temperature of from about 480° F. to about 1,200° F., or more preferably from about 800° F. to about 1,100° F.
[0037] The invention is an improvement over conventional processes for separately hydrotreating heavy and intermediate catalytically cracked naphtha fractions. In a conventional process, illustrated in FIG. 1A, HCN ( 1 ) from a naphtha fractionator (not shown) is conducted to a furnace ( 2 ) where it is heated to the appropriate reactor inlet temperature. The heated HCN is then conducted to hydrotreater ( 3 ), and the hydrotreated naphtha is conducted away from the process. Similarly, an ICN fraction ( 4 ) is conducted from a naphtha fractionator (not shown) to heat exchanger ( 5 ) where hydrotreated ICN effluent from ICN hydrotreater ( 7 ) preheats the ICN. The pre-heated ICN is then conducted to a furnace ( 6 ) where heat is added to the ICN until it attains a temperature appropriate for the inlet of ICN hydrotreater ( 7 ). Although the ICN hydrotreater may be operated under selective hydrotreating conditions that generally lead to reduced olefin saturation, the high olefin content of the ICN results in sufficient heat generation in ICN reactor ( 7 ) to warrant use of the ICN reactor effluent to provide part of the heat required by the ICN feed in exchanger ( 7 ). However, a furnace ( 6 ), or some other heat generating equipment, would be required to sufficiently heat the ICN further so that it reaches the reactor ( 7 ) inlet temperature.
[0038] This difficulty is overcome in the process illustrated in FIG. 1B because hot HCN effluent from HCN hydrotreater ( 14 ) provides heat to the ICN fraction in heat exchanger ( 18 c ). Conditions in HCN reactor ( 14 ) are regulated so that the hydrotreated HCN effluent is sufficient in quantity and temperature to preheat the ICN feed to the ICN hydrotreater ( 22 ). ICN hydrotreater ( 22 ) is operated under selective hydroprocessing conditions, but with sufficient severity that the heat from its effluent in heat exchanger ( 18 b ) together with the heat from the HCN effluent in heat exchange ( 18 c ) are in total sufficient to overcome the need for furnace ( 6 ) that would be required in the conventional process.
EXAMPLES:
[0039] 1. This example, based on model calculations and illustrated in figure 1 A, shows that while the conventional process is capable of providing desulfurized HCN and a hydrotreated ICN without undesirable ICN olefin saturation, the process requires the use of a furnace to preheat the ICN. Accordingly, 9,000 Barrels/day (9 Kbd) of an ICN fraction at a temperature of 320° F. and a pressure of about 50 psia is conducted from separation equipment to a pump (not shown), and the pump's ICN effluent is combined with about 1500 scf/bbl of a hydrogencontaining treat gas having a temperature of about 180° F. and a pressure of about 350 psia. The combined ICN-treat gas ( 4 ) at a temperature of about 300° F. enters ICN heat exchanger ( 5 ), and the heat exchanger's effluent has a temperature of 450° F., i.e., outside the range of preferred ICN hydrotreater ( 7 ) inlet temperature. A furnace ( 6 ) is therefore required to increase the ICN hydrotreater inlet temperature into the preferred range, in this example 500° F. For a model ICN feed having 1500 ppm sulfur and a bromine number of 50, selective hydrotreating conditions in ( 7 ) would result in a product having 30 ppm sulfur (98% HDS), a bromine number of 30.8(about 38% olefin saturation), and product temperature about 120° F. higher than the hydrotreater inlet temperature. As shown in the figure, the product is conducted to the heat exchanger ( 5 ) to provide the heat required for increasing the combined ICN-treat gas from 300° F. to 450° F.
[0040] Conventional processing of the HCN fraction is also illustrated in FIG. 1A. 3 Kbd of an HCN fraction at a temperature of about 400° F. and a pressure of about 50 psia is conducted from separation equipment to a pump (not shown), and the pump's HCN effluent is combined with about 1500 scf/bbl of a hydrogen-containing treat gas having a temperature of about 180° F. and a pressure of about 350 psia. The combined HCN-treat gas ( 1 ) at a temperature 380° F. enters furnace ( 2 ) and is heated into the desired HCN hydrotreater ( 3 ) inlet temperature range, 620° F. in this example. For a model HCN feed having 4000 ppm sulfur and a bromine number of 13, non-selective hydrotreating conditions in ( 3 ) would result in a product having 5 ppm sulfur, a bromine number of 3 and product temperature about 60° F. higher than the HCN hydrotreater inlet temperature. The HCN effluent would therefore have a temperature of about 680° F. While not illustrated in the figure, HCN effluent may be used to pre-heat the combined HCN-treat gas, for example via at heat exchange, in order to reduce the heating requirements of furnace ( 2 ).
[0041] 2. This example, based on model calculations and illustrated in figure 1 B, shows the benefits of the invention. As in example 1, 9 Kbd of the same model ICN fraction at a temperature of 320° F. and a pressure of about 50 psia is conducted from separation equipment to a pump (not shown), and the pump's ICN effluent is combined with about 1500 scf/bbl of a hydrogen-containing treat gas having a temperature of about 180° F. and a pressure of about 350 psia. ICN reactor ( 22 ) conditions are as set forth in example 1. The combined ICN-treat gas ( 20 ) at a temperature of about 300° F. enters a first heat exchanger ( 18 b ), where the 620° F. effluent of ICN hydrotreater ( 22 ) is used to heat the combined ICN-treat gas to a temperature of 450° F. The ICN-treat gas effluent from the first heat exchanger is conducted to a second heat exchanger ( 18 c ) where the ICN-treat gas is further heated by the HCN hydrotreater's ( 14 ) product. For the same amount and type of HCN model feed as in example 1, and under the conditions set forth therein, the HCN hydrotreater would have an effluent with a temperature of about 680° F. The second heat exchanger's ICN-treat gas effluent would therefore be about 500° F., i.e., in the preferred ICN hydrotreater inlet temperature range, and no furnace or other external heat source need be employed to achieve the preferred ICN hydrotreater inlet temperature.
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The invention relates to a method and dual reactor system for hydrotreating a wide cut cat naphtha stream comprising heavy cat naphtha (HCN) and intermediate cat naphtha (ICN). Accordingly, a HCN fraction is hydrotreated under non-selective hydrotreating conditions and an ICN fraction is hydrotreated under selective hydrotreating conditions. The hydrotreated HCN and ICN effluents may be conducted to heat exchangers to pre-heat the ICN feed, obviating the need for a furnace.
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FIELD OF THE INVENTION
This invention relates generally to emission control valves that are used in emission control systems associated with internal combustion engines in automotive vehicles. The invention particularly relates to force-balance and anti-coking improvements in exhaust gas recirculation (EGR) valves.
BACKGROUND OF THE INVENTION
Controlled engine exhaust gas recirculation is a known technique for reducing oxides of nitrogen in products of combustion that are exhausted from an internal combustion engine to atmosphere. A typical EGR system comprises an EGR valve that is controlled in accordance with engine operating conditions to regulate the amount of engine exhaust gas that is recirculated to the fuel-air flow entering the engine for combustion so as to limit the combustion temperature and hence reduce the formation of oxides of nitrogen.
Because they are typically engine-mounted, EGR valves are subject to harsh operating environments that include wide temperature extremes and vibrations. Tailpipe emission requirements impose stringent demands on the control of such valves. An electric actuator, such as a solenoid that includes a sensor for signaling position feedback to indicate the extent to which the valve is open, can provide the necessary degree of control when properly controlled by the engine control system. An EGR valve that is operated by an electric actuator is often referred to as an EEGR valve.
When an engine with which an EEGR valve is used is a diesel engine, further considerations bear on the valve. Because such engines may generate significantly large pressure pulses, attainment of acceptable control may call for the use of a force-balanced EEGR valve so that any influence of exhaust gas pressure on valve control is minimized, and ideally completely avoided. For example, a large pressure pulse should not be allowed to force open an EEGR valve that is being operated to closed position by the solenoid.
A double-pintle type valve can endow an EEGR with a degree of force balance that is substantial enough to minimize the influence of exhaust gas pressure on valve control, for example minimizing the risk that large exhaust pressure pulses will open the EEGR valve when the engine control strategy is calling for the valve to be closed. A double-pintle type valve allows the valve to have a split-flow path where each pintle is associated with a respective valve seat. Such a valve can handle larger flow rates with a degree of control suitable for control of EGR.
Because of various factors that bear on an EEGR valve's ability to control tailpipe emissions for compliance with relevant regulations, including considerations already mentioned, construction details of a double-pintle EEGR valve become important. Individual parts must be sufficiently strong, tightly toleranced, thermally insensitive, and essentially immune to combustion products present in engine exhaust gases.
Certain combustion products in engine exhaust gases may tend to deposit on certain surfaces of certain parts of an EEGR valve. This phenomenon is sometimes called “coking”, and it can be detrimental to valve performance.
For example, when an EEGR valve pintle is unseated from its seat to allow exhaust gas flow through an annular space between the outer perimeter of the pintle and the inner perimeter of the seat, surface zones of the perimeter margins of both pintle and seat become exposed to exhaust gas flow. Depending on the particular design of the pintle-seat interface, deposits may form on those zones. The nature of the deposited material may cause a pintle to stick to some extent on the seat when the pintle is closed, and that can interfere with proper valve operation. For example, when the valve is to re-open, sticking may require extra force to unseat the pintle, particularly when the valve is cold. The presence of such material can also interfere with proper pintle re-seating on the seat, possibly resulting in leakage through the valve when the pintle should seat fully closed on the seat.
Constructing one or the other of the pintle and the seat to have a sharp corner, 90° for example, rather than a flat angled surface that makes contact with a similarly angled surface of the other when the valve is closed, tends to resist the depositing of material at and near the corner. However, the degree of sharpness of such a corner may complicate the process of making the part containing the edge. For example, machining a seat to create circular edge having a sharp 90° corner that is intended to seat on a frustoconical surface of a pintle may require an operation, such as de-burring, to assure that no imperfections, such as burrs, are present in the edge. Such an edge may be prone to nicking, also undesirable.
In mass-production automotive vehicle applications, the cost-effectiveness of the construction of a component, such as an EEGR valve, is important, and so it is desirable to avoid extra processing operations in the manufacture of such a component whenever possible.
SUMMARY OF THE INVENTION
The present invention relates to certain improvements in the construction of an EEGR valve, such as a double-pintle EEGR valve, particularly improvements in the pintle-seat interfaces.
One improvement is directed to an interface that tends to discourage the deposit of materials from the exhaust gases passing through the valve on surfaces at the interface so that proper performance of an EEGR valve can continue during its useful life free of deposits at the interface that might otherwise seriously impair acceptable valve performance.
Another improvement is directed to better force-balancing of the pintle in a double-pintle EEGR valve for minimizing the influence of exhaust pressure fluctuations on valve operation. The conjunction of these improvements in an EEGR valve can contribute to better valve performance and longer useful life of an EEGR valve in an exhaust emission control system of a diesel engine, and with cost-effectiveness.
A general aspect of the invention relates to an emission control valve for use in an emission control system of an internal combustion engine. The valve comprises valve body structure providing an inlet port at which flow enters the valve and an outlet port at which flow exits the valve. A valve element comprises first and second closures spaced apart along an axis for respective cooperation with respective seats that are axially spaced apart to selectively seat on the respective seat for disallowing flow between the inlet port and the outlet port and to unseat from the respective seat for allowing flow between the inlet port and the outlet port. An actuator selectively positions the valve element along the axis relative to the seats.
Each seat circumscribes a respective through-hole for flow. The through-hole of one seat is large enough diametrically to allow the closure that seats on the other seat to pass through during fabrication of the valve. Each through-hole comprises a respective frustoconical surface zone coaxial with the axis and tapered in the same axial direction. The closure that seats on the other seat seats on a radially outermost portion of the frustoconical surface zone of the through-hole of the other seat when the valve element is disallowing flow, and the other closure seats on a radially innermost portion of the frustoconical surface zone of the through-hole of the one seat when the valve is disallowing flow.
Another general aspect relates to an exhaust gas recirculation system having such a valve.
The accompanying drawings, which are incorporated herein and constitute part of this specification, include one or more presently preferred embodiments of the invention, and together with a general description given above and a detailed description given below, serve to disclose principles of the invention in accordance with a best mode contemplated for carrying out the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an elevation view of an EEGR valve embodying principles of the invention.
FIG. 2 is a left side elevation view of FIG. 1 .
FIG. 3 is an enlarged cross section view in the direction of arrows 3 — 3 in FIG. 1 .
FIG. 4 is an elevation view of one part of the valve by itself, that part being a double-pintle.
FIG. 5 is a cross section view in the direction of arrows 5 — 5 in FIG. 3 .
FIG. 6 is an elevation view of another part of the valve by itself, that part being a seat element having a double-seat.
FIG. 7 is a right side elevation view of FIG. 6 .
FIG. 8 is a rear elevation view of FIG. 6 .
FIG. 9 is a top plan view of FIG. 8 .
FIG. 10 is a cross section view in the direction of arrows 10 — 10 in FIG. 8 , but including the pintle.
FIG. 11 is an enlarged fragmentary view of a portion of FIG. 10 showing a modification.
FIG. 12 is an enlarged fragmentary view of another portion of FIG. 10 showing a modification.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIGS. 1–3 illustrate the general arrangement and organization of an exemplary EEGR valve 20 embodying principles of the present invention. Valve 20 comprises a base 22 and an elbow 24 assembled together to form a flow path 26 through the valve between an inlet port 28 provided in a flange at a side of base 22 and an outlet port 30 provided in a flange at one end of elbow 24 .
Base 22 is a metal part that has a main longitudinal axis 32 . Base 22 may be considered to have a generally cylindrical shape about axis 32 comprising a generally cylindrical wall bounding an interior space that is open at opposite axial end faces of the base. Base 22 is constructed so that its interior space is also open to inlet port 28 .
An end of elbow 24 that is opposite the end containing outlet port 30 is fastened in a sealed manner to the lower end face of base 22 so that the interior of elbow 24 is open to the interior space of base 22 . A cover 34 is fastened in a sealed manner to the upper end face of base 22 to close that end of the interior space of base 22 while providing a platform for the mounting of an electric actuator 36 on the exterior of the cover.
Actuator 36 comprises a solenoid that, when the valve is installed on an engine in a motor vehicle, is electrically connected via an electric connector 38 (shown out of position in FIG. 3 ) to an electrical system of the motor vehicle to place the valve under the control of an engine controller in the vehicle.
A bearing 40 is centrally fit to cover 34 such that a guide bore of the bearing is coaxial with axis 32 . Bearing 40 serves to axially guide a double-pintle 42 (shown by itself in FIG. 4 ) of valve 20 along axis 32 via a guiding fit of the bearing guide bore to an upper portion of a stem 44 of double-pintle 42 that extends completely through the bearing guide bore from an armature of the solenoid into the interior space of base 22 where upper and lower pintles 46 , 48 are disposed on stem 44 .
A double-seat element 50 shown by itself in FIGS. 6–9 is fit to base 22 within the latter's interior space. Element 50 is a machined metal part that has a generally cylindrical shape. It comprises a generally cylindrical wall 52 that is coaxial with axis 32 in valve 20 and that is open at opposite axial ends. Element 50 comprises axially spaced apart upper and lower seats 54 , 56 (see FIG. 10 ) with which pintles 46 , 48 respectively cooperate. Wall 52 comprises two pairs of openings, or apertures: an upper pair 58 , 60 , and a lower pair 62 , 64 . The lower pair are arranged axially between seats 54 , 56 to provide for the open interior of element 50 that is circumscribed by wall 52 between seats 54 , 56 to communicate through the opening in base 22 to inlet port 28 . The upper pair 58 , 60 are arranged axially beyond seat 54 relative to the lower pair 62 , 64 to provide for the open interior of element 50 that is circumscribed by wall 52 beyond upper seat 54 to communicate with respective entrances to an internal passageway 66 (see FIG. 5 ) than runs within base 22 internally through a portion of the generally cylindrical wall of the base that is in the semi-circumferential portion of that wall opposite inlet port 28 .
The outside diameter surface of wall 52 is stepped, comprising zones of successively larger diameter from bottom to top so as to allow element 50 to be assembled to base 22 by inserting element 50 into the interior space of base 22 through the opening in the upper end face of the base. The smallest outside diameter zone of wall 52 is at the bottom of element 50 essentially coextensive with seat 56 . The next larger diameter zone is the one containing apertures 62 , 64 , and at the juncture of those two zones is a chamfered shoulder 68 .
The next larger diameter zone is the one containing apertures 58 , 60 , and at its juncture with the zone containing apertures 62 , 64 , there is a raised circular ridge 70 having an inclined surface 72 that wedges with a portion of the inside diameter of the cylindrical wall of base 22 when element 50 is assembled to the base. The uppermost zone of wall 52 comprises a circular lip 76 on the outside and a shoulder on the inside.
When element 50 is assembled to base 22 , the zone of wall 52 containing apertures 62 , 64 fits to the circular inside diameter surface of the wall of base 22 in an orientation about axis 32 that places apertures 62 , 64 in registration with inlet port 28 , as shown in FIG. 2 . Thereafter, a sub-assembly of cover 34 , bearing 40 , and actuator 36 are assembled to base 22 at the upper end face of the base by fastening the cover to the base. Before elbow 24 is placed on the lower face of base 22 , double-pintle 42 is assembled into the valve through the open lower end face of the base. Stem 44 passes through the guide bore in bearing 40 and into the interior of the actuator where it attaches to the solenoid armature. With the solenoid not being energized, each of the two pintles 46 , 48 seats on a respective seat, closing the respective opening, or through-hole, circumscribed by the respective seat. The armature is spring-biased to urge the pintles against the seats with an appropriate amount of force.
It can be appreciated that the outside diameter of upper pintle 46 is less than that of the through-hole circumscribed by lower seat 56 so that the former can pass through the latter during assembly of the double-pintle into the valve. Thereafter elbow 24 is fastened to base 22 to complete the assembly.
Valve is substantially force-balanced because of the particular double-pintle design. When inlet port 28 is communicated to the engine exhaust system so that hot engine exhaust gases can enter the valve, the pressure of those gases acting on the pintles creates forces that are substantially equal in magnitude, but in opposite directions along axis 32 , although the upward force acting on pintle 48 will have a slightly larger magnitude than the downward one acting on pintle 46 . Hence, pressure pulses will at most have a very minor, and ideally negligible, effect on the positioning of double-pintle 42 by actuator 36 . This is important for control accuracy.
For the accurate handling of flow within a rather large range of flow rates, it is also important that the internal construction of the valve be substantially immune to the effects of exhaust gas constituents, exhaust gas temperature extremes, and exhaust gas pressure extremes. Parts that are important to control accuracy need strict manufacturing tolerances. Restriction of the flow path through the valve should be determined by the positioning of the valve element in relation to the valve seat, meaning that the design of other parts of the valve that define the flow path should impose a restriction that is essentially negligible when compared to the restriction between the valve element and the valve seat.
These objectives are best met by rigid metal parts that can be machined to the required dimensional accuracy. A double-pintle valve, as described, splits the entering exhaust gas flow so that the flow divides more or less equally as it passes through seat element 50 . Ideally there should be essentially no restriction to the incoming flow entering the seat element from inlet port 28 . For maximizing the cross sectional area through which the incoming flow enters seat element 50 , the circumferential span of the opening in the wall of seat element 50 should be essentially its semi-circumference. Collectively, apertures 62 , 64 do just that. But in order to minimize the wall thickness of the seat element while retaining the necessary degree of strength, rigidity, and dimensional accuracy of the seat element, the seat element is a machined part where the two apertures 62 , 64 are separated by a narrow axial bar 80 in the wall, rather than being a single aperture having a like semi-circumferential span. Similarly, apertures 58 , 60 are separated by a somewhat wider bar 84 .
FIG. 10 shows the closed condition with each pintle 46 , 48 seated on the respective seat 54 , 56 . Seat 54 circumscribes a circular through-hole defined by a circular cylindrical surface zone 54 A both parallel and coaxial with axis 32 and a frustoconical surface zone 54 B that extends from a circular edge 54 C at its junction with zone 54 A coaxial with axis 32 in the direction toward the space circumscribed by wall 52 between the two seats. The cone angle of zone 54 B is 30° in this particular embodiment. Zone 54 B ends at a flat surface zone 54 D that is perpendicular to axis 32 . The geometric relationship between zones 54 B and 54 D endows the seat with an obtuse-angled circular corner edge 54 E against which a frustoconical surface 46 A of pintle 46 seats when valve 20 is closed. Surface 46 A has a cone angle of 42° in this particular embodiment.
Seat 56 circumscribes a circular through-hole defined by a circular cylindrical surface zone 56 A both parallel and coaxial with axis 32 and a frustoconical surface zone 56 B that extends from an obtuse-angled circular corner edge 56 C at its junction with zone 56 A coaxial with axis 32 in the direction away from the space circumscribed by wall 52 between the two seats. Zone 56 B ends at a flat surface zone 56 D that is perpendicular to axis 32 . The cone angle of zone 56 B is 60° in this particular embodiment. A frustoconical surface 48 A of pintle 48 seats on corner edge 56 C when valve 20 is closed. Surface 48 A has a cone angle of 42° in this particular embodiment.
So that double-pintle 42 can be assembled into the valve, the diameter of zone 56 A is made larger than the largest outside diameter of pintle 46 , with an appropriate amount of radial clearance to facilitate assembly. The largest outside diameter of pintle 46 occurs in a circular cylindrical portion that extends axially from frustoconical surface 46 A.
When each pintle is seated on the respective seat as shown in FIG. 10 , the obtuse-angled corner edge 54 E at the junction of seat surface zones 54 B, 54 d makes essentially circular line edge contact with surface 46 A of pintle 46 , and the obtuse-angled corner edge 56 C at the junction of seat surface zones 56 A, 56 B makes essentially circular line edge contact with surface 48 A of pintle 48 .
With the smallest diameter portion of the through-hole in seat 56 contacting pintle 48 and the largest diameter portion of the through-hole in seat 54 contacting pintle 46 , greatest correspondence between the effective areas of the two pintles on which exhaust gas pressure acts is attained, maximizing the extent of force-balance. The effective areas have respective diameters of 25.1 centimeters and 26.0 centimeters in this example.
At the same time, the geometries of the respective seat-pintle interfaces tend to discourage deposit of certain exhaust gas constituents at the interfaces. With the valve just slightly open, exhaust gas flowing through seat 54 is increasingly constricted between surfaces 54 D, 46 A as it approaches the point of maximum restriction at the obtuse-angled corner edge 54 E, but once past that corner edge, the flow is allowed to expand as it passes between surfaces 54 B, 46 A.
The same is true at the other seat-pintle interface where the flow is increasingly constricted as it approaches corner edge 56 C, and then once past corner edge 56 C, it is allowed to expand due to the angular relationship between surfaces 48 A, 56 B.
FIGS. 11 and 12 show respective modifications to seats 54 and 56 in another example. The drawings are exaggerated for clarity of illustration. Edge 54 E has a slight chamfer 54 F instead of being sharp. The cone angle of the chamfer is slightly larger (1° larger in the example) than the cone angle of surface 46 A. Similarly, edge 56 C has been modified to includes a slight chamfer 54 E, whose cone angle is also 1° larger than the cone angle of surface 48 A. It is believed that the inclusion of the chamfers can improve durability and performance.
Anti-coking features are embodied in the pintle-seat interfaces because of the geometries that have been described. A seat having an obtuse corner with a sharp edge or alternately a slightly chamfered one, as shown and described, makes substantial circular edge contact with a frustoconical surface zone of the corresponding pintle. When the valve is operated just slightly open, the flow is increasingly constricted as it approaches the corner edge. Once past the corner edge, the flow is allowed to expand due to the angular relationship between the seat and pintle surface zones.
While the foregoing has described a preferred embodiment of the present invention, it is to be appreciated that the inventive principles may be practiced in any form that falls within the scope of the following claims.
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A double-pintle valve ( 20 ) has two seats ( 54, 56 ) each circumscribing a respective through-hole for exhaust gas flow. The through-hole of one seat ( 56 ) is large enough diametrically to allow the closure ( 46 ) that seats on the other seat ( 54 ) to pass through during fabrication of the valve. The closure ( 46 ) seats substantially on a radially outermost portion of a frustoconical surface zone ( 54 B) of the seat ( 54 ) and the other closure ( 48 ) seats substantially on a radially innermost portion of a frustoconical surface zone ( 56 B) of the one seat ( 56 ) when the valve is disallowing flow.
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FIELD OF THE INVENTION
[0001] The present invention relates to a method for installation or removal of objects at sea, particularly relating to installation or removal of objects that are part of the infrastructure in oil and gas fields offshore.
[0002] Conventional methods are normally based on transporting a platform deck to the destination on the deck of an installation vessel or a transportation barge, with subsequent offshore lift from barge deck onto the platform-deck carrying structure (jacket or substructure). Such operations set high demands to crane capacity and deck space and can be very weather sensitive operations and are tying up costly construction vessels for long periods of time.
[0003] This has led to the introduction of the principle of “barge floatover” for the installation where the barge transporting the platform deck has large capacity ballasting system.
[0004] At the site the jacket substructure will have been pre-installed. On arrival at site the barge will be prepared for the deck installation. On a favourable weather forecast and acceptable environmental conditions the barge with the deck will be docked and positioned inside the jacket substructure. The barge will thereafter be ballasted to transfer the deck load through shock-absorbing cells normally called Leg Mating Units (LMU) into the jacket legs. The barge will then continue ballasting until the barge deck clears the underside of the deck structure, after which the barge will be withdrawn from the structure and the two structures can be welded together.
[0005] The same but inverted principle called “barge float-under” can be used when a platform deck is to be removed from a jacket substructure. The ballasted barge will be docked and positioned under the platform deck and inside the jacket substructure. In advance the platform deck and substructure has been prepared for the “lift off operation” by cutting and securing the structural legs between the jacket structure and deck structure at the appropriate level. The barge will thereafter be deballasted to transfer the deck load through shock-absorbing cells called Deck Supporting Units (DSU) onto the barge deck. The deballasting will continue until the the deck legs clear the jacket legs, after which the barge with the platform deck will be withdrawn.
[0006] Normally, as mentioned above, to reduce the impact loads arising from wave induced motion of the barge, two types of shock-absorbing installation aids, LMU and DSU, are foreseen required consisting of spring supports, rubber or elastomeric design giving restrains in the vertical and lateral directions. For a barge “float-over” or “float-under” (removal) operation:
[0007] Leg mating units (LMU) are normally located on the top of the jacket legs, and are aimed at reducing the impact loads between deck stabbing cones and jacket legs during the various stages of the installation and load transfer.
[0008] Deck support units (DSU) are installed in the deck support structures of the barge, in order to reduce any impact loads between vessel and deck underside arising during and after load transfer while the barge is being ballasted down and separates from the deck.
[0009] Oil and gas field developments are experiencing a push towards more remote areas with less infrastructure and tougher environments that are increasing the needs for more efficient methods for installation or removal of objects. Also, with an increasing number of oil and gas fields being decommissioned, there is a growing need for removal of objects. More of the objects that are to be installed or removed from the offshore sites are of large dimensions and weights, typically 60×60 m wide and weighing 15,000 tons. Based on these aspects there is a need to develop new and alternative methods for installation/removal of objects, as conventional methods become unfit or inadequate.
[0010] A method according to the preamble of claim 1 is known from U.S. Pat. No. 5,522,680. In this method the jack mechanism in each deck leg is a large hydraulic cylinder device which requires a very substantial hydraulic system in order to function properly. The hydraulic cylinders and their system are complicated and very expensive equipment and require a reliable power supply and operator attention in order to function as intended.
[0011] Is The object of the present invention is to alleviate the drawbacks and deficiencies mentioned above and particularly to obtain a method and arrangement by which the deck transfer can be accomplished in a fairly simple and substantially automatic manner by means of equipment that is reliable, generally self-contained and relatively inexpensive.
[0012] This object is attained by a method and an arrangement as defined in the claims.
[0013] When applying the invention one achieves several advantages compared to above mentioned conventional methods. Advantages to be mentioned in particular are that, with the use of a rather simple mechanical system, one can reduce the period to a minimum where the structures and barge deck are exposed to great shock loads during the load transfer caused by wave motion. Thereby one is reducing the risk for failures in a very sensitive phase of this offshore operation. Also, the requirements and strain normally put onto the very expensive shock cells can be alleviated as the invention is reducing the possibilities for structural separation or “lift off” once contact has been made between the two structures.
[0014] The installation and removal method is summarised as follows:
[0015] When a barge with a platform deck has been positioned between the jacket legs ready to start transferring the load of the deck onto the jacket legs called a “deck float-over” type of operation, a ratchet jack type of mechanism situated in the lower part of the deck legs are brought into contact with the jacket legs or via the leg mating units (LMU) on the top of the jacket legs. Instantly, depending on the barge and deck wave induced vertical motion, the mechanism starts working. Each time the barge and deck is moving upwards on a wave, the mechanism will let the deck move freely upwards but at the same time keeping contact with the top of the jacket legs. When the barge movement starts turning downwards on the crest, the mechanism will lock the deck in its position relative to the jacket leg and the deck load is started being transferred from the barge onto the jacket. In this way one avoids “lift off” or separation of the structures and thereby also reduces the great dynamic shocks into these and into the barge. Subsequent wave induced motions with larger amplitudes than the earlier waves will thus very soon lift the deck up further relative to the barge deck and unload the barge. The major and most weather sensitive part of the load transfer is thus done more quickly and completion of the balancing part of the load transfer with the final ballasting can start earlier and the whole operation including undocking of barge completed in less time and more safely than with more conventional methods.
[0016] The need and requirements for the leg mating units on top of the jacket legs have to be addressed on a project to project basis depending on the type of ratchet mechanism chosen but some degree of lateral restrains will always be required during the initial load transfer in order to make up for misalignment and tolerances between the legs. Likewise, the need for deck support units on the barge with vertical and lateral restrains and shock absorbing mechanism has to be addressed on a project to project basis depending on the type of ratchet-mechanism chosen.
[0017] The same but inverted principle called “barge float-under” can be used when a platform deck is to be removed from a jacket substructure. When a ballasted barge has been positioned between the jacket legs under a platform deck ready to start transferring the load of the deck onto the barge, the ratchet jack type of mechanism now situated in the lower part of the deck nodes above the barge deck are brought into contact with the deck support structure on the barge deck or via deck support units (DSU). Instantly, depending on the barge and its wave-induced vertical motion, the mechanism starts working. Each time the barge is moving downwards on a wave, the mechanism is following the barge down and thus keeping contact with the top of the deck support structure on the barge or via a DSU on the same structure. When the barge is starting the upward movement from a wavetrough, the ratchet type of mechanism will lock the platform deck in its position relative to the barge deck and the deck load is started being transferred from the jacket onto the barge. In this way one avoids “lift off” or separation of the deck structure relative to the barge and thereby also reduces the great dynamic shocks into platform deck and barge. Subsequent wave-induced motions with larger amplitudes than the earlier waves will very soon lift the platform deck further up relative to the barge deck and continue transferring load onto the barge. The major and most weather-sensitive part of the load transfer is thus done more quickly, and completion of the balancing part of the load transfer with the final deballasting can start earlier and the whole operation including undocking of barge completed more safely and in less time than with more conventional methods. The need for deck support units with vertical and lateral restrains and shock absorbing mechanism consisting of spring supports, rubber or elastomeric design has to be considered on a project to project basis.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] The present invention shall be described in the following with reference to the attached drawings which illustrate a preferred embodiment, wherein:
[0019] [0019]FIG. 1 is a transverse section of barge and a platform deck in a typical float-over operation scenario ready to start the transfer operations of the deck load onto a jacket structure. A view of a typical float-under operation scenario for deck removal will be similar but there will be no LMU situated in the jacket and the ratchet jack type of mechanism will be located in the deck nodes above the deck support structure located on the barge deck.
[0020] [0020]FIG. 2 is a section of the lower part of the deck leg in FIG. 1 showing a ratchet jack type of mechanism called ratchet jack ready to be dropped into contact directly with the jacket leg or alternatively via a LMU as shown in the top of a jacket leg in a float-over operation scenario.
[0021] [0021]FIG. 3 is a section showing the ratchet jack type of mechanism called ratchet jack applied in a float-under (removal) operation scenario. The ratchet jack is here located in the lower part of a deck node ready to be dropped directly into contact with deck support structure on the barge deck or alternatively via a DSU as shown on the same structure for starting the load transfer.
[0022] [0022]FIGS. 4-6 are sections of the lower part of a deck leg in FIG. 1 showing the five main operational working steps of a ratchet jack type of mechanism called sand trap ratchet jack in a float-over operation scenario shown without any LMU in the jacket leg. A view of a typical float-under (removal) operation scenario will be similar but the sand trap ratchet jack will be located in the deck nodes above the deck support structure on the barge deck similar as shown on FIG. 3.
[0023] [0023]FIGS. 7-10 are sections of the lower part of a deck leg in FIG. 1 showing the five main operational working steps of a ratchet jack type of mechanism called sand trap ratchet jack located in a float over operation scenario with the vertical and lateral shock absorbing functions shown integrated in the sand trap ratchet jack mechanism. A view of a typical float-under (removal) operation scenario will be similar but the sand trap ratchet jack will be located in the deck nodes above the deck support structure on the barge deck similar as shown on FIG. 3.
[0024] [0024]FIGS. 11-12 are sections of DSU and deck support structure stool located on the barge deck underneath the platform deck in a float-over operation scenario as indicated in FIG. 1 showing means for rapid withdrawal after load transfer has been accomplished to avoid shock impact in the period after transfer. Alternatively, this can also be achieved by hydraulic means as indicated.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0025] [0025]FIG. 1 shows a platform deck object on a barge 12 in a typical float-over operation scenario with sway motions limited by inflated fenders 20 and surge motions by fore and aft mooring lines (not shown) ready to start the transfer operation of the deck load onto the legs 13 of the jacket structure with the piston jack 1 of the invention situated in the deck leg 5 and the shock-absorbing mechanism LMU 3 disposed in the top of the jacket legs 13 . A typical float-under operation for deck removal will be of a similar arrangement, but the piston jack 1 of the invention will now be located in the deck nodes 14 above the deck support unit with the shock absorbing mechanism DSU 15 on the barge deck with its support structure 16 .
[0026] [0026]FIG. 2 shows a preferred embodiment of the present part of the invention called ratchet jack applied in a float-over operation scenario. The piston jack 1 constitutes a part of the piston jack assembly 7 inserted in the deck leg 5 and the piston jack is free to move inside this assembly which is also fitted with lateral supports 6 . The lower part of the piston jack is designed as a cone. The cone shall assist guiding the deck leg 5 onto the jacket leg 13 and into a leg mating unit 3 located in the top part of the jacket leg having a receptacle fitting the cone. The piston jack assembly 7 is fitted with a ratchet 2 consisting of a number of spring loaded pawls or arrestors 20 located around the threaded section 17 of the piston jack 1 , enabling the jack to move freely downwards relatively whenever it has no load and to be locked to take on load whenever it is starting on an relative upward movement.
[0027] The piston jack 1 is shown in the pre-dropped position ready to be dropped onto the jacket leg 13 by a release mechanism 18 consisting of a number of hydraulic operated pins penetrating the top of the piston jack 1 . When the actual load transfer operation is to be started, the piston jack 1 is released and, through operation of the ratchet 2 , is allowing the piston jack 1 to drop down inside the assembly 7 hitting the top of the jacket leg 13 . When the barge is lifted upwards in the wave, the piston jack assembly 7 is allowing contact to be maintained between the piston jack cone 19 and the LMU 3 in the top of the jacket leg 13 by letting the ratchet 2 further operate freely. When reaching the maximum uplift on the wave, no load transfer has yet taken place.
[0028] When the platform deck and barge are just passing the wave crest, the ratchet 2 will lock onto the threaded section 17 of the piston jack 1 , thus starting to transfer load through the ratchet 2 , piston jack 1 , piston jack cone 19 and onto jacket leg 13 via the LMU 3 located in the top of the jacket leg. On the subsequent waves with amplitudes larger than the earlier waves very soon deck load will continue to be transferred and accumulated onto the jacket leg 13 and a point reached where the wave lift of the deck has arrived at a maximum and been locked in by the ratchet jack. The balance of load will then be transferred through the ballasting operation or, alternatively, by a combined operation of ballasting and rapid retrieval of the DSU or deck support stool by drainage of a sand-cushion underneath as shown in FIGS. 11 and 12 or, alternatively, by hydraulic means of lowering.
[0029] [0029]FIG. 3 shows a preferred embodiment of the present part of the invention called ratchet jack being of a similar type as shown in FIG. 2 but applied in a float-under (removal) operation scenario. The piston jack 1 constitutes a part of the piston jack assembly 7 inserted in the deck node 14 and fastened to this node by typically a number of hydraulic wedges 21 on the flange of the assembly 7 , and the jack is free to move inside this assembly, which is also fitted with lateral supports 6 . The lower part of the piston jack is designed as a cone 19 . The cone shall assist guiding the deck node 14 onto the DSU 15 located on the deck support structure 16 on barge deck and having a receptacle fitting the cone. The piston jack assembly 7 is fitted with a ratchet 2 consisting of a number of spring loaded pawls or arrestors 20 located around the threaded section 17 of the piston jack 1 , enabling the jack to move freely downwards relatively whenever it has no load and to be locked to take on load whenever it is starting on an upward relative movement.
[0030] The piston jack 1 is shown in the pre-dropped position ready to be dropped onto the DSU 15 on the barge deck by a release mechanism 18 consisting of a number of hydraulic operated pins penetrating the bottom part of the piston jack 1 . When the actual load transfer operation is to be started, the piston jack 1 is released and through operation of the ratchet 2 is allowing the piston jack 1 to drop down inside the assembly 7 , hitting the top of the receptacle in the DSU 15 . When the barge is moving downwards in the wave, the piston jack assembly 7 is allowing contact to be maintained between the piston jack cone 19 and the top of the DSU 15 by letting the ratchet 2 further operate freely. When reaching the trough of the wave, no load transfer has yet taken place.
[0031] When the barge is just passing the trough of the wave, the ratchet 2 will lock onto the threaded section 17 of the piston jack 1 starting to transfer deck load through the ratchet 2 , piston jack 1 , piston jack cone 19 and onto the DSU 15 on the deck support structure 16 on barge deck. Upon subsequent waves with amplitudes larger than the earlier waves, very soon deck load will continue to be transferred from the jacket and accumulated onto the barge and a point reached where the wave lift of the deck has arrived at a maximum and has been locked in by the ratchet jack. The balance of load will be transferred through a deballasting operation.
[0032] [0032]FIG. 4 shows a preferred embodiment of the present part of the invention called sand trap type of ratchet jack wherein the piston jack denoted 1 is shown in the first of two working steps in a float-over type of operation scenario. The piston jack constitutes a part of a jack assembly 7 inserted and fastened internally in the deck leg and is free to move inside this assembly and is also fitted with lateral shock absorbers 28 . The shock absorbers can be of an elastomeric design as indicated here or can be of a rubber or spring type design. The lower part of the pistonjack is designed as a cone 29 , which also can be fitted with elastomeric as shown in the figure. The cone shall assist in guiding the deck leg 5 onto the jacket leg 13 . Above the piston jack in the deck leg is shown a sand cushion 26 consisting of sand with high quality homogenized equal sized particles. A sand cushion 30 can also be introduced in the jacket leg 13 below the piston jack 1 as indicated in the figure as an alternative to have a LMU in the jacket leg. Above the sand cushion in the deck leg 26 is shown the sand trap 22 enabling the mechanism to work as a ratchet jack type of mechanism. The sand trap consists of the perforated bottom plate 23 located in the sand storage 27 situated above the sand cushion 26 in the deck leg 5 and is underneath covered with a flapper ring 24 of flexible material typical rubber kept in place with a bolted steel retainer ring 25 beneath the perforated bottom plate 23 . This arrangement is allowing the piston jack 1 to move freely downwards relatively whenever it has no load and to be locked to take on load whenever it is starting on an upward relative movement as subsequently described.
[0033] The piston jack 1 is in step 1 shown in the pre-dropped position ready to be dropped onto the jacket leg 13 by a release mechanism release 18 consisting of a number of hydraulic operated pins penetrating the top part of the piston jack 1 . In this position the sand cushion 26 and sand-storage 27 is filled up completely with sand. When the actual load transfer operation is wanted to be started the piston jack assembly 7 is allowing the piston jack 1 , released by the operating the release mechanism 18 , to drop down hitting the top of the jacket leg 13 as shown in step 2 . The increased volume of the sand cushion space 26 in the deck leg 5 will now establish a differential sand pressure across the flapper ring 24 in the sand trap 22 forcing the ring to bend downwards uncovering the perforations in the bottom plate 23 and allowing sand to pass through the sand trap 22 from the storage 27 and fill up the void space in the sand cushion 26 of the deck leg column 5 .
[0034] [0034]FIG. 5 is in step 3 showing the mechanism when the barge and platform deck is lifted upwards on a wave. The piston jack assembly is allowing contact to be maintained between the piston jack cone and the top of the jacket leg. During this vertical movement of the deck the differential sand-pressure across the sand trap will cause the sand to flow downwards and the void space in the sand cushion in the deck leg to be filled up with sand from the storage. When reaching the maximum uplift on the wave in step 3 , the sand cushion will have been filled up but no load transfer has yet taken place.
[0035] Step 4 is showing the mechanism when platform deck and barge is just passing the wave crest with the sand trap in closed position and sand cushion compressed starting to transfer load through the trapped sand cushion column, piston jack, piston jack cone and onto jacket leg with a possible sand cushion in the top of the jacket leg. Upon the subsequent waves with larger amplitudes than the earlier waves, very soon deck load will be further transferred and accumulated onto the jacket leg until a point reached where the wave lift of the deck has arrived at a maximum and been locked in by the sand trap ratchet. The balance of load will then be transferred through the ballasting operation or, alternatively, by a combined operation of ballasting and rapid retrieval of the DSU 15 or deck support stool 32 on the barge by drainage of a sand cushion underneath, as indicated in FIGS. 11 and 12 or, alternatively, lowering by hydraulic means.
[0036] [0036]FIG. 6 is showing the position of the platform deck relative to the jacket leg after former has been lowered by draining the sand out from the sand cushions by opening the sand plug 31 in the deck leg 5 and jacket leg 13 , enabling the structures to come into contact and be welded together at the interface point 32 .
[0037] [0037]FIG. 7 shows a preferred embodiment of the present part of the invention called sand trap type of ratchet jack and is shown in the first two working steps in a float-over type of operation scenario. The piston jack 1 constitutes a part of the piston jack assembly 7 and is inserted and fastened internally in the deck leg 5 and is free to move inside this assembly and is also fitted with lateral and vertical shock absorbers and restraints, item 28 and 36 . The shock absorbers can be of an elastomeric design as indicated here or can be of a rubber or spring type design. The lower part of the piston jack is designed as a cone 29 , which also can be fitted with elastomeric as shown in the figure to absorb lateral shock loads. The cone shall assist guiding the deck leg 5 onto the jacket leg 13 . Above the piston jack in the deck leg is shown a sand cushion 26 consisting of sand with high quality homogenized equal sized particle. Sand cushion 30 can also be introduced in the jacket leg 13 below the piston jack as indicated in the figure.
[0038] Above the sand cushion in the deck leg is shown the sand trap 22 , enabling the mechanism to work as a ratchet jack type of mechanism. The sand trap consists of the perforated bottom plate of the sand storage 23 located above the sand cushion 26 in the deck leg and is covered underneath with a flapper ring 24 of flexible material, typical rubber, kept in place with a bolted steel retainer ring 25 beneath the perforated bottom plate. This arrangement is allowing the piston jack 1 to move freely downwards relatively whenever it has no load and to be locked to take on load whenever it is starting on an upward relative movement.
[0039] The piston jack 1 is in step 1 shown in the pre-dropped position ready to be dropped onto the jacket leg 13 by a release mechanism of a similar type as shown in item 18 of FIG. 4. In this position the sand cushion 26 and sand storage 27 is filled up completely with sand. When the actual load transfer operation is to be started, the piston jack 1 is released by the release mechanism, allowing the piston jack to be dropped down hitting the top of the jacket leg 13 as shown in step 2 . The increased volume of the sand cushion space 26 in the deck leg 5 will now establish a differential sand pressure across the flapper ring 24 in the sand trap 22 , forcing the ring to bend downwards, uncovering the perforations in the bottom plate and allowing sand to pass through the sand trap 22 from the storage 27 and fill up the void space in the sand cushion 26 .
[0040] [0040]FIG. 8 is in step 3 showing the mechanism when the barge and platform deck is being lifted upwards on a wave. The piston jack assembly is allowing contact to be maintained between the piston jack cone and the top of the jacket leg. During this vertical movement of the deck the differential sand pressure across the sand trap will cause the sand to start flowing downwards and the void space in the sand cushion in the deck leg to be filled up with sand from the storage. When reaching the maximum uplift on the wave, the sand cushion will have been filled up but no load transfer has yet taken place.
[0041] In FIG. 9 step 4 is showing the mechanism when the platform deck and barge is just passing the wave crest with the sand trap in closed position and sand cushion compressed, starting to transfer load through the trapped sand cushion column, piston jack with the vertical and lateral shock absorbing elements activated and compressed, piston jack cone with lateral shock absorbing elements activated and onto jacket leg, with possible sand cushion in the top of the jacket leg. Upon subsequent waves with larger amplitudes than the earlier waves, very soon deck load will be further transferred and accumulated onto the jacket leg until a point reached where the wave lift of the deck has arrived at a maximum and the deck has been locked in by the sand trap ratchet. The balance of load will be transferred through the ballasting operation, or alternatively, by a combined operation of ballasting and rapid retrieval of the DSU 15 or deck support stool 32 on the barge by drainage of a sand cushion underneath, as indicated in FIGS. 11 and 12 or, alternatively, lowering by hydraulic means.
[0042] [0042]FIG. 10 is showing the position of the platform deck relative to the jacket leg after the former has been lowered by draining the sand out from the sand cushions in the deck leg and jacket leg by opening the sand plug 31 , enabling the structures to come into contact and be welded together at the jacket and deck interface 32 .
[0043] [0043]FIG. 11 is showing a sand cushion 33 in cylinder 34 located underneath the DSU 15 with its cylinder 39 which is free to move inside the cylinder 34 and standing on the deck of the barge 12 . When load transfer to jacket has been accomplished, rapid withdrawal of DSU 15 onto the deck support structure 16 to avoid impact loads can be done by rotating cylinder ring 35 , allowing ports in the base of cylinder 34 and in ring 35 to coincide, causing sand to be drained out from the sand cushion 33 underneath the DSU 15 and the DSU to be lowered down quickly. The same can also be accomplished by hydraulic means by replacing sand cushion 33 with hydraulic jacks, as indicated by item 38 .
[0044] [0044]FIG. 12 is showing a sand cushion 33 in cylinder 34 located underneath the deck support structure stool 32 which is free to move inside the cylinder 34 . When load transfer to jacket has been accomplished, rapid withdrawal of stool 34 to avoid impact loads can be done by rotating cylinder ring 35 , allowing ports in the base of cylinder 34 and in ring 35 to coincide causing sand to be drained out from the sand cushion 33 underneath the stool and the stool to be lowered down quickly. The same can also be accomplished by hydraulic means by replacing sand cushion 33 with hydraulic jacks as indicated by item 38 .
[0045] The invention is not limited to the exemplifying embodiments described above, but may be varied and modified within the scope of the appended claims. Thus, this application of the principles of “barge float-over/under” as described above may not be limited to only installation of a deck onto a jacket or substructure standing on sea bottom, as the principle of load transfer by the jack type of mechanism will also be working in the same manner as described having a transfer of the deck onto or from a floating substructure with one or more legs or columns in lieu of transfer onto or from a substructure resting on sea bottom.
[0046] Likewise, the deck transportation unit may not be limited to a single barge, as the principle of load transfer by the jack type of mechanism will also be working having the deck located on a catamaran type of vessel or even having the deck resting on two separate barges or pontoons during the transfer of the deck load.
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A method and a suitable arrangement for installation of a deck structure at an offshore location, where the deck structure is put on a vessel at a location inshore, then transported on the vessel to the offshore location and positioned relative to legs ( 13 ) of a jacket or gravity base type support structure standing on the sea bottom, or the legs or columns of a floating substructure, the deck structure having deck legs ( 5 ) corresponding to support legs ( 13 ) on the support structure, the deck legs ( 5 ) each being provided with a jack type of mechanism with an associated piston ( 1 ) which is extended into contact with and supported by the top part ( 3 ) of the corresponding support leg ( 13 ) at the beginning of a procedure for transferring the weight of the deck structure from the vessel to the support legs ( 13 ). Said procedure comprises ballasting the vessel ( 12 ) while permitting wave induced motions of the vessel ( 12 ) to further lift the deck structure with respect to the support structure and permitting the pistons ( 1 ) to extend further below the respective deck legs ( 5 ) when a higher wave is encountered. The pistons ( 1 ) are prevented from moving into the respective deck legs ( 5 ) during the weight transfer by mechanically locking the pistons ( 1 ) in the legs by means of a one-way ratchet type mechanism.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Application No. 62/059,519 filed Oct. 3, 2014.
FIELD OF THE INVENTION
The present invention is related to an automatic child safety lock release during an accident.
BACKGROUND OF THE INVENTION
“Child safety locks” are present on most vehicles. In particular, vehicles with a back seat have a manual release in the outer portion of the door which is exposed by opening of the door. Typically, there is a recessed switch in the door that is actuated by a screwdriver, or key, or by hand, and switched manually from an open position where the locks function in a normal manner, or a locked position where the exposed locks in a rear door cannot be manually manipulated by a rear seat occupant.
The purpose for this type of lock is to avoid undesired opening by a child or other rear seat occupant of the rear door which might place the child or occupant at risk. Additionally, the door cannot be opened from the outside which also protects the child from external unwanted entries by strangers or the like.
While this acts to protect the child or other occupant during normal operation of the vehicle, the child locks can produce a potentially dangerous situation. For example, if there is an accident and the vehicle catches on fire, the child or any occupant from the rear seat cannot be removed from the vehicle by opening the door from the inside or outside unless the door is unlocked from a different location like a key fob or door unlock switch near front seats. In the case of a rollover accident or other accident, the passenger cannot exit nor potentially can a rescue person open the rear door for removal of the occupant.
Therefore, there is a need in the art to provide an automated child safety device that opens upon impact.
SUMMARY OF THE INVENTION
The present invention relates to an automated child safety unlocking system for automobiles which disengages the child safety locks and unlocks the doors at appropriate times during events such as vehicle crashes. The system includes two or more crash sensors each configured to generate a crash signal upon detection of an event, such as the vehicle striking an object. A vehicle ECU is configured to receive the crash signal from each of the two or more crash sensors and then transmit one of at least two CSL command signals. The vehicle ECU continually monitors the status of the vehicle to check if a crash event has occurred via various methods such as the status of airbag deployment, accelerometers placed in the car, and crumple points. The at least two CSL command signals are each specific to an event severity and event type, where one of at least two CSL command signals generated by the vehicle ECU is transmitted with general signals over a general vehicle communication bus. The signal generated by the vehicle ECU is continually passed to a child safety lock ECU which then interprets the signal and acts according to the signal. If the data interpreted indicates a severe crash, the child safety lock ECU unlocks the child safety locks immediately, and if it is determined a minor crash or no crash has occurred, the locks remain engaged.
The child safety lock ECU is configured to receive the general signals transmitted through the general vehicle communication bus and filter the one of at least two CSL command signals from the general vehicle communication bus signal. The child safety lock ECU engages or disengages a child safety lock actuator depending on the one of at least two CSL command signals received by the child safety lock ECU.
The system becomes engaged (i.e. the ECUs are activated and begin transmission) upon start-up of the vehicle and are subsequently re-initialized upon successive start-ups.
Various other data is transmitted along with the signals from the vehicle ECU provide different functionality. A rolling counter is employed in order to ensure consistent transmission of data from the ECUs. General data on the operation of the ECUs is transmitted concerning the operating parameters of the ECU such as, but not limited to, voltages, temperatures, and number of transmissions by the ECUs. This data can be interpreted in order to provide optimal operation by the ECU. Checksum protection is transmitted in order to verify the entire signal has been sent from the vehicle ECU to the child safety lock ECU and prevent miscommunication between the ECUs. An ECU identification signal is employed in order to establish the identity of the ECU which is currently transmitting.
Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a general schematic diagram of an automated child safety unlocking system in accordance with one embodiment of the invention;
FIG. 2A is a graphical illustration of an analog control signal for use in the automated child safety unlocking system in accordance with another embodiment of the invention;
FIG. 2B is a graphical example of an analog pulse width modulated control signal for use in connection with the automated child safety unlocking system;
FIG. 3 is a schematic diagram of the automated child safety unlocking system in accordance with a second embodiment of the present invention;
FIG. 4A is a schematic diagram of digital communications between the vehicle ECU and the child safety lock ECU;
FIG. 4B is a schematic diagram of digital communications between the vehicle ECU and the child safety lock ECU;
FIG. 5 is a decision box diagram of the automated child safety unlocking system in accordance with the present invention;
FIG. 6 is a decision box diagram showing an operational overview of the automated child safety unlocking system in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The following description of the preferred embodiment(s) is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses.
Referring now to the Figures, with particular reference to FIG. 1 , a schematic diagram of an automated child safety unlocking system 10 is shown. The child safety unlocking system 10 uses two or more crash sensors 12 that are each configured to generate a crash signal upon detection of an event. The two or more crash sensors 12 are located at various portions on a vehicle body. The crash sensors 12 can include pressure sensors, accelerometers, light sensors, or virtually any other type of sensor capable of sensing or detecting an event such as a vehicle collision with an object or other vehicle. Depending upon the number of crash sensors 12 that generate a crash signal 13 , the child safety unlocking system can be configured to determine the severity of a vehicle impact using the information or crash signal or the number or type of crash signal generated from the crash sensors 12 . The crash sensors 12 are configured to generate the crash signal 13 only upon detection of an event, where if no event is detected, no signal will be sent. The crash sensors 12 are placed at different locations on the vehicle exterior and interior of the vehicle cabin. Examples of sensor locations and functions include front, side and rear sensors, brake sensors, airbag sensors and virtually any other type of sensor suitable for detecting an event, such as a vehicle crash.
Crash sensors 12 generate a crash signal to a vehicle ECU 14 that is configured to receive a crash signal from each of the sensors 12 . The vehicle ECU 14 is then configured to transmit one of at least two child safety lock (CSL) command signals 16 . The type of CSL command signal transmitted is specific to an event severity and event type, which can be determined by the number of crash signals 13 or the types of crash sensors 12 transmitting the crash signal 13 . The CSL command signals 16 are generated by the vehicle ECU 14 to a child safety lock ECU 18 .
The transmission of the CSL command signals 16 can be done by an independent communication bus directly coupled to the child safety lock ECU 18 or, in a preferred embodiment of the invention; the vehicle ECU 14 transmits the CSL command signals 16 as part of the general signals over a general vehicle communication bus 20 . The general signals over the general vehicle communication bus 20 include other types of signals that go to other vehicle systems. This allows for a general or centralized arrangement of communication between the vehicle ECU 14 and the child safety lock ECU 18 , without having to provide a designated wiring or communication link.
The child safety lock ECU 18 is configured to receive the general signals transmitted through the general vehicle communication bus 20 . The child safety lock ECU 18 filters the one of at least two CSL command signals 16 from the general vehicle communication bus 20 . The child safety lock ECU 18 then selectively disengages a child safety lock actuator 22 in response to the type of CSL command signal 16 received by the child safety lock ECU 18 . Disengagement of the child safety lock actuator 22 can mean that the child safety features are disengaged so that the door can be unlocked by anyone inside of the vehicle. Additionally disengagement of the child safety lock actuator 22 also includes disabling the child safety lock features and unlocking the vehicle door so that someone from outside of the vehicle can open the unlocked door.
The engagement or disengagement of the child safety lock actuator 22 is controlled by the child safety lock ECU 18 . The child safety lock ECU 18 is configurable to adjust the amount of time before the child safety lock ECU 18 disengages the child safety lock actuator 22 depending upon the type of CSL command signal 16 transmitted by the vehicle ECU 14 . For example, if the child safety lock ECU 18 receives a CSL command signal 16 that indicates that the event severity was not very great or the type of event that occurred was not overly dangerous, then the child safety lock ECU 18 may forgo disengaging the child safety lock actuator 22 . Or, if the event severity or event type is such that it indicates that the crash is occurring for a certain duration or period of time, such as a multiple vehicle collision or vehicle roll over scenario, then the child safety lock ECU 18 may delay the disengagement of the child safety lock actuator 22 for a predetermined period of time that is programmed into the child safety lock ECU 18 , while in another example, if the event severity or event type was severe and the circumstances are known to indicate that the crash has ended, but there is imminent danger and person need to exit the vehicle, the child safety lock ECU 18 is preprogrammed to immediately disengage the child safety lock actuator 22 without any delay of time. This allows for the door to be immediately opened from the inside or outside. The amount of delay or action to be taken by the child safety lock ECU is all pre-programmable onto the child safety lock ECU and can be changed or adjusted depending upon the circumstances or known circumstances of a crash.
The communication between ECUx and ECUy (crash notification data) can be realized by one or a combination of the following types of communication:
Digital: e.g. CAN, Flex-ray, LIN, Kline, etc. Analog: Based on exceeding an analog threshold in the signal (positive or negative slopes); Analog PWM: Based on an analog PWM signal. Frequency/period can be configured based on needs.
It will be readily appreciated that combinations of these may be used for redundancy if necessary.
FIGS. 2A and 2B show examples of analog signals that are transmittable as the CSL command signal 16 between the vehicle ECU 14 and the child safety lock ECU 18 . FIG. 2A shows two analog signals implementing a positive pulse or negative pulse in the signal when a crash occurs. As shown a constant value signal is transmitted between the vehicle ECU 14 and the child safety lock ECU 18 . When an event is detected by the vehicle ECU 14 the analog signal, transmitted as the CSL command signal 16 can pulse positive, negative or both. Depending on if the signal pulses positive or negative will control whether the child safety lock ECU 18 engages or disengages the child safety lock actuator 22 . For example the child safety lock ECU 18 can be programmed to delay disengagement of the child safety lock actuator 22 for any programmable period of time such as 5, 10, 15, 20 seconds if the pulse is negative, which is programmed to indicate a severe or longer duration crash or event. In the same example the child safety lock ECU 18 can be programmed to immediately disengage the child safety lock actuator 22 if the pulse if positive, indicating a less severe of short duration crash or event.
FIG. 2B shows an example of a pulse width modulated analog signal 48 that is transmittable as a CSL command signal 16 between the vehicle ECU 14 and the child safety lock ECU 18 . The signal 48 contains a first set of pulses 50 of varying interval and intensity, a second set of pulses 52 of varying interval and intensity and a third set of pulses 54 of varying interval and intensity. The child safety lock ECU 18 is programmable to monitor the pulse width modulated signal 48 and determine what type of event has occurred based on the set of pulses received and how the child safety lock actuator 18 is programmed to respond. For example the set of pulses 50 could indicate no action should be taken and the child safety lock actuator 22 should not change state because either no event has occurred or the type of event that has occurred does not warrant disengagement of the child safety lock actuator 22 . An example of such an event would be if a minor crash occurred and the driver might need to exit the vehicle, but would not want the child safety lock doors unlocked to keep children from exiting the vehicle where they would be exposed to passing traffic. The set of pulses 52 could indicate an event that is severe but short in duration and require the immediate disengagement of the child safety lock actuator 22 . Example could be a vehicle crash where the car has stopped moving but is on fire. The set of pulses 54 could indicate that a severe event has occurred that will be long in duration, therefore, there will be a delay before disengagement of the child safety lock actuator 22 . An example would be a crash where the vehicle rolls multiple times or a multi-vehicle crash. The way the child safety lock ECU 18 reacts to the different pulses is completely programmable to any desired action or duration before action takes place depending on a particular application or customer requirement.
FIG. 4 is a schematic diagram of digital CSL signals 16 transmitted between the vehicle ECU 14 and the child safety lock ECU 18 . As shown the top portion of the diagram schematically shows a digital signal 24 transmitted from the vehicle ECU 14 to the child safety lock ECU 18 , while the bottom portion of the diagram shows a digital signal 26 transmitted from the child safety lock ECU 18 to the vehicle ECU 14 . The digital signal 24 includes a transmitter identification portion 28 and a receiver identification portion 30 , which allows the child safety lock ECU 18 to identify that the digital signal 24 is coming from the vehicle ECU 14 and is intended for the child safety lock ECU 18 . This enables the child safety lock ECU 18 to filter the digital signal 24 from the other signals of the general communication bus 20 . The digital signal 24 also contains a rolling counter portion 32 that defines the size of the signal being transmitted. A general data portion 34 of the digital signal 24 contains information concerning the event status, severity and type. The general data portion is used by the child safety lock ECU 18 to determine when and whether to disengage the child safety lock actuator 22 . Additionally the general data portion 24 contains other data or information requests concerning but not limited to child safety lock actuator 22 status request, customer diagnostic request, child safety lock ECU 18 and child safety lock actuator 22 verification of test request. The digital signal 24 also contains a checksum protection portion 36 that allows the child safety lock ECU 18 to confirm that the entire message of the digital signal 24 was received.
When the general data portion 34 contains a request for information from the child safety lock ECU 18 or when the child safety lock ECU 18 is programmed to automatically send a signal to the vehicle ECU 14 , the digital signal 26 is transmitted. The digital signal 26 includes a transmitter identification portion 38 and a receiver identification portion 40 , which allows the vehicle ECU 14 to identify that the digital signal 26 is coming from the vehicle ECU 14 and is intended for the child safety lock ECU 18 , this enables the vehicle ECU 14 to filter the digital signal 26 from the other signals of the general communication bus 20 . The digital signal 26 also contains a rolling counter portion 42 that defines the size of the signal being transmitted. A general data portion 44 of the digital signal 26 contains information concerning the event status, severity and type. Additionally the general data portion 44 contains other data or information requests concerning but not limited to child safety lock actuator 22 status, customer diagnostic information, child safety lock ECU 18 and child safety lock actuator 22 verification of test response. The digital signal 26 also contains a checksum protection portion 46 that allows the child safety lock ECU 18 to confirm that the entire message of the digital signal 26 was received.
FIG. 3 depicts a second embodiment of the invention showing an automated child safety lock unlocking system 100 using the same reference numbers for identical components show in FIG. 1 , with variations labelled with prime numbers. The automated child safety lock unlocking system 100 has the same crash sensors 12 as shown in FIG. 1 , with crash signals 13 being transmitted directly to a child safety lock ECU 18 ′. The child safety lock ECU 18 ′ determines the type of crash and the appropriate time for disengaging the child safety lock actuator 22 . The present embodiment eliminates the need for having the vehicle ECU 14 and sending signals through the general communications bus 20 as described in FIG. 1 above.
Referring now to FIG. 5 a decision box diagram of the automated child safety unlocking system 10 , 100 in accordance with the present invention where the steps outlining the monitoring the operation of the automated child safety unlocking system 10 , 100 is functioning. At a start step 48 the vehicle ignition is turned on and the child safety lock system has gone through a check sequence as described below in FIG. 6 . At decision step 50 “Has Crash Occurred/” the system 10 , 100 determines if a crash has occurred. The term “crash” as used herein means any event that warrants a change in the child safety lock status. This determination is made by the vehicle ECU or the child safety lock ECU depending on the arrangement and programming of the controllers. If at the decision step 50 it is determined that no crash has occurred then the child safety lock ECU will move to a “Do Nothing” step 52 and take no action to disengage the child safety lock actuator. The system 10 , 100 will continue to cycle back to the decision step 50 at programmed intervals or up receipt of more information by the vehicle ECU or child safety lock ECU until at the decision step 50 it is determined that a crash has occurred. At the decision step 50 a determination is also made as to the type of crash and event and whether or not there should be a delay in taking action. If the system 10 , 100 determines that a crash has occurred then at step 54 the child safety lock actuator is commanded to disengage. After step 54 the system 10 , 100 will take no further action until the vehicle has turned off and then will restart the process at step 48 upon starting of the vehicle.
FIG. 6 is a decision box diagram showing more details concerning the operational routine of the invention. Upon a vehicle turn on step 58 , vehicle ECU (if present) and the child safety lock ECU at step 60 “ECU init” operates in an initialization mode. At step 62 “Diagnose CSL State” the child safety lock ECU determines that state of the child safety lock actuator, which can be engaged or disengaged. At a decision step 64 the child safety lock ECU waits until a determination is made whether a “crash occurred?” This includes a determination of whether a crash has occurred that warrants unlocking the child safety lock. If at decision step 64 the answer is “YES” then at decision step 66 a determination is made whether “child safety lock locked?” This determination is made by information obtained at step 62 where the child safety lock state is determined, however, the child safety lock ECU may also perform a subsequent diagnosis of the state of the child safety lock. If is determined that the child safety lock is locked then at step 68 the child safety lock will be unlocked and at step 70 operational routine until the vehicle is turned off and then back on.
If at decision step 64 it is determined that no crash occurred than at steps 72 the child safety lock ECU will “diagnose the child safety lock” and step 74 will “define child safety lock state” in order to perform a self test or diagnose the child safety lock. This will allow the child safety lock ECU to check or confirm the status of the child safety lock to store in the memory of the child safety lock ECU where the routine will cycle back to decision step 64 . Steps 72 , 74 will also allow the child safety lock ECU to check for failure of the child safety lock.
The description of the invention is merely exemplary in nature and, thus, variations that do not depart from the gist of the invention are intended to be within the scope of the invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention.
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An automated child safety unlocking system for automobiles which disengages the child safety locks and unlocks the doors at appropriate times during events such as vehicle crashes. The vehicle ECU continually monitors the status of the vehicle to check if a crash event has occurred via various methods such as the status of airbag deployment, accelerometers placed in the car, and crumple points. In the event of a crash the vehicle ECU transmits one of at least two CSL command signals a child safety lock ECU. The command signals are each specific to an event severity and event type, and the child safety lock ECU then interprets the signal and acts according to the signal type. If the data interpreted indicates a crash, the child safety lock ECU unlocks the child safety locks, and if it does not determine a crash has not occurred, the locks remain engaged.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to an ignition system for a gasoline engine.
2. Description of the Prior Art
Generally, in ignition systems of the type in which the interrupting signal from the contact breaker of the distributor is amplified by a transistor, means are provided for minimizing the amount of current applied to the contact breaker so as to enhance the durability (increase the wear-life) of the contact breaker contacts. This however, gives rise to the possibility of causing fouling or poor conductivity of the contact points due to the points being stained by lubricating oil used on the sliding parts in the distributor or other factors. As a countermeasure to avoid this, attempts have been made to use a lubricating oil which is less liable to inhibit conduction; an alternative measure has been to increase the voltage or current applied to the contact points to a certain elevated level. But increased current invites a reduction in the durability of the contact points.
SUMMARY OF THE INVENTION
In view of the above, the present invention proposes an improved ignition system in which the amount of current supplied to the interrupter is increased only when the gasoline engine is operating under a certain special condition, in order to thereby improve the durability of the contact points contacts and to prevent fouling.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a circuit diagram showing one embodiment of the present invention; and FIG. 2 is a circuit diagram showing another embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The invention will now be described in detail by way of some preferred embodiments thereof with reference to the accompanying drawings.
Referring first to FIG. 1, an embodiment of the present invention is shown where the value of current supplied to the contact points is controlled in correspondence with the starting condition of the engine. A battery 1, grounded at its cathode, is connected at its anode to the primary winding of an ignition coil 3 through a main switch 2. The secondary winding of ignition coil 3 is grounded through a spark plug 4. The connecting point of the primary and secondary windings of ignition coil 3 is connected to the collector of an NPN type transistor 5, the emitter of which is connected to ground. Resistors 6 and 7 are connected in series to the base of transistor 5 to supply an electric current or voltage from the battery 1 to transistor 5 through the main switch 2. The base electrode of transistor 5 is grounded through a resistor 8 and also through a contact 10 of a contact breaker 9. The main switch 2 is connected to the junction point of resistors 6 and 7 through a switch 11 and is further connected to one of the terminals of an engine starting motor 13 through a switch 12, the other terminal of starting motor 13 being grounded. A screw-like spline, which is meshed with a pinion 14, is formed at one end of the revolving shaft of starting motor 13. Pinion 14, in turn, is arranged to mesh with a gear 15 of the engine. A lever 16 for controlling axial movement of pinion 14 is also provided.
The main switch 2 is connected to the coil of an electromagnet 18 which operates lever 16 through a starter switch 17. When starter switch 17 is closed, an electric current flows to the coil to energize electromagnet 18 to let the lever 16 pivot clockwise about its axis, causing the pinion 14 to mesh with the gear 15 and at the same time closing switches 11 and 12.
Now the engine is rotated by the starting motor 13, while the transistor 5 becomes conductive and nonconductive repetitively as the contact points 10 of the interrupter 9 is opened and closed successively. At the instant when the transistor 5 becomes nonconductive, a high voltage develops in the secondary winding of the ignition coil 3 to generate sparks in the spark plug 4 to start operating the engine. During this period, since the resistor 6 is shortcircuited by the closure of the switch 11, a high voltage is applied or a large current flows to the contact points 10.
When the rotational frequency of the engine becomes greater than that of the starting motor 13, the pinion 14 moves to the right on the spline of the motor shaft and disengages from the gear 15 of the engine. This rightward movement of the pinion 14 causes the lever 16 to swing counterclockwise against the magnetic force of the electromagnet, consequently opening the switches 11 and 12. Now the starting motor 13 is disconnected from the battery 1 and the engine proceeds into a normal operating condition. When the switch 11 is opened, the contact points 10 becomes connected to the battery 1 through both resistors 6 and 7, with the result that a a current smaller than that applied at the time of engine starting is applied to contact points 10.
FIG. 2 shows another embodiment where the value of current supplied to the contact points 10 is controlled in accordance with the vacuum pressure of the engine carburetor. As in the embodiment of FIG. 1, the battery 1 is connected through a main switch 2 to an ignition coil 3, spark plug 4, transistor 5, resistance 8 and contact points 10 of contact breaker 9. In this case, however, a resistance 19 and a switch 20 (which are connected in series) and a resistance 21 are connected between the main switch 2 and the base of the transistor 5; switch 20 is provided with a diaphragm 23 adapted to close switch 20 when the vacuum pressure of the engine carburetor 22 is small. Owing to this arrangement, when the vacuum pressure is large, electric current flows only to the resistors 8 and 21, and only a small current flows or a low voltage is applied to the points 10. However, if the vacuum pressure of the carburetor 22 is reduced, such as at the time of acceleration, the switch 20 is closed by the diaphragm 23 to connect the resistance 19 in parallel to the resistance 21, thereby reducing the effective resistance between battery 1 and contact point 10 in a known manner, so that the contact point 10 is supplied with a current greater than that applied when the negative suction pressure is high.
Thus, according to the present invention, as is apparent from the foregoing description, the current supplied to the contact points is increased at the time of starting of the engine or when the vacuum pressure of the carburetor is low to thereby prevent fouling or damage of the contact points, and during the other condition of engine operation, the current supplied to the interrupter contact is reduced to enhance the durability and increase the life of this contact. Therefore, the interrupter contact is less likely to be fouled or damaged, as by lubricating oil or the like and is also free from damage by high current.
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An ignition system for a gasoline engine comprising an ignition coil to which an electric current is supplied from a battery through a transistor. The transistor is so controlled as to turn on and off in response to switching off and on of a contact breaker. A current flowing through the breaker points of the contact breaker is increased temporarily in accordance with the operating conditions of the engine for preventing fouling or damage of the breaker points due to contaminants deposited thereon.
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TECHNICAL FIELD
The present invention relates to the servicing or workover of hydrocarbon wells and, in particular, to a method and apparatus for the servicing or workover of a hydrocarbon well when tubing does not need to be run into or removed from the well.
BACKGROUND OF THE INVENTION
Hydrocarbon production wells which are drilled in the earth to produce oil or gas must be reworked or serviced from time to time. Wells may require service for a number of reasons. For example, worn or faulty valves may require replacement, seals may need to be replaced or renewed, or it may be necessary or desirable to insert a new flange or remove a flange from the wellhead, etc. Well workover generally entails well treatments to stimulate hydrocarbon production. Such treatments may include high pressure fracturing and/or acidizing. During well stimulation it is common knowledge that it is preferable to introduce stimulation fluids into the well at the highest possible transfer rate. Consequently, the wellhead is now frequently removed and stimulation fluids are pumped through the blowout preventers and into the casing. In order to protect the blowout preventers, blowout preventer protectors have been invented, as described in Applicant's U.S. Pat. No. 5,819,851 which issued on Oct. 13, 1998. Generally, a workover rig is brought in and setup to remove the wellhead components when well workover is required. Such rigs comprise a derrick or mast which supports pulleys or block and tackle arrangements operable to pull the wellhead from the well and may also be used to pull the production tubing string from the well bore or run a production tubing string or other tools into the well.
The rig is used to remove and replace the wellhead, unseat and reseat the packers and/or anchors in the well, etc. Although workover rigs are functional and adapted to perform any job associated with manipulating well components during a well workover, they are large assemblies of equipment that are expensive to move and setup. Besides, they require a crew of four, so they are expensive to operate.
A workover rig may also be brought in for servicing a well to install blowout preventers (BOPs), repair or replace valves or seals, etc. In each of these servicing operations the production tubing is not removed from or run into the well. Nonetheless, the production tubing may have to be lifted with the wellhead.
Efforts have been made to develop various types of lifting apparatus for use in well workovers and well servicing operations. In particular, a portable or compact apparatus has been invented for replacing a large conventional well rig for lifting a wellhead and production tubing string in certain well servicing or workover applications. U.S. Pat. No. 4,756,366 which issued to Maroney et al. on Jul. 12, 1988 and is entitled “WELL SERVICING METHODS USING A HYDRAULIC ACTUATED WORKOVER MAST”, discloses a portable workover rig for lowering and raising objects such as pipe into and out of a borehole. The workover rig is mounted to a heavy vehicle and includes a mast which can be raised from a horizontal to a vertical position, a hydraulic system and drum cable system. Nevertheless, the portable workover rig disclosed in this patent is expensive to construct and operate because a dedicate vehicle, a dedicated hydraulic system and a complicated mechanical structure are involved.
A tool useful in pulling casing from a dead well is illustrated in U.S. Pat. No. 2,661,063, which issued to Owens on Dec. 1, 1953 and is entitled “METHOD AND MEANS OF PULLING PIPE FROM A WELL”. Owens discloses the use of a pair of hydraulic jacks to loosen a pipe that gets stuck while being pulled from a dead well by a rig. The jacks exert an upward force through two arms affixed to a collar attached by shearable pins to the pipe being pulled by the rig. The pins shear unless the pipe dislodges from the stuck position. The shearing of the pins causes a downward jar or jerk on the pipe that tends to loosen the pipe. After the pipe is loosened, it is pulled from the well using the rig until it is removed, or it gets stuck again. It is apparent that the jacks used in this application are auxiliary and only used in conjunction with a rig. The jacks are not designed to lift a wellhead for well servicing or workover. Nor is the pipe being lifted by the jacks rotatable relative to the collar due to the shearable pin connection between the two. Therefore, this apparatus is not adapted for well servicing or workover.
There therefore exists a need for a safe, economical apparatus for well servicing or workover which permits a servicing or workover operation to be rapidly and efficiently accomplished when tubing does not need to be run into or removed from the well.
SUMMARY OF THE INVENTION
An object of the invention is to provide an apparatus for lifting a wellhead, a production tubing string, or a wellhead with an attached production tubing string for well servicing or workover.
Another object of the invention is to provide an apparatus and method for well servicing or workover in a safe, economical and fast manner when the production tubing does not need to be run into or removed from the well.
A further object of the invention is to provide a portable apparatus for lifting a wellhead, a production tubing string or a wellhead with an attached tubing production string.
In accordance with one aspect of the invention, there is provided an apparatus for well servicing or workover comprising:
a pair of base assemblies connected to each other in a spaced apart relationship adapted to flank a wellhead;
a pair of lifting devices respectively mounted to the base assemblies for lifting the wellhead, the wellhead with an attached production tubing string, or a production tubing string;
a workover beam supported at opposite ends by the lifting devices; and
a lifting sub connected to the workover beam and adapted for detachable connection to the wellhead or the production tubing string so that the wellhead is rotatable when disconnected from the well and the lifting devices are operated to raise the workover beam.
The lifting devices are preferably a pair of hydraulic cylinders. Each of the base assemblies preferably comprise a base beam, a plate extending longitudinally of and upwardly from the base beam, and a locking device associated with the plate for releasably retaining the lifting devices in a vertical position.
Each of the cylinders is preferably mounted to the plate by a pivotal axis perpendicular to the plate so that the lifting devices are pivotally moveable to a horizontal position for transportation, in which position the lifting devices are parallel to the base beam. The base beams are preferably parallel to each other and interconnected by a plurality of cross-members. The cross-members are preferably permanently affixed to one end of the base beams and detachably connected to the other end of the base beams to permit the apparatus to be positioned so that the base beams flank the wellhead.
The lifting sub is preferably rotatable relative to the workover beam so that the wellhead and/or the production tubing string may be rotated while it is attached to the lifting sub. The apparatus may further comprise a motor mounted to the workover beam and associated with the lifting sub to permit the wellhead or a production tubing connected to the lifting sub to be rotated under mechanical force exerted by the motor.
In accordance with another aspect of the invention, a method of well servicing or workover comprises:
a) placing on a well site an apparatus which includes lifting devices that are respectively supported by a pair of interconnected base assemblies so that the wellhead is flanked by the lifting devices;
b) connecting the wellhead to a lifting sub secured to a workover beam supported on opposite ends by the respective lifting devices;
c) disconnecting the wellhead at a point required for the well servicing or workover operations;
d) raising the workover beam by operating the lifting devices;
e) performing the well servicing or workover operations;
f) lowering the workover beam by operating the lifting devices after the well servicing or workover operation is completed;
g) reconnecting the wellhead and disconnecting the lifting sub from the wellhead; and
h) removing the apparatus from the well site.
Preferably, step b) is completed by removing a wellhead cap and connecting the lifting sub to a top of the wellhead.
The advantageous structure of the apparatus and the method according to the invention provide a simple, safe, fast and economic manner of performing a well service or workover operation, particularly, in the cases in which the production tubing does not need to be run into or removed from the well. The use of hydraulic cylinders as lifting devices also provides a convenient method of calculating the weight of the wellhead, and/or any production tubing that has been lifted. The weight can be calculated using a reading from a pressure gauge that is connected to the service line for supplying hydraulic fluid to the cylinders.
The structure of the apparatus is also adapted to facilitate transportation. The apparatus may be constructed as a skid or may be rubber wheel mounted and provided with a hitch to permit towing behind a crane truck or the like. If rubber wheel mounted, the wheels are preferably pivotally mounted to the base beams and rotatable from a transport position to a working position. Hydraulic cylinders may be used to shift the wheels from the transport to the working position.
Other features and advantages of the apparatus will be clearly understood from the detailed description of the preferred embodiment which follows.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described in more detail by way of example only and with reference to the accompanying drawings, in which:
FIG. 1 is a schematic side elevational view of a preferred embodiment of an apparatus in accordance with the invention, illustrating the apparatus with a pair of lifting devices in a horizontal position for transportation;
FIG. 2 illustrates the embodiment shown in FIG. 1 in the same view with the lifting devices in a vertical working position;
FIG. 3 is a schematic plan view of the embodiment shown in FIG. 1, in a working position over a wellhead;
FIG. 4 is a schematic elevational view from a point indicated by arrow A of FIG. 3, illustrating a step in the servicing or workover of a hydrocarbon well using the apparatus shown in FIGS. 2 and 3;
FIG. 5 is a schematic elevational view of a workover beam shown in FIG. 4, with a motor mounted thereto to facilitate rotation of a wellhead or a production tubing;
FIG. 6 is a schematic side elevational view of the apparatus shown in FIGS. 1-5 equipped with wheels and a tongue to permit the apparatus to be towed to a well site, the wheels being in a lowered position adapted for transport;
FIG. 7 is a schematic side elevational view of the apparatus shown in FIG. 6, showing the apparatus in a working position with the wheels raised; and
FIG. 8, which appears on sheet one of the drawings, is a schematic diagram of a hydraulic system, showing a pressure gauge which may be used for calculating the weight of a wellhead and/or a production tubing during a well servicing or a workover operation.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
As shown in FIGS. 1 and 2, the apparatus of the present invention for well servicing and workover is generally designated by reference numeral 10 . The apparatus 10 includes a pair of spaced apart base assemblies 12 and lifting devices 14 . The lifting device 14 are preferably hydraulic cylinders, but may be ball jacks (not shown) or any other appropriate and robust lifting device. Each base assembly preferably includes an elongated steel base beam 16 which has a rectangular cross-section. A trapezoidal plate 18 extends upwardly from a center portion of the base beam 16 and is affixed to an inner side of the base beam 16 , as more clearly illustrated in FIGS. 3 and 4. A vertical ram support 20 which extends from a top of the base beam 16 to a top edge of the trapezoidal plate 18 supports the lifting device 14 in a vertical working position. The entire base assembly 12 is preferably a welded steel structure.
The lifting device 14 is mounted to the outside of the plate 18 by a pivot pin 22 that is located above the base beam 16 adjacent the ram support 20 , so that the lifting device 14 is pivotally moveable from a horizontal position for transport, as shown in FIG. 1, to a vertical position for working, as shown in FIG. 2. A bore 24 , or the like, is provided near a top of the plate 18 for detachably receiving a lock pin 26 that is more clearly illustrated in FIG. 4 . The lifting device 14 is securely supported in the vertical position between the ram support 20 and the lock pin 26 .
As illustrated in FIGS. 3 and 4, the pair of base assemblies 12 are interconnected at one end by permanent cross-members 28 which are preferably welded to the base beams 16 and at the other end by detachable cross-members 30 which are detachably connected to the base beams 16 using connector pins 32 , or the like. The detachable cross-members are preferably received in pockets 31 formed in the base beams 16 to ensure maximum rigidity of the apparatus 10 . The detachable cross-members 30 are removed when the apparatus 10 is to be positioned so that the wellhead 34 is flanked by the lifting devices 14 , as shown in FIG. 3 . The two pivot pins 22 should be lined up with a center of the wellhead 34 when the apparatus 10 is in the working position. The detachable cross-members 30 are re-connected to the base beams 16 after the apparatus is manoeuvred into the working position. A workover beam 36 is supported at each end by a cradle 40 that is fixed to an end of a ram 38 of the lifting device 14 . The workover beam 36 is preferably attached to the cradle 40 by lock pins 42 (FIG. 3) that are releasably received in bores in the workover beam 36 (the bores are not shown). A lifting sub 44 is releasably received in an aperture (not shown) in a middle of the workover beam 36 . The lifting sub 44 preferably incorporates a swivel 46 to permit the wellhead 34 and attached production tubing to be rotated while attached thereto. Alternately, the lifting sub 44 may be rotatably mounted to the workover beam 36 using ball bearings or the like. Extensions for the lifting sub 44 may be provided to accommodate connection to wellheads of varying height.
FIG. 5 illustrates a workover beam 48 which may be used in place of the workover beam 36 described above. A hydraulic motor 50 is mounted to the workover beam 48 and is operably connected to a lifting sub 52 . The hydraulic motor 50 is adapted to rotate the wellhead and attached tubing string to unseat or reseat packers or anchors, etc. when the lifting sub 52 is attached to the wellhead 34 .
The apparatus 10 may be constructed as a skid, as illustrated in FIG. 1, or it may be rubber wheel mounted and provided with a hitch for towing. The apparatus 10 is preferably not more than 8 feet (2.44 m) wide to enable legal highway towing and about 12 feet (3.66 m) long for extra base stability over the wellhead. The lifting devices 14 are preferably not less than 8 feet (2.44 m) long to ensure at least an 8 foot (2.44 m) stroke. The apparatus 60 , illustrated in FIG. 6, has a similar configuration to the apparatus 10 , except that a pair of wheel assemblies 62 are pivotally mounted to the base beams 16 , and a hitch member 64 that is mounted to the endmost permanent cross-member 28 . Alternatively, the hitch member 64 may be mounted to one or both of the removable cross-members 30 . Each wheel assembly 62 includes a wheel 66 which is rotatably supported by a pivot member 68 . The pivot member 68 is, in turn, pivotally mounted to an anchor member 70 which is welded to the outer side of the base beam 16 . A double-acting hydraulic cylinder 72 is pivotally mounted to the outside of the base beam 16 and a ram of the double-acting cylinder is pivotally connected to the pivot member 68 so that the wheel assembly 66 pivots down to support the apparatus 60 when the ram of the double-acting hydraulic cylinder 72 is stroked in. The pivot member is preferably locked in the lowered position shown in FIG. 6 using a locking pin (not shown), or the like. To place the apparatus 60 in the working position shown in FIG. 7, the locking pin (not shown) is removed from the pivot member 68 and the double-acting hydraulic cylinder 72 is operated so that the ram is extended and the wheel 66 pivots up off from the ground as illustrated in FIG. 7 .
FIG. 8 illustrates a hydraulic system used to augment the lifting device 14 when the lifting devices 14 are hydraulic cylinders. A pressure gauge 74 is connected to a hydraulic fluid supply line 76 which is connected to a pressurized hydraulic fluid source 78 and the lifting devices 14 . Readings taken from the pressure gauge 74 may be used to calculate the weight of the wellhead 34 and attached production tubing being lifted, using methods well known in the art.
In operation, the apparatus 10 is transported to a well site and is moved to a position in which the wellhead 34 is flanked by the base assemblies 12 and the two pivots 22 are aligned with the center of the wellhead 34 . The lifting devices 14 are pivoted from the horizontal position to the vertical position where they are stopped by the ram supports 20 . The lock pins 26 are inserted in the respective bores 24 to lock the cylinders 14 in the vertical position. The workover beam 36 is placed in the cradles 40 on the ram end of each lifting device 14 , and the lock pins 42 are inserted into the corresponding bores in the workover beam 36 . A lifting sub 44 and swivel 46 are assembled with a length that reaches a top of the wellhead 34 . Typically, a cap 35 on the wellhead 34 is removed after appropriate valves are closed and the lifting sub 44 is threadedly attached to a top of the wellhead 34 . The apparatus 10 is now ready to lift the wellhead 34 . The BOP 80 is closed and the wellhead 34 is unbolted at an appropriate flange depending on a specific workover or servicing to be done.
If the BOP is to be lifted, the well is killed first by injecting an appropriate fluid to overbalance natural pressure in the well. For example, in preparation for a well stimulation operation, a blowout preventer protector (BOP) disclosed by the Applicant in the U.S. Pat. No. 5,819,851 which issued on Oct. 13, 1998 is mounted to a top of the BOP 80 . Consequently, the well is killed and the wellhead is split below the tubing hanger. The wellhead 34 is lifted along with a production tubing 82 by the workover beam 36 as pressurized hydraulic fluid is injected into the lifting devices 14 . As will be understood by those skilled in the art, the wellhead 34 and the production tubing 82 may have to be rotated as they are lifted in order to unseat packers and/or anchors that support the production tubing 82 downhole. After the wellhead 34 is raised to a desired height, slips (not shown) are placed around the production tubing 82 to lock the production tubing 82 to the top of the flange of the tubing head spool 37 and then pressurized hydraulic fluid is released from the lifting devices 14 . The lifting sub 44 is removed from the wellhead 34 while the wellhead 34 is supported by a crane truck or the like. The wellhead 34 is then detached from the production tubing 82 and removed from the area. A BOP and a BOP protector (not shown) is placed on the top of the tubing head spool, a high pressure valve is mounted to the BOP protector and a blast joint is connected to a top of the production tubing string.
The workover beam 36 is replaced and the lifting sub 44 is connected to a top of the production tubing string 82 . High pressure hydraulic fluid is injected into the lifting devices 14 so that the slips can be removed. The production tubing string is then positioned and connected to a top of the high pressure valve in a manner well known in the art. Advantageously, a high pressure gauge (not shown) is connected to a top end of the production tubing string 82 to permit downhole pressure to be monitored during the well stimulation process. Thereafter, the kill fluid is blown out of the well and a fracturing or other stimulation operation can be conducted through the high-pressure valve and the BOP protector. After the stimulation treatment is completed, the process is reversed until the wellhead is repositioned on the well and the apparatus 10 is removed from the well site.
The apparatus 10 in accordance with the invention provides many distinct advantages over the prior art. For example, it is lightweight and can be quickly manoeuvred into position to service most wells. It requires only a few minutes of setup time and can be used to perform most workover and servicing jobs as long as there is no need to remove an extensive amount of production tubing from a well. It is also quickly removed from a well site. Furthermore, it requires fewer operators than a conventional rig, so operating overhead is reduced.
Changes and modifications to the above-described embodiment will no doubt be apparent to those skilled in the art. The scope of the invention is therefore intended to be limited solely by the scope of the appended claims.
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The present invention relates to a method and apparatus for the servicing or workover of a hydrocarbon well. The apparatus includes a pair of hydraulic cylinders pivotally mounted to a pair of base beams connected to each other. The cylinders are moveable from a horizontal position for transportation to a vertical position for operation in which position the two cylinders flank a wellhead and are adapted to lift the wellhead and attached production tubing using a workover beam and a lifting sub. The wellhead and production tubing can be rotated as or after they are elevated. A motor may be mounted to the workover beam to rotate the wellhead and the tubing. A calibrated pressure gauge may be used to indicate the weight being lifted. The apparatus can be wheel mounted and towed behind a crane truck. The advantage is a safe, economical and timesaving apparatus for performing jobs that previously required the setup and operation of a workover rig.
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REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Application for Patent No. 60/277292 titled “A Method of Effectively Reusing a Common Template File System Tree in an Environment With Concurrent Access and a Separate Private Modification Area” filed on Mar. 20, 2001 for priority under 35 U.S.C. § 119(e), is related thereto, is commonly assigned therewith, and the subject matter thereof is incorporated herein by reference in its entirety.
FIELD
The system of the present invention relates to the implementation of a common template computer data storage file system to be used in an operating environment including concurrent access from multiple operating systems.
BACKGROUND
The problem of effective utilization of computer resources, such as a data storage file system in a multi-user environment, has existed from virtually the first use of computers. In such data storage file systems, the data storage files are traditionally separated into several classes: the personal files of the user, the data storage files shared by all the users, temporary files, etc. The classes of these data storage files usually differ in their disposition in the data storage file system and in their access mode. Depending on the settings of the operating system, only the owner of the data storage file or someone with explicitly declared access rights has write-ability access to these data storage files. Everyone has write-ability access to temporary data storage files. The majority of users have read-only access to the general system files. In the system area, only the auxiliary data storage files are deposited. Therefore, the auxiliary data storage file provides the working information for the operating system.
Ordinary computer users generally are not interested in modifications of the content of system data storage files. Therefore, most often, all of the system data storage files, including the configuration of files, are usually seen by all the users of the operating system, and they are typically seen only in the read-only mode. Nevertheless, it is often necessary to provide for the possibility of multiple users making corrections to the system area. For example, for the configuration of system utilities, it is desirable that the unique data storage file modifications made by each computer user do not influence the configurations of others. This means that each computer user should be provided with an independent file system tree with the data storage files suitable for writing. If there are many such computer users with independent file systems on the same computer, it would be essential to implement an effective method for each computer user to access such data storage files. Traditionally, this problem is solved in two ways: 1) copying corresponding data storage files for each computer user; 2) using the data storage file system to create and support hard links. With these solutions, multiple references would need to be created to the same data storage file using different names.
Copying corresponding data storage files for each computer user leads to the multiple duplication of data storage files and is not an efficient use of data storage resources because of the typically large size of the system area. Another possible solution to this problem in the form of using the file system to create and support hard links, limits the user's ability to modify the data storage file system.
Since all of the users view the same system data storage file, its modification by one computer user will be immediately apparent to the other computer users who have access to the hard links of the same data storage file.
Thus, the need arises for an efficient solution that will allow many computer users to work on one physical computer. Each of the computer users has his/her own version, not only of their personal local data storage files, but also the system file area of the operating system.
Other prior art solutions have been discussed in the following references (See Bibliography). Partial solutions for this problem exist in many operating systems. For instance, in a UNIX type operating system, the primitive chroot is used to provide a certain level of security and separation for the computer users to allow them to have their own version of root data (Bach 1987, T HE D ESIGN AND I MPLEMENTATION OF THE 4.4BSD O PERATING S YSTEM ). But this solution assumes that each computer user should have his/her own unique data storage file system tree and that the data storage file system tree cannot be effectively implemented.
Another partial solution is the separation of read and write operations provided by a so-called Union file system (Pendry 1995, T HE D ESIGN AND I MPLEMENTATION OF THE 4.4BSD O PERATING S YSTEM ). The Union file system proposes a mount of one data storage file system tree on top of another tree. In such a case both trees become visible during the namespace lookup procedure. This allows the creation of separate write and read areas, but does not allow modification of data storage files which reside in the read-only area.
SUMMARY
The present invention offers a solution for the effective implementation of a multiple, partially shared tree of the data storage file system with the division of read-ability and write-ability streams in different areas of the namespace. As defined in O PERATING S YSTEMS: A D ESIGN -O RIENTED A PPROACH , namespace is a collection of unique names, where name is an arbitrary identifier, usually an integer or a character string (See C HARLES C ROWLEY , O PERATING S YSTEMS : A D ESIGN -O RIENTED A PPROACH (Irwin, 1997) ISBN 0-256-15151-2). Usually the term “name” is applied to such objects as files, directories, devices, computers, etc. More information about typical distributed file system name space and related problems can be found in (Kumar 1991, Lebovitz 1992, The Distributed File System (DFS) for AIX/6000, Rosenberry 1992).
The search for a data storage file to be opened in the read-only mode is carried out in two stages. First, the search is done in the computer user's personal private area; and in case of failure, the search is done in the common read-only shared area. Writing to data storage files is carried out only in the computer user's personal private area. Thus, from the point of view of the computer user, the computer user has only one tree of the data storage file system that can be modified in every place. Nevertheless, only the differences between the data storage file system common to all of the users of the computer and the modified user copy is actually preserved. The common part of the data storage file is preserved on the computer only in one copy and does not need duplication. Operation parsing is carried out on its type. When a data storage file is opened in read-only mode, then if the private data storage file is present, it is opened in the private modification area. If not, the single copy of one data storage file from the shared data storage file system is opened.
When the data storage file is opened for write-ability and the private data storage file is present, the file is opened in the private area of the computer user. If the private data storage file is not present, the data storage file from the shared area is at first copied into the private area and only then it is opened. Such organization of the work of the data storage file system makes the implementation much easier for journaling because all the changes for each computer user are localized and are kept in his/her private area.
The data storage file being observed from different views of the same common template data storage file system is treated by the operation system as the only file. This promotes the efficient utilization of computer memory. For instance, if this data storage file contains executable code, the operation system stores in memory only the shared copy for all instances of processes using this data storage file from different views.
BRIEF DESCRIPTION OF THE DRAWING
A better understanding of the data storage system and method of the present invention may be had by reference to the drawing figure wherein:
FIG. 1 is a schematic illustration of the relationship between a common root template of the data storage file system and the private modification area.
DETAILED DESCRIPTION OF THE EMBODIMENTS
The disclosed invention describes a way to effectively implement multiple, partially shared trees of a data storage file system by separating the read-ability and write-ability streams into different areas of the namespace. Namespace is a collection of unique names, where name is an arbitrary identifier, usually an integer or a character string. Usually the term “name” is applied to such objects as files, directories, devices, computers, etc.
The idea behind the instant invention is that the disclosed system 10 separates the modified part of the data storage file system from the non-modified part of the data storage file system in such a way that it creates two complete data storage file system trees of the required area of the file system imposed upon each other. Specifically, as VE 1 10 uses an integral data storage file system visible by the computer user; some visible data storage files exist only in some templates, and some visible files exist only in the private modification areas.
In the initial moment of time, the first data storage file system tree for read-only material contains the complete set of data storage files. The data storage file system tree for write-ability is empty, but it has the same directory structure.
FIG. 1 is a schematic illustration of the relationship between a common root template of the data storage file system and the private modification area. Data storage files could appear in read-only templates (see Template I 40 ) and in private modification areas (see VE 1 private data 30 ) which are visible from the same data file storage tree (see VE 1 20 ). Data storage files visible from VE 1 20 could be placed in different read-only templates, as for example, data storage files with names “Ibin/ed” 50 and “/X11R6/bin” 60 here, or in a private area as for example, the data storage file “/bin/red” 70 . Even if a data storage file such as “/usribin/gcc” 80 is available in both template, e.g., Template I 40 , (see /usribin/gcc 90 ) and private modification area, e.g., VE 1 private data 30 , (see /usr/bin/gcc 100 ) the user will see only the file 100 in the private modification area 30 .
As shown in FIG. 1 , the first data storage file system tree 20 is never changed and is kept in one copy so that it can be seen by all of the computer users. The second data storage file system tree 30 is kept only in the personal private area of the computer user, and it is unique. If a search is made for some data storage file in such a structure, the data storage file is sought out twice: First, in the private tree 30 for write-ability; then second, in the common read-only tree 20 , in the case of failure.
Opening of data storage files in the read-only mode is carried out in two stages. First, an attempt is made to open the data storage file in the personal private modification area of the computer user 30 . Then in case of failure, the data storage file is opened in the common read-only shared area 20 .
Writing data into data storage files is carried out only in the personal area of the computer user. At first, it is defined if such a data storage file exists in the personal area. And then it is opened for write-ability in the case of a successful search. If the data storage file does not exist, then the data storage file is copied into the private area 30 of the computer user from the shared data storage file system tree 20 and the obtained copy of the data storage file is opened to allow the writing of data to the data storage file.
Accordingly, from the point of view of the computer user, the computer user has only one data storage file system tree within the data storage file system that can be modified in every place. Nevertheless, only the difference between the data storage file system common to all of the users of the computer and the modified user copy is actually stored. The shared part of the data storage file system is preserved in the computer only in one copy, and it does not need duplication.
In case the data storage file is removed, the data storage file is just marked as removed in the personal area of the computer user and the search procedure, when such notation exists, is finished with the reply to the computer user that the file does not exist.
Such organization of work of the data storage file system sufficiently simplifies the implementation of journaling because all the changes for every computer user are localized and kept in his/her private area. The consequences of writing into a private area is conditioned by algorithms that: i) service the file system, and ii) could be easily tracked by special processes of the operating system that serve the procedures of journaling. Accordingly, this method for reusing a common template file system may form the separate private modification area as a transaction and could store the separate private modification area in a manner that allows the organization of the standard journaling.
Those of ordinary skill in the art will understand that numerous embodiments have been enabled by the above disclosed invention. Such other embodiments shall be included within the scope and meaning of the appended claims.
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A common template file system tree is utilized by isolated operating system processes groups for effective read-only common file set access via multiple file system paths. Files are opened from different views of the file system template for write-ability access and copied into a private modification area; this is also convenient for subsequent online changes and replication.
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This application claims benefit, under U.S.C. §119 or §365 of French Application Number 02/00596, filed Jan. 17, 2002; and PCT/FR03/00114 filed Jan. 15, 2003.
BACKGROUND OF THE INVENTION
Field of the Invention
The present invention relates to supramolecular polymers. Supramolecular polymers are polymers in which the units are monomers or prepolymers of low mass which are connected to one another via hydrogen bonds (H bridges or H bonds), whereas, in a conventional polymer, the units are connected to one another via covalent bonds. An advantage of these supramolecular polymers is that these hydrogen bonds are reversible. For example, in coating technology, it is necessary to have a polymer which has a low viscosity under high-speed shear when it is being applied and which becomes viscous again after it has been applied. Preferably, the prepolymer units in the present invention comprise imidazolidone groups, which form hydrogen bonds according to the following scheme:
These prepolymer units can be prepared very easily by reaction of urea with polyalkyleneimines, polyamines or polyamides.
U.S. Pat. No. 6,320,018 discloses supramolecular polymers based on units having ureidopyrimidone groups. Patent Application EP 1 031 589 discloses supramolecular polymers based on units comprising isocyanate functional groups or their derivatives. Patent Application EP 1 136 506 discloses supramolecular polymers based on units comprising glutarimide functional groups. Patent Application WO 01/07396 discloses supramolecular polymers based on units having hydroxyl functional groups and carboxylic acid functional groups carried by aromatic nuclei.
The discovery has now been made of supramolecular polymers in which the units are monomers or prepolymers which can be manufactured in a very simple way much simpler than in the prior art. It is sufficient, for example, to react urea with a product having NH 2 or NH functional groups separated by 2 or 3 carbon atoms. Furthermore, some of these monomers or prepolymers are novel products in themselves.
SUMMARY OF THE INVENTION
The present invention relates to a supramolecular polymer comprising units connected via hydrogen bonds, these units being monomers or prepolymers comprising at least one functional group chosen from the functional groups (1) and (3) and a second functional group chosen from the following functional groups (1) to (5):
in which A denotes oxygen, sulphur or NH and X denotes any unit; the hydrogen bonds in the supramolecular polymer being formed between two identical or different functional groups chosen from the functional groups (1) to (5). The carbon atoms in the formulae (1) to (4) can be substituted.
The monomers or prepolymers comprising at least one of the functional groups (1) to (4) can be obtained by reaction of a product of following formula (6):
with any monomer chain or prepolymer chain comprising —NH 2 and —NH— or —NH— and —NH— functional groups separated by 2 or 3 carbon atoms, it being possible for these carbon atoms to carry substituents other than hydrogens.
The functional group (1) is obtained by reaction of the product (6) with a monomer or a prepolymer comprising the following linkages (1′):
The functional group (2) is obtained by reaction of the product (6) with a monomer or a prepolymer comprising the following linkages (2′):
The functional group (3) is obtained by reaction of the product (6) with a monomer or a prepolymer comprising the following linkages (3′):
The functional group (4) is obtained by reaction of the product (6) with a monomer or a prepolymer comprising the following linkages (4′):
It is very clear that, in the formulae (1′) to (4′), the carbon atoms which are between the nitrogens can be substituted.
The polymers of the invention can be used alone, that is to say in the form of a composition composed essentially of these polymers and optionally of stabilizers, antioxidants, and the like, or in the form of a blend with other polymers or other products.
The polymers of the invention are of particular use as:
rheology modifiers for paints or coatings, additives for varying the fluidity of epoxy paints with temperature and in particular in powder paints, additives in the processing of thermoplastics for carrying out reversible crosslinking, additives for facilitating the recycling of thermoplastics by destroying the hydrogen bonds with a specific solvent, additives in coatings for subsequently facilitating their stripping by a solvent specific for hydrogen bonds, additives for the impact modification of polyamides, additives in hot melts, hot melts additives in lubricants.
The present invention also relates to the abovementioned uses and to the compositions comprising the supramolecular polymers of the invention.
DETAILED DESCRIPTION OF THE INVENTION
As regards the monomers or prepolymers comprising at least one functional group chosen from the functional groups (1) and (3) and a second functional group chosen from the functional groups (1) to (5), advantageously “A” denotes an oxygen atom.
The monomers or prepolymers comprising one or more of the functional groups (1) to (4) can be obtained by reaction of a product of formula (6) with monomers or prepolymers carrying the corresponding precursors (1′) to (4′), as explained above.
These monomers or prepolymers comprising at least one of the functional groups (1) to (4) can also be manufactured by attaching these functional groups to a product in order to convert it to a monomer or prepolymer carrying these functional groups (1) to (4).
For example, a polyamine is reacted with urea, that is to say the product of formula (6) in which A is an oxygen atom, and then this polyamine, carrying functional groups (1) and an —NH— functional group, reacts with an alkyl halide to form a monomer or a prepolymer carrying the functional groups (1). This is illustrated by the following scheme with a specific polyamine:
According to another example, urea is reacted with diethylenetriamine; the following product is obtained:
which product is subsequently reacted with a monomer or a prepolymer carrying at least one carboxylic acid functional group to produce a monomer carrying the functional groups (1) and (5).
Depending on the uses of the polymers of the invention, the monomers and the prepolymers constituting it may comprise other monomers or prepolymers which bring about a molecular disorder which prevents crystallization.
As regards the product of formula (6), it is possible to use a mixture of several products (corresponding to the various meanings of “A”), that is to say a mixture of urea, thiourea and guanidine. Advantageously, urea is used.
As regards the monomers or prepolymers comprising —NH 2 and —NH— or —NH— and —NH— functional groups separated by 2 or 3 carbon atoms, mention may be made of polyamines, such as diethylenetriamine (DETA), triethylenetetramine (TETA) and tetraethylenepentamine (TEPA). Examples of monomers or prepolymers carrying functional groups (1) and (2) in which A is an oxygen atom are illustrated below.
Mention may also be made of the diamines derived from acid dimers; the formation of the functional groups (1) in which A is an oxygen atom is illustrated below:
Mention may also be made of the prepolymers of polyamide type resulting from the condensation of polyamines, such as the abovementioned DETA, TETA and TEPA, with diacids. These diacids are preferably fatty acids. These diacids preferably comprise traces of acid trimers. This is illustrated by the following scheme, in which the product of formula (5) is urea.
In this diagram, “x% starlike oligomers” denotes starlike oligomers produced as by-products due to the presence of the acid trimers “x% acid trimer”.
EXAMPLES
Example 1
16 g (110 mmol) of triethylenetetramine (Dow Chemicals, appr. 60% purity Note 1), 12 g (200 mmol) of urea and a small piece of carborundum are placed in a 100 ml round-bottomed flask equipped with a magnetic stirrer and a reflux condenser. The temperature is gradually brought to 120° C. The urea dissolves and gaseous evolution of ammonia takes place. The heating is progressively continued. At approximately 160° C., the viscosity greatly increases and the use of a pH indicator paper placed at the top of the reflux condenser allows the evolution of ammonia to be monitored. When the temperature approaches 190° C., the reaction mixture crystallizes. After cooling, the crystals are washed with methanol and two fractions are collected:
the solid fraction, composed essentially of ethylenebisdiimidazolidone and recrystallizable from water, M.p.=252.4° C. (lit. 240-245° C.). The ethylenebisdiimidazolidone, which comprises 2 functional groups (1), is very pure and therefore crystallizes. the fraction which is soluble in methanol, evaporated to dryness and dissolved in water at 33% by mass. This aqueous solution is referred to as the mother solution and it comprises the monomer of the invention comprising the functional groups (1).
This fraction does not crystallize because of a molecular disorder caused by impurities in the triethylenetetramine. Analysis shows that this fraction is predominantly composed of ethylenebisdiimidazolidone (A), N-(piperazinoethyl)imidazolidone (B), BisAEP: N,N′-bis(2-aminoethyl)piperazine (C) and Branched TETA: tris(2-aminoethyl)amine (D).
Example 2
The use of the polymers of the invention as modifiers is illustrated.
The crosslinking of polyacrylic acid by the polymer of the invention is illustrated.
150 mg (mass on a dry basis) of polyacrylic acid PAA, in the form of an aqueous solution, are added to 3 g of mother solution (Example 1).
The mixture is poured into a circular PTFE mould (Ø=50 mm). After a time of three weeks in a climate-controlled chamber (T=23° C., RH=50%), the films obtained (thickness appr. 0.4 mm) can be detached from the mould and handled. The glass transition temperatures (Tg), measured by differential scanning colorimetry (DSC), are recorded in the following table:
Sample
1
2
3
PAA ref.
Coatex DV375
Coatex DV49
Coatex DV284
PAA Mn
1 800–2 000
8 000
500 000
PAA % on a dry basis
50%
45%
35%
Tg sample
57° C.
53° C.
70° C.
Example 3
10.5 g (41 mmol) of triethylenetetramine (Dow Chemicals, appr. 60% purity Note 1) and 50 ml of ethanol are placed in a 500 ml round-bottomed flask equipped with a magnetic stirrer and a reflux condenser. The solution is brought to reflux (oil bath at 90° C.). 6.47 g (34 mmol) of 1,2-dibromoethane in solution in 50 ml of ethanol are added dropwise using a dropping funnel. After the addition, the reaction mixture is maintained at reflux for 3 hours.
Analysis by gas chromatography coupled to mass spectrometry shows a decrease in the proportion of TETA and an enrichment in monoaddition products: BisAEP and PEEDA, and the diaddition product bispiperazinylethylene BPE:
The procedure (dropwise addition of 34 mmol of dibromoethane and then reflux for 3 hours) is repeated until the TETA and PEEDA contents are approximately equal in the mixture.
After evaporating the solvent and other volatile materials under vacuum and cooling, 2.4 g (40 mmol) of urea are added. The mixture is then treated according to the directions of Example 1. At the end of the reaction, the reaction mixture does not crystallize but forms a water-soluble vitreous mass.
The mixture obtained, combined with polyacrylic acid, makes it possible to form films according to the directions of Example 2
Example 4
20.8 g (110 mmol) of tetraethylenepentamine (Dow Chemicals, appr. 60% purity Note 2) and 12 g (200 mmol) of urea are treated according to the directions of Example 1. At the end of the reaction, the reaction mixture does not crystallize but forms a water-soluble vitreous mass.
The mixture obtained, combined with polyacrylic acid, makes it possible to form films according to the directions of Example 2.
Note 2: The grade used is a mixture of linear, cyclic and branched ethyleneamines with similar boiling pints. TEPA: N-(2-aminoethyl)-N′-{2-[(2-aminoethyl)amino]ethyl}-1,2-ethanediamine, AETETA: 4-(2-aminoethyl)-N-(2-aminoethyl)-N′-{2-[(2-aminoethyl)amino]ethyl}-1,2-ethanediamine, APEEDA: 1-(2-aminoethyl)-4-[(2-aminoethyl)aminoethyl]piperazine, PEDETA: 1-[2-[[2-[(2-aminoethyl)amino]ethyl]amino]ethyl]piperazine, Polyethylenepolyamines [CAS #029320-38-5, CAS #068131-73-7]
Example 5
47 g of Crayamid 115 (Note 3) and 16 g of urea are placed in a 500 ml round-bottomed flask equipped with a magnetic stirrer and a reflux condenser. The round-bottomed flask is immersed in an oil bath at 100° C. The temperature of the bath is gradually raised (appr. +20° C./hour). The use of a pH indicator paper placed at the top of the reflux condenser makes it possible to monitor the evolution of ammonia. When the temperature reaches 180° C., stirring becomes difficult. After reacting for a minimum of 2 h at 180° C., the heating is turned off. On completion of the reaction, it may happen that an excess of urea has sublimed and condensed on the walls of the round-bottomed flask.
After cooling, the possible excess of urea is removed with water by rapid rinsing of the walls of the round-bottomed flask. The reaction mixture, with a vitreous appearance, is dissolved in 300 ml of chloroform and the solution obtained is dried over magnesium sulphate and then filtered through 4 g of silica gel. The slightly cloudy solution obtained is known as the mother solution.
A portion of the mother solution is evaporated to dryness at 60° C. under vacuum for analysis:
IR: (KBr, cm −1 )3302, 2924, 2853, 1654, 1608, 1546, 1490, 1456, 1377, 1271 Tg (DSC)=49° C.
Linear viscoelastic properties at 1 Hz (cone/plate 20 mm):
Temperature/° C.
10
20
40
60
80
Storage modulus
9 120 000
5 770 000
6 540 000
246 000
20 700
G′/Pa
Dissipation
834 000
829 000
1 180 000
272 000
41 300
modulus G″/Pa
Note 3:
Crayamid 115 is a polyamide (Mw ~2 000–4 000 g/mol), the condensation product of a TOFA-type acid dimer (TDFA being an abbreviation for Tall Oil Fatty Acid) and of triethylenetetramine.
Example 6
30 g portions of mother solution (Example 5) are poured into PTFE moulds (Ø=75 mm) placed in a not completely hermetic chamber, making possible the very slow evaporation of the solvent.
After one week, the film obtained can be detached from the mould and handled.
The residual solvent is completely removed after a few hours under vacuum or a few weeks at ambient pressure. This method produces flexible and translucent films (thickness at the center 0.65 mm) which are slightly tacky at ambient temperature.
Example 7
50 g of Crayamid 140 (Note 4) and 15 g of urea are treated according to the directions of Example 5. The mother solution obtained (with a solids content of 13%) is washed with 2×100 ml of aqueous saline solution, dried over magnesium sulphate and filtered through 4 g of silica gel. The films prepared from this solution according to the directions of Example 6 are transparent, flexible and nontacky. The thickness at the center is 0.70 mm. These films can be precisely cut out with a hollow punch or using cutting tools. The objects thus obtained retain their dimensional characteristics.
Note 4: Crayamid 140 is a polyamide (Mw˜2000-4000 g/mol), the condensation product of a TOFA-type acid dimer (TDFA being an abbreviation for Tall Oil Fatty Acid) and of triethylenetetramine.
Example 8
0.22 g of squalane (2,6,10,15,19,23-hexamethyltetracosane) are added to 10 g of mother solution (Example 7). The mixture is poured into a circular PTFE mould with a diameter of 50 mm. The film prepared according to the directions of Example 6 (film thickness=0.65 mm) is hard and strongly scattering, Tg=42° C.
Example 9
0.22 of tripropylene glycol are added to 10 g of mother solution (Example 7). The mixture is poured into a circular PTFE mould with a diameter of 50 mm. The film prepared according to the directions of Example 6 (film thickness=0.65 mm) is soft and transparent, Tg=18° C.
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The invention relates to a supramolecular polymer containing units which are linked by hydrogen bonds, said units being monomers of prepolymers comprising at least one functional group selected from the functional groups (1) and (3) and a second functional group chosen from functional groups (1) to (5) wherein A denotes oxygen, sulphur or NH and X is any unit; the hydrogen bonds in the supramolecular polymer being formed between two identical or different functional groups chosen from the functional groups (1) to (5). The inventive polymers can be used alone, i.e. in the form of a composition which is essentially made from said polymers and, optionally, stabilizers, antioxidants, etc. or in the form of a mixture with other polymers or other products.
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FIELD OF THE INVENTION
The present invention relates to a device that expands the ironing surface on a conventional ironing board.
DESCRIPTION OF RELATED ART
Ironing boards have been in use over many years in order to facilitate the crisp, fresh, wrinkle-free look to clothing adorned by many. The general purpose of ironing is readily evident. The ironing board allows the user to lay clothing for application of heat via an iron in order to smooth wrinkles to achieve the desired look. The iron board shape has remained consistent over the years where one end includes three sides at about 90 degrees from each other and the other end converging to a curved point. A top view of a conventional ironing board is shown in FIG. 1A . Iron board 15 includes a straight edge 17 with side edges 18 a , 18 b that extend forward to the converging end 19 . The top surface of board 15 provides an ironing surface for the user. Although the shape of the ironing board 15 apparently has been used quite extensively, the ironing board 15 presents some shortcomings to the user, mainly when ironing articles of clothing, the user may have to reposition clothing on the board several times to complete the task of ironing.
Ironing a shirt or a blouse requires multiple positioning during the ironing process. Furthermore, even when the user repositions the clothing, the user may be unable to reach certain areas or occasionally the repositioning may be ineffective in providing the user with the necessary area to complete the ironing task. A conventional shirt or blouse may include a large flat area, typically the back side, in order to iron this area the user must continually reposition the shirt. This repositioning becomes even more tedious around the shoulder and armpit areas. The constant flipping or repositioning of the shirt inevitably causes problems in completing the task of ironing. Furthermore, each reposition of the iron process may necessitate that the user reposition and re-iron certain areas in order to have a completely ironed and wrinkle-free shirt.
The prior art contains various variations of the conventional ironing board in order to address some of these problems. One piece of prior art which shows a modification of conventional ironing boards is U.S. Pat. No. 6,151,817 to Eiben (Eiben reference). The Eiben reference relates to an ironing board that possesses two end sections that extend side by side wherein one section provides an area for ironing clothing and a narrow section is provided to iron shirt sleeves where the two sections are separated by a gap. The Eiben reference discusses a modification to the conventional ironing board, however, it does not address the requirement of maneuvering a shirt over the surface in order to complete the ironing process.
Another prior art reference that includes modifications to the conventional ironing board is U.S. Pat. No. 5,016,367 to Breen, et al. (Breen reference). The Breen reference relates to an iron board that includes a main board and two swingable board extensions that are retractably attached to the main board. The extensions and main board of the Breen reference provide for the ironing of trouser legs and sleeves on the narrow portions thereof. The Breen reference, again, fails to address each area that a shirt may possess and, thus, still facilitates a process that requires a significant amount of flipping of the article of clothing.
U.S. Pat. No. 6,286,237 to Toutounchian relates to a multiple function ironing board which has various periphery attachments to help facilitate the ironing process. The multiple attachments attempt to expand the surface area at one end of the ironing board and to provide for multiple iron resting plates at the opposite end thereof. The drawback of the Toutounchian reference is that it includes multiple attachments and, therefore, makes for a fairly cumbersome ironing board assembly.
The prior art lacks any versatility or capability to expand a conventional board as used throughout the consumer market. Accordingly, consumers need an optional attachment that enables the expansion of the iron board surface area that could be easily attached and removed from a conventional ironing board. Such an attachment could easily be implemented into the current consumer market for ironing boards.
SUMMARY OF THE INVENTION
The present invention relates to a platform assembly and method that expands the surface area of a conventional ironing board. The platform assembly easily connects to an ironing board through the insertion of the converging end of the ironing board to a cavity on the bottom side of the platform assembly. The platform assembly covers the converging end and expands the surface area of the ironing board. The user may first remove the ironing board's pad and cover, or the platform assembly may be conveniently secured to the ironing board with pad and cover intact. The platform assembly may be secured to the ironing board by using a strap or cross member. The platform assembly comprises two wing portions and a platform that are assembled to form a platform assembly for use with any conventional application. The platform assembly has parabolic shaped outer edges that provide a configuration especially useful in the ironing of shirts. A user may easily remove and store the platform assembly in order to convert the ironing board back to its original form. It is therefore an object of the present invention to provide an expansion platform assembly comprising: a first wing portion, where the first portion includes a substantially parabolic upper outer edge and a curved inner edge said; a second wing portion, where said second portion includes a substantially parabolic upper outer edge and a curved inner edge; a platform, said platform having symmetrical substantially parabolic upper outer edges, said platform having a top side and a bottom side, where said first wing portion and second wing portion are affixed to the bottom side of said platform, where said outer edge of said platform aligns with said outer edge of each wing portion; and a cavity, where said cavity lies between the first wing portion, the second wing portion and the bottom side of said platform.
It is also an object of the present invention to provide a method for expanding the area of an ironing board surface comprising the steps of: creating a first wing portion, where the first wing portion includes an upper parabolic outer edge; creating a second wing portion, where the first wing portion includes an upper parabolic outer edge; aligning the outer edge of the first wing portion with an outer edge of a platform; aligning the outer edge of the second wing portion with the outer edge of the platform; affixing the first wing portion and the second wing portion to a bottom side of the platform, wherein the step of affixing creates a platform assembly; and securing the platform assembly onto a converging end of a ironing board.
It is also an object of the present invention to provide a method for expanding the area of an ironing board surface comprising the steps of: lying a shirt across a flat surface; sketching an outline along the outside edges of said shirt, where said outline creates a template; using the template to create a first wing portion, a second wing portion and a platform; affixing the first wing portion and second wing portion to a bottom side of the platform, where the other edges of the each wing portion aligns with the outer edge of the platform wherein the step of affixing creates a platform assembly; and securing the platform assembly onto a converging end of a ironing board.
In accordance with these and other objects which will become apparent hereinafter, the instant invention will now be described with particular reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A shows a top surface area of a conventional ironing board.
FIG. 1B shows a perspective view of a conventional ironing board.
FIG. 2 shows a top surface of a platform assembly according to the present invention.
FIG. 3 shows a bottom view of the platform assembly attached to a conventional ironing board.
FIG. 4 shows a perspective of the layers that are associated with the platform assembly according to the present invention.
FIG. 5A shows a bottom view of the platform assembly and a cavity thereof.
FIG. 5B shows a bottom view of the platform assembly wherein a connection member is shown across the cavity according to the present invention.
FIG. 5C shows an alternative embodiment of the platform assembly according to the present invention.
FIG. 6 shows a top view of the platform assembly on a conventional ironing board.
FIG. 7 a design template for the platform assembly according to the present invention.
FIG. 8 shows the components of the platform assembly according to the present invention.
FIG. 9A shows another embodiment of the platform assembly according to the present invention.
FIG. 9B shows the wing portions of the embodiment of FIG. 9A .
FIG. 9C shows the assembly of the components of the embodiment of FIG. 9A .
FIG. 10 shows a perspective view of the platform assembly as attached to the conventional ironing board.
FIG. 11 shows the foam padding used in conjunction with the platform assembly according to the present invention.
DETAILED DESCRIPTION
FIG. 1A shows a top view of a conventional ironing board 15 . FIG. 1B shows a perspective view of the ironing board 15 . Sides 18 A and 18 B extend from a straight edge 17 to converging edge 19 . The conventional ironing board 15 usually is supported upon folding legs 16 that allow for easy storage of ironing board 15 . However, some ironing boards may be stored in a wall or closet and may extend from the wall along with supporting members. Regardless of support means, ironing boards usually have the shape as shown in 1 A and 1 B.
FIG. 2 shows the top surface view of a platform assembly according to the present invention. Platform assembly 10 includes a top surface 14 . The underside of the platform assembly 10 is shown in FIG. 3 as attached to the converging edge 19 of the ironing board 15 . As shown, the underside includes a first wing portion 12 a and a second wing portion 12 b . The platform assembly 10 includes a cover 20 with cover straps 20 a and 20 b . Cover straps 20 a and 20 b may connect through any conventional fastening device such as velcro, fasteners or a button assembly. Also another embodiment may allow for the simple tying of the cover straps in order to secure the platform assembly along with cover 20 to the conventional ironing board 15 .
As shown in FIG. 3 , the platform assembly engages the converging edge of the conventional ironing board and expands the surface area for use during ironing. The expanded surface area provides a convenient mechanism in order to increase the surface area for the user. The platform assembly is particularly useful in ironing shirts that may fit over the platform assembly. The platform assembly includes the wing portions 12 a and 12 b that extend into the sleeve areas of a typical shirt and the top surface area 14 provides for a large, flat surface to provide coverage for a significant portion of any subject shirt. Also, the platform assembly's shape allows for the user to flip the shirt fewer times than with a conventional board while providing significant coverage of larger portions of the subject shirt. The platform assembly thus reduces the required repositioning of a shirt during the ironing process as opposed to using the conventional board with the converging edge 19 . Consequently, in addition to reducing the repositioning requirements, the platform assembly 10 also reduces the time associated with ironing a shirt.
FIG. 4 shows the components of the platform assembly according to the present invention. As shown in FIG. 3 , the top cover 20 covers a top pad surface 51 and the top surface 14 of the platform assembly 10 . The cover 20 extends over platform assembly 10 and covers not only the platform assembly 10 but also the other portion of the conventional ironing board 15 .
FIGS. 5A and 5B show the component portions of the platform assembly 10 . As shown in both FIGS. 5A and 5B , wing portions 12 a and 12 b are two separate components that are joined to platform 23 of the platform assembly 10 . Both wing portions 12 a , 12 b include upper outer edges that have a parabolic shape. The upper outside edges of the platform 23 also have a parabolic shape that aligns with the outer edges of the wing portions 12 a , 12 b . Once the components 12 a , 12 b and 23 are joined, a cavity 22 is created. The cavity 22 provides for the insertion of the converging edge 19 of a conventional ironing board. During use, the converging edge 19 abuts the outer perimeter of cavity 22 along the curved inner edges 13 a and 13 b of the wing portions 12 a , 12 b . The platform 23 includes a bottom surface 26 which is substantially flat in accordance with the top surface area 14 of the platform assembly. The embodiment of FIG. 5B includes cross member 12 c which provides another mechanism in order to secure the platform assembly to the ironing board 15 . The cross member 12 c as shown extends across cavity 22 and is adjoined to the inner portions of wing portions 12 a and 12 b.
FIG. 5C shows another embodiment of the present invention. The platform assembly of FIG. 5C is essentially the same configuration of FIG. 5A , however the platform 23 includes a hinge portion 26 a that enables the platform 23 to bend and fold as shown. A user may easily fold and store the platform assemble when not in use.
FIG. 6 shows a top view of the placement of platform assembly 10 onto a conventional ironing board 15 . This top view merely shows the attachment of the platform assembly 10 without the placement of cover 20 over the assembly and ironing board 15 . Preferably, the platform assembly 10 completely covers the converging edge 19 of the ironing board 15 also the platform assembly abuts to sides 18 a and 18 b in order to create a continuous straight edge that extends perpendicular to straight edge 17 of the ironing board 15 . Once cover 20 is placed over the platform assembly 10 and ironing board 15 , a continuous flat surface is provided for the purpose of ironing. The platform assembly ideally includes the wing portions that include parabolic outer edges that curve outwardly and extend back into the side edges 18 a and 18 b.
FIG. 7 shows the template that may be used to create the shape of the platform assembly. As shown, template 25 includes the placement of a shirt 30 where the surrounding edges of the template to extend outwardly and follow the outer edges of the shirt 30 . The template 25 then can be used to cut both the platform 23 and the wing portions 12 a , 12 b.
FIG. 8 shows an exploded view of the platform assembly 10 and wing portions 12 a , 12 b . As shown in FIG. 8 , these components are joined together to create the complete platform assembly 10 . The materials that may be associated with these various components may include wood, hardened plastic, metal or suitable fiberboard. The components may be connected by way of additional fastening components, such as screws, clamps or other fastening devices. Also, these components may be connected through use of suitable glues that may be available in order to bind these components together for a composite platform assembly 10 .
FIGS. 9A , 9 B and 9 C show another embodiment of the platform assembly 10 according to the present invention. The platform assembly 10 of FIGS. 9A through 9C has substantially the same shape as the above described embodiment, however, the wing portions 12 a and 12 b are smaller in order to extend into the sleeve area of smaller sized shirts. However, consistent with the prior embodiment, the components may be adjoined as shown in FIG. 9C , the wing portions 12 a and 12 b are joined to the bottom surface 26 of the platform 23 and then the cavity 22 allows for the insertion of the converging edge 19 of the ironing board.
FIG. 10 shows a perspective view of the platform assembly onto a conventional ironing board. The broken off section at the straight edge 17 of the ironing board shows the ironing board is covered first with a pad 55 and then cover 20 extends over the pad and extends over the platform assembly to create the composite flat surface for ironing. In order to provide for a smooth surface over the entire ironing surface, padding under cover 20 is shown in FIGS. 11 and 11A . As shown in FIG. 11 , surface pad 51 extends over the platform assembly area 10 that abuts to the ironing board 15 . This pad 51 extends the entire surface of the ironing board 15 to straight edge 17 . Below top pad 51 is a bottom pad 53 that extends from the straight edge 17 of the ironing board into and abuts the back straight edge of the platform 23 of the platform assembly 10 . Surface pad 51 provides the padding over the platform assembly 10 . The padding, platform assembly 10 and iron board are all placed within the cover 20 once the platform assembly 10 has been secured to the ironing board 15 .
The instant invention has been shown and described herein in what is considered to be the most practical and preferred embodiment. It is recognized, however, that departures may be made therefrom within the scope of the invention and that obvious modifications will occur to a person skilled in the art.
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The present invention relates to a platform assembly and method that expands the surface area of a conventional ironing board. The platform assembly covers a converging end of an ironing board and expands the surface area of the ironing board. The platform assembly of the present invention includes parabolic shaped outer edges that provide a configuration especially useful in the ironing of shirts. A user may easily remove and store the platform assembly in order to convert the ironing board back to its original form.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention relates to semiconductor devices. More specifically, the present invention relates to the production of semiconductor devices where wet chemical treatments are used on a wafer with high aspect ratio nanostructures that are sensitive to pattern collapse during processing.
[0003] 2. Description of the Related Art
[0004] Semiconductor devices are fabricated using a long complex procedure. One portion of the procedure involves etching features into a stack of materials on a silicon wafer. The stack of materials may comprise a single layer of silicon based material such as SiO or SiN, or the stack may comprise multiple layers of materials such as SiO, SiN, TEOS, polysilicon or silicon in different orders within the stack. The stack may be formed by a number of methods, including physical vapor deposition, chemical vapor deposition, electrochemical deposition and molecular beam epitaxy, for example. Once the stack of materials is created, a photoresist layer is applied. This photoresist layer is used as a mask for etching. Many methods of etching may be used including methods of wet etching and dry etching. After the etching, the photoresist layer is usually removed, often by a plasma ashing procedure.
[0005] During the fabrication, the wafers are subjected to wet processing such as wet cleaning. Wet cleaning is helpful to prepare the surfaces and to remove residue left behind by some of the other processing. The cleaning process usually consists of chemical treatment in combination with megasonics, jets and/or other particle removal techniques followed by rinsing and drying. The drying may include bulk liquid removal from the surface by spin off, vacuum suction, Marangoni effect with isopropyl alcohol or combination of these commonly known techniques
[0006] A wafer may go through multiple occurrences of these steps during the entire fabrication process. Hence, as device features shrink on a wafer and as much liquid is used in the processing, strong capillary forces may exert enough force to collapse the structures during drying steps.
SUMMARY OF THE INVENTION
[0007] To achieve the foregoing and in accordance with the purpose of the present invention, a method of processing a wafer used in fabricating semiconductor devices is provided. The method teaches processing the wafer in such a way as to reduce or eliminate collapse of high aspect ratio features on the wafer. High aspect ratio features are formed in a silicon based layer that has been produced on the wafer. The sidewalls of the features are treated to make them more hydrophobic. A wet processing of the wafer is performed on the wafer and then the wafer is dried.
[0008] In another embodiment, a method of processing a wafer used in fabricating semiconductor devices is provided. High aspect ratio features are formed in a silicon based layer on the wafer. A wet processing of the wafer is performed. The wet processing includes wet cleaning the wafer, depositing a primer on the wafer that modifies surface properties of the features so as to increase the hydophobicity of the surfaces of the features and rinsing the wafer. After the wet processing, the wafer is then dried.
[0009] These and other features of the present invention will be described in more details below in the detailed description of the invention and in conjunction with the following figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The present invention is illustrated by way of example, and not by way of limitation, in the figures of the accompanying drawings and in which like reference numerals refer to similar elements and in which:
[0011] FIGS. 1A and 1B show high level flow charts of some embodiments of the invention.
[0012] FIGS. 2A-2C show an exemplary wafer undergoing a damaging wet processing and drying.
[0013] FIGS. 3A-3G show an exemplary wafer undergoing select steps of an embodiment of the invention.
[0014] FIGS. 4A-4G show an exemplary wafer undergoing select steps of an embodiment of the invention.
[0015] FIGS. 5A-5H show an exemplary wafer undergoing select steps of an embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0016] The present invention will now be described in detail with reference to a few preferred embodiments thereof as illustrated in the accompanying drawings. 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 skilled in the art, that the present invention may be practiced without some or all of these specific details. In other instances, well known process steps and/or structures have not been described in detail in order to not unnecessarily obscure the present invention.
[0017] Oxides and nitrides of silicon grown by low-temperature oxidation (LTO), chemical vapor deposition (CVD) and implantation have been traditionally used in front-end-of-the-line (FEOL) processing for electrical and thermal isolation, masking and encapsulation in high aspect ratio nanostructures. The use of such materials in FEOL applications has continued to offer the selectivity to reduce feature sizes and increase aspect ratios to achieve the desired densities of devices for 32 nm integrated circuit (IC) fabrication and beyond. Aspect ratios are now commonly in the range of 10:1 to 25:1 and possibly higher. However, as the critical dimensions continue to shrink and aspect ratios continue to increase in FEOL applications, problems associated with processing such densely fabricated nanostructures have surfaced and are anticipated to pose tremendous challenges for wet clean processes. One commonly observed problem has been the collapse of densely packed high aspect ratio nanostructures used for shallow trench isolation.
[0018] FIG. 2A shows a wafer 201 together with a set of nanostructures 202 . Feature collapse occurs during wet cleaning and subsequent drying. FIG. 2B shows the nanostructures 202 of FIG. 2A during a wet cleaning where the fluid 204 has gathered between the nanostructures 202 . Fluid enters the features during wet processing and strong capillary forces may exert sufficient force to damage the delicate nanostructures. In addition, the surface tension forces of the drying liquid tend to pull surfaces of adjacent nanostructures into contact. These forces are often exacerbated by the lack of balance of pressures across the many features due to non-uniformity of the fluid amounts gathered in the features, as well as non-uniformity in drying. These forces often lead to the collapse of the features individually or also through bridging. Bridging occurs when at least two adjacent nanostructures collapse against one another and become adhered together. The sidewalls of adjacent nanostructures themselves may adhere together, or a residue material may gather between the nanostructures, joining them together. FIG. 2C shows two examples of feature collapse. One example is the single collapse of a nanostructure 206 . The other example shows a bridging of two nanostructures 205 . Other types of feature collapse are possible as well. Feature collapse can be a significant problem in semiconductor fabrication and can lead to defects in the circuits produced.
[0019] Some methods of reducing feature collapse have been explored. Examples include rinsing with ultra-low surface tension liquids such as 2-propanaol γ=22 dynes/cm, use of fluorinated organic surfactants (HFE, γ=14 dynes/cm) supercritical carbon dioxide drying, and drying using similar approaches at elevated temperatures. Some of these techniques have met with limited success; however, such techniques are costly and often require elaborate setups. For example, supercritical carbon dioxide requires high pressures to go to the critical point.
[0020] A wafer may go through multiple occurrences of wet processing and drying during the entire fabrication process. As device features shrink on a wafer, strong capillary forces may exert enough force to collapse the structures during drying steps. A cost-effective and simple method of processing the wafers is needed that reduces the occurrence of the collapsing of high aspect ratio nanostructures during sequential wet processing. In light of this notion, the present invention outlines a methodology that can be used during single wafer wet cleaning of high aspect ratio nanostructures on a wafer to avoid collapse and sticking.
[0021] FIG. 1A is a high level overview of an embodiment of the invention. At the start of the method, at least one silicon based layer is deposited upon a wafer (step 102 ). A photoresist patterned mask is formed over the silicon based layer (step 104 ) and features are etched into the silicon based layer using the photoresist as a mask (step 108 ). The photoresist mask is then stripped away (step 112 ). A procedure is then used to make the sidewalls of the features more hydrophobic (step 116 ). In one embodiment, this procedure may include depositing a primer on the wafer that chemically alters the surface of the features as a first step in the process flow without needing to wet the features. This step can be carried out by exposing the surface of interest to the vapor of the modifying agent prior to the wet processing. Wet processing is then performed on the wafer (step 120 ), which may include a sequential series of wet cleaning steps to clean the features of common residues left behind after etch. The wafer is then dried (step 124 ).
[0022] FIG. 1B is a high level overview of another embodiment of the invention. In this embodiment, the steps of making the sidewalls more hydrophobic (step 116 ) and the wet processing (step 120 ) are combined into one step of making the sidewalls more hydrophobic during the wet processing (step 124 ). For example this step can be carried out by exposing the surface of interest to a liquid solution that contains the modifying agent prior to or after the wet clean sequence. The liquid solution that contains the surface modifying agent can be derived from solvents that are miscible with the agent such as n-Hexane, Toluene, NPM, DMSO, Acetone, DMF, DMAC, or HFEs. The other steps may be left unchanged.
[0023] FIGS. 3A-3G show an example of a wafer with high aspect nanostructures at selected steps of an embodiment of the disclosed method. FIG. 3A shows the result after step 102 has been performed. A layer of silicon based material 306 has been formed on the wafer 301 . There are many processes that may be used to form the silicon based layer 306 . For example, the layer may be formed by physical vapor deposition, chemical vapor deposition, electrochemical deposition or molecular beam epitaxy. While FIG. 3A shows a single uniform silicon based layer 306 , it is important to note that multiple layers of materials may be used depending on many factors, such as the intended use of the circuit being fabricated or the specific fabrication process being used. Examples of multilayer structures include a common shallow trench isolation (STI) stack consisting of TEOS at the top followed by SiN, then PolySi, and then Si at the bottom, or a stack consisting of SiN at the top followed by TEOS, then another layer of SiN, then PolySi, and then Si at the bottom. In another embodiment, a silicon based layer 306 is not formed on the wafer 301 . Instead, the silicon wafer 301 is etched.
[0024] FIG. 3B shows the wafer 301 with the layer of silicon based material 306 and a photoresist layer 305 that has been patterned. A photoresist layer 305 is deposited on the silicon based material, often using a spin coating process and the photoresist is patterned using photolithography (step 104 ). The photoresist layer 305 is used as a mask to determine what silicon based material to remove and what to leave behind during the etching process. A wet or dry etching process (step 108 ) is used to remove the material not covered by the photoresist 305 .
[0025] FIG. 3C shows the wafer 301 after the etching, showing the nanostructures 302 formed by the etching (step 108 ). At this point the photoresist 305 is still present. After the etching, the photoresist material may then be removed (step 112 ). The photoresist may be removed by a chemical stripping process or by an ashing process.
[0026] FIG. 3D shows a wafer 301 and four columns of the silicon based material that remains after etching and photoresist removal. The columns of the silicon based material make up the nanostructures 302 . It is important to note that while the figures show a particular example of features that may be etched on the wafer 301 , other numbers and types of features are possible.
[0027] FIG. 3E shows the wafer 301 and nanostructures 302 after a layer of primer 303 has been deposited on the nanostructures 302 (step 116 ). The primer 303 may be a monolayer formed by self-assembly or any other known deposition process. Alternatively, the primer layer 303 may be thicker, such as a film. Some examples of possible surface modifying agents include hexamethyldisiloxane (HMDS), and various alkoxysilanes and alkysilanes. More specifically, fluorinated or long chain hydrocarbon based trichlorosilane, dichlorosilane, monochlorosilane, trimethoxysilane, dimethoxysilane, methoxysilane, triethoxysilane, diethoxysilane, and ethoxysilane to name a few examples.
[0028] Adding the primer 303 to the nanostructures 302 helps reduce feature collapse by modifying the surface properties of the nanostructures 302 . The surface of the nanostructures 302 is chemically altered such that the stiction force between two adjacent surfaces is reduced or preferably eliminated by making the surfaces of the nanostructures 302 more hydrophobic. One example of a chemical modification that would modulate stiction would be substituting polar hydroxyl groups of a nanostructure surface (for example Si—O or Si—N, often used to fabricate high aspect ratio nanostructures) with nonpolar groups, such as Si—CH3, Si—R or Si—RF (where R is a hydrocarbon or fluoro substituted chain of n-length). The Si—CH3 groups may be provided, for example, by HDMS (C 6 H 18 OSi 2 ). Another example of chemical modifier is 1H, 1H, 2H, 2H-perfluorooctyltrichlorosilane (FOTS, C 8 F 13 H 4 SiCl 3 ). The presence of nonpolar groups provides a stable modified surface with DI water contact angles varying from 70-130° where development of excessive forces due to liquid meniscus formation can be prevented.
[0029] The primer 303 may be added before the wet phase of processing via reaction of the surface with its vapor. When added before the wet phase, the primer 303 additionally acts to minimize or prevent the excessive stictional forces that are often exerted by the adsorption of water on surfaces that are in close proximity. A sample process flow using FOTS is first generating a stock solution of chemical modifier by mixing a solution of 0.1-50% FOTS by weight with anhydrous n-hexane, then co-heating one drop of the stock solution with the sample to be modified in an oven at a temperature of 40-200° C. After approximately 2-300 seconds, the stock solution evaporates completely and FOTS molecule reacts with the sample surface. A surface prepared this way has DI water contact angle larger than 120°.
[0030] Alternatively, the primer may be added during the wet phase processing (step 126 ) by use of suitable solvents containing the modifying agent. This step could be applied either before or after the wet clean steps in the sequential process flow. A sample process using FOTS is immersing the sample into 0.01-50% by weight of FOTS in HFE-7100 (3M, Minneapolis, Minn.), Toluene, n-hexane, chloroform, or acetone for approximately 10 seconds up to 1 hour under nitrogen, followed by rinsing ultrasonically with fresh HFE-7100, then drying with nitrogen.
[0031] FIG. 3F shows the wafer 301 undergoing a wet processing (step 120 ) such as a wet cleaning after having the primer 303 applied. The liquid 304 from the wet processing is gathered within the nanostructures 302 and is repelled by the now more hydrophobic sidewalls of the nanostructures 302 . The increased hydrophobicity of the sidewalls of the nanostructures 302 reduces the capillary forces present between the nanostructures 302 and prevents the formation of a concave meniscus in the fluid gathered within the features. FIG. 3G shows the wafer 301 after it has been dried from a DI water rinse (step 124 ). Optionally, the primer 303 may be removed after the drying, for example by an oxygen or carbon dioxide flash process. This would return the wafer 301 and nanostructures 302 to the state shown in FIG. 3D , but with any processing residue greatly reduced or removed.
[0032] FIGS. 4A-4G show an example of a wafer 301 with high aspect ratio nanostructures 302 at selected steps of another embodiment of the disclosed invention. FIG. 4A shows the result after step 102 has been performed. A layer of silicon based material 306 has been formed on the wafer 301 . There are many processes that may be used to form the silicon based layer 306 . For example, the layer may be formed by physical vapor deposition, chemical vapor deposition, electrochemical deposition or molecular beam epitaxy. While FIG. 4A shows a single uniform silicon based layer 306 , it is important to note that multiple layers of materials may be used depending on many factors, such as the intended use of the circuit being fabricated or the specific fabrication process being used. Examples of multilayer structures include a stack consisting of TEOS at the top followed by SiN, then PolySi, and then Si at the bottom, or a stack consisting of SiN at the top followed by TEOS, then another layer of SiN, then PolySi, and then Si at the bottom.
[0033] FIG. 4B shows the wafer 301 with the layer of silicon based material 306 and a photoresist layer 305 that has been patterned. A photoresist layer 305 is deposited on the silicon based material, often using a spin coating process and the photoresist is patterned using photolithography (step 104 ). The photoresist layer 305 is used as a mask to determine what silicon based material to remove and what to leave behind during the etching process. A wet or dry etching process (step 108 ) may be used to remove the material not covered by the photoresist 305 .
[0034] FIG. 4C shows the wafer 301 after the etching, showing the nanostructures 302 formed by the etching (step 108 ). At this point the photoresist 305 is still present. After the etching, the photoresist material 305 may then be removed (step 112 ). The photoresist 305 may be removed by a chemical stripping process or by an ashing process.
[0035] FIG. 4D shows a wafer 301 and four columns of the silicon based material that remain after etching and photoresist removal (step 112 ). The columns of the silicon based material make up the nanostructures 302 . It is important to note that while the figures show a particular example of features that may be etched on the wafer 301 , other numbers and types of features are possible.
[0036] In this embodiment, the sidewalls of the nanostructures 302 are made more hydrophobic (step 116 ) by a roughening process. The surface of the nanostructures 302 can be reacted with a chemical substituent such that the surface morphology of the nanostructures 302 is changed. For example, while the photoresist 305 is spin-coated on the silicon based layer 306 the polymer resist can be exposed to a fluorine (F) and oxygen (O) mixture plasma to induce polymer re-deposition on the substrate. The re-deposited polymer generated by the plasma reaction is not a smooth thin film hence it can be used as a mask to etch the underlying substrate. An alternating deposition and etch process can be used to vary the surface roughness and achieve the required topography to produce a super-hydrophobic surface via a subsequent C 4 F 8 plasma thin film coating process. The change results in rough interfaces 401 , as shown in FIG. 4E , with increased surface area for subsequent reactions with surface modifiers such that the surface becomes more hydrophobic. Roughening may be implemented by RIE texturing using polymerzing plasma and dry or vapor phase fluoride etching at increased temperature, for example.
[0037] FIG. 4F shows the wafer 301 undergoing a wet processing (step 120 ) such as a wet cleaning after having surfaces of the nanostructures roughened to increase surface area for subsequent surface modification reactions. The liquid 304 from the wet processing is gathered within the nanostructures 302 and is repelled by the now more hydrophobic sidewalls of the nanostructures 302 . The increased hydrophobicity of the sidewalls of the nanostructures 302 reduces the capillary forces present between the nanostructures 302 and prevents the formation of a concave meniscus in the fluid gathered within the features. FIG. 4G shows the wafer 301 after it has been dried (step 124 ) and showing no signs of feature collapse.
[0038] FIGS. 5A-5H show an example of a wafer 301 with high aspect ratio nanostructures 302 at selected steps of another embodiment of the disclosed invention. FIG. 5A shows the result after step 102 has been performed. A layer of silicon based material 306 has been formed on the wafer 301 . There are many processes that may be used to form the silicon based layer 306 . For example, the layer may be formed by physical vapor deposition, chemical vapor deposition, electrochemical deposition or molecular beam epitaxy. While FIG. 5A shows a single uniform silicon based layer 306 , it is important to note that multiple layers of materials may be used depending on many factors, such as the intended use of the circuit being fabricated or the specific fabrication process being used. Examples of multilayer structures include a stack consisting of TEOS at the top followed by SiN, then PolySi, and then Si at the bottom, or a stack consisting of SiN at the top followed by TEOS, then another layer of SiN, then PolySi, and then Si at the bottom.
[0039] FIG. 5B shows the wafer 301 with the layer of silicon based material 306 and a photoresist layer 305 that has been patterned. A photoresist layer 305 is deposited on the silicon based material, often using a spin coating process and the photoresist is patterned using photolithography (step 104 ). The photoresist layer 305 is used as a mask to determine what silicon based material to remove and what to leave behind during the etching process. A wet or dry etching process (step 108 ) may be used to remove the material not covered by the photoresist 305 .
[0040] FIG. 5C shows the wafer 301 after the etching, showing the nanostructures 302 formed by the etching (step 108 ). At this point the photoresist 305 is still present. After the etching, the photoresist material 305 may then be removed (step 112 ). The photoresist 305 may be removed by a chemical stripping process or by an ashing process.
[0041] FIG. 5D shows a wafer 301 and four columns of the silicon based material that remain after etching and photoresist removal (step 112 ). The columns of the silicon based material make up the nanostructures 302 . It is important to note that while the figures show a particular example of features that may be etched on the wafer 301 , other numbers and types of features are possible.
[0042] FIG. 5E shows the wafer 301 undergoing a wet cleaning during wet processing to clean etch or ash residue from previous processes. The wet cleaning chemicals 501 may include: aqueous, semi-aqueous or organic solutions of chemicals or combination of chemicals including HCl, HF, NH 4 F, NH 3 aqueous solution, H 2 SO 4 , H 2 O 2 , for example.
[0043] FIG. 5F shows the surfaces of the nanostructures 302 being made more hydrophobic by depositing surface modifying agents 303 during wet processing (step 126 ) after the wet cleaning shown in FIG. 5E . One particular example of a procedure to make the surfaces of the nanostructures 302 more hydrophobic is: 1) rinsing away the wet cleaning chemicals 501 with DI water, 2) replacing DI water with isopropyl alcohol, 3 ) replacing isopropyl alcohol with HFEs, 4) immersing the wafer into 0.01-50% by weight of FOTS in HFE for approximately 2 seconds-10 minutes, and 5) rinsing with HFE. An alternative example is: 1) rinsing away the wet cleaning chemicals 501 with DI water, 2) replacing DI water with organic solvents that don't contain an —OH group, but are also miscible with DI water (Examples of solvents having such properties include: DMF, DMAC, acetone, NMP.), 3) immersing the wafer into 0.01-50% by weight of FOTS in the organic solvent solution for approximately 2 seconds-10 minutes, and 4) rinsing with the organic solvent. Item 502 of FIG. 5F represents the chemicals used during the procedure of making the surfaces of the nanostructures 302 more hydrophobic.
[0044] FIG. 5G shows the step to re-introduce DI water 304 into the hydrophobic nanostructures 302 after FIG. 5F to exploit the high Laplace pressure generated by convex water meniscus inside the hydrophobic nanostructures 302 to prevent the nanostructures 302 from collapse during the drying process. One particular example of doing so is: 1) replacing the HFE with isopropyl alcohol, and 2) replacing isopropyl alcohol with DI water. Since isopropyl alcohol has a lower surface tension than DI water and is miscible with DI water, immersion in isopropyl alcohol first then in DI water can introduce DI water into the hydrophobic nanostructures 302 through diffusion process. Alternatively, if the step represented by FIG. 5F ends with an organic solvent that does not contain —OH group, but miscible with water, a simple DI water wash step can be applied here.
[0045] FIG. 5H shows intact high density high aspect ratio nanostructures 302 after drying.
[0046] While this invention has been described in terms of several preferred embodiments, there are alterations, permutations, modifications and various substitute equivalents, which fall within the scope of this invention. It should also be noted that there are many alternative ways of implementing the methods and apparatuses of the present invention. It is therefore intended that the following appended claims be interpreted as including all such alterations, permutations, modifications, and various substitute equivalents as fall within the true spirit and scope of the present invention.
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A method is provided for treating the surface of high aspect ratio nanostructures to help protect the delicate nanostructures during some of the rigorous processing involved in fabrication of semiconductor devices. A wafer containing high aspect ratio nanostructures is treated to make the surfaces of the nanostructures more hydrophobic. The treatment may include the application of a primer that chemically alters the surfaces of the nanostructures preventing them from getting damaged during subsequent wet clean processes. The wafer may then be further processed, for example a wet cleaning process followed by a drying process. The increased hydrophobicity of the nanostructures helps to reduce or prevent collapse of the nanostructures.
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BACKGROUND AND SUMMARY OF THE INVENTION
The present invention relates generally to methods and apparatus for automatically cleaning a plurality of planar pads of material having a surface of closely spaced projections. More specifically, the present invention relates to methods and apparatus for poultry husbandry operations in cleaning nest pads.
In layer and breeder houses, poultry are typically provided with partially enclosed, individual nests for roosting. Previously, wood shavings, straw and other particulate matter have been placed in the bottom of these nests to simulate the grass of a natural nest. However, such materials have not been sufficiently sanitary and require frequent replacement. To minimize the time and effort in replacement and to maintain more sanitary conditions for the poultry and the eggs, artificial nest pads have been used in place of particulate matter.
Various different types of nest pads are currently in use. In general, these pads formed from plastic material and have a planar configuration with a plurality of closely spaced projections on the top surface, the surface the bird would be in contact with when roosting. These pads are dimensioned so as to fit within the nest enclosure and are also often flexible so as to conform to the configuration of the nest floor. In some pads the projections are blunt or round-end soft, rubber-like cones. In other pads the projections are irregularly oriented, flexible tabs, such as is found in Astroturf®. In yet other pads the projections may be a regular array of flexible tabs arranged in a matrix of tufts. Many pad designs include spacings or holes between some or all of the projections in the top surface to allow some debris, manure and moisture to fall through the pad and out of the nest as well as to permit air circulation into the nest.
In virtually every case, however, after a period of time debris and manure will accumulate on the nest pad in and about the projections. Since that accumulation would create an unsanitary environment for the bird and/or the eggs, it is necessary to periodically remove the nest pads. Unlike with prior nests formed from particulate matter, it is usually desirable to clean and reuse the nest pads. However, given that the typical poultry layer and/or breeder facility would have hundreds or thousands of nest pads and that debris and manure tend to cling to the projections, this cleaning project can be an enormous undertaking in terms of time and effort.
Previously, nest pads have been cleaned manually, such as by hosing down and/or scrubbing each pad. Unfortunately, the relatively small size and weight of the pads required a substantial amount of individual handling. Prior devices have been suggested for automating the cleaning process, such as by placing the pads on a conveyor and spraying the pads with cleaning fluid and/or water from a rotating nozzle. Unfortunately, such devices have not always been able to remove all of the debris and manure, particularly that which is not on the pad top surface, but has been trapped between the projections or migrated through the spacings to adhere to the back surface. Further, the particular nature of poultry manure is such that wetting can cause it to become gummy and glue-like and adhere to the projections.
Accordingly, it is an object of the present invention to provide and improved method and apparatus for cleaning poultry nest pads. Other objects of this invention are to provide for:
a. more complete cleaning of the nest pads with minimal labor,
b. efficient utilization of cleaning fluid and energy resources in the cleaning process,
c. a portable and compact pad cleaning apparatus which is readily installed at a cleaning site, and
d. rapid throughput of pads in the cleaning and sanitizing process.
To accomplish these objectives, an apparatus has been provided wherein nest pads are moved on a conveyor between a plurality of cleaning stations, involving first bending the pads prior to wetting in order to separate debris and dried manure by cracking and breaking from the projections and to further expose the recesses, then spraying the pads with a cleaning fluid at high pressure in a wiping motion across the bent pad, and then spraying with a sheet of cleaning fluid at low pressure across the top and bottom surfaces of the pad while it is in an inverted orientation over a tank or receptacle for receiving the debris, manure and spent cleaning fluid. That receptacle includes an auger or like conveyor for removing settled manure and debris. A filtering and recirculating system is incorporated with the receptacle for reusing at least a portion of the spent cleaning fluid. The conveyor is arranged to remove individual pads from a stack of dirty pads, support the pads through the cleaning stations and return the pads to a stack of clean pads. The entire apparatus can be mounted on a wheeled stand for transport to the poultry house to be serviced.
Other objects, advantages and novel features of the present invention will now become readily apparent to those of skill in the art from the following drawings and detailed description of preferred embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a side view of a portable cleaning apparatus according to the teachings of the present invention.
FIG. 2 shows an enlarged, partial cross-sectional side view of the cleaning apparatus of FIG. 1 with portions of the washer cabinet removed to show internal operation and components.
FIG. 3 shows a top view of the conveyor portion of the cleaning apparatus of FIG. 1, taken along line 3--3, with select related components.
DESCRIPTION OF PREFERRED EMBODIMENTS
FIGS. 1-3 show a preferred embodiment of the cleaning apparatus 10 of the present invention as mounted on a portable, wheeled frame. This apparatus includes an automatic pad loading system 20, a washer cabinet 50, a circulation system 90, and an automatic pad stacking system 120. As an overview, dirty pads are received by loading system 20 and then cleaned at a plurality of cleaning stations within washer cabinet 50 and then provided as clean pads to stacking system 120. Preferably, this apparatus is formed so as to be compact in its dimensions. For example, it has been found that apparatus 10 can be made approximately two feet wide (the depth into the drawing of FIG. 1 ), under six feet high (along axis 12), and eight feet long (along axis 14).
Automatic loading system 20 receives dirty pads 22 in a bin 24 that holds the pads in a vertical stack 26. Typically, bin 24 will be open at its top and front end 25 so as to facilitate loading of the pads. The embodiment shown has been configured to clean a plurality of pads, each having approximately the same dimensions. Each pad 22 includes a top side 28, upon which the poultry are in most frequent contact, and a bottom side 30. Preferably, pads 22 are loaded into bin 24 when dry and with the top side up.
A conveyor 32 is disposed under bin 24 and supports stack 26 at the bottom of the bin. This conveyor includes, for example, a pair of spaced apart endless chains 34 mounted for rotation between drive sprockets 36 and idler sprockets 38. The top surfaces 35 of chains 34 serve as support surfaces to engage bottom sides 30 of each pad. A cross bar, length of angle iron, or like device can be mounted to both of chains 34 traversely of the conveyor width to serve as projections or lugs 40. Such lugs are preferably spaced apart along conveyor 32 by a distance greater than the length of pads 22 and project vertically no more that the height of each pad. In the view of FIGS. 1 and 2, conveyor 32 rotates clockwise. Thus, lugs 40 serve to remove pads 22 one at a time from the bottom of stack 26, as the conveyor rotates, and to transport each pad into washer cabinet 50. In especially preferred embodiments, the speed of travel of conveyor 32 is approximately six feet per minute. At that rate conventional poultry nest pads can be cleaned at the rate of approximately 310 pads per hour.
Guide elements or rods 42 are mounted adjacent conveyor 32 from loading system 20 to stacking system 120. Rods 42 are spaced apart from conveyor 32 over the side regions of the conveyor by, for example, a distance approximately equal to the height of pads 22 such that the pads slide under rods 42 as the pads are moved along by conveyor 32. Thus, rods 42 serve to retain pads 22 to the support surfaces of conveyor 32 throughout the path taken between the pad stacks.
Preferably, pads 22 are loaded into cleaning apparatus 10 when the manure and like debris on the pads is dry. In the process of loading and in the removal of individual pads from stack 26 by conveyor 32, some of that manure and/or debris may become dislodged. Shield 44 is mounted below conveyor 32 and stack 26 to receive such manure and debris and direct it to circulation system 90.
Washer cabinet 50 includes the plurality of cleaning stations for removing manure and debris from pads 22, the operation of which is preferably controlled via electrical control box 52 on the exterior of the cabinet. Conventional safety shut off and other desirable switches and controls can be installed on control box 52 as needed. It has been found to be particularly advantageous to include three types of cleaning stations within washer cabinet 50: a pad bending station, a high pressure wiping spray station and a low pressure sheeting spray station.
The pad bending station is located, for example, at the curve of conveyor 32 about drive sprockets 36. Rods 42 follow conveyor 32 around this curve, and, thus, pads 22 are constrained to follow as well. Preferably, the diameter of drive sprockets 36 is sufficiently small compared to the length of pads 22 that the pads are bent back upon themselves at this curve. In so doing, the spacing between projections on top sides 28 is enlarged sufficiently to force at least some of the dried manure and debris to loosen, break off and/or crack away from some projections and surfaces of the pad. Even if the manure and debris does not immediately fall off of the pads, it has been found to become significantly easier to remove by spraying after this cracking. Bending the pads in this way also exposes for cleaning more of the recessed portions of the pad between the projections, especially where the pad projections are closely spaced. Since the bending occurs prior to wetting of the pads, the manure and debris does not have a tendency to become gummy and adhere excessively to the pads.
The high pressure wiping spray station is preferably located adjacent the pad bending station and includes a high pressure spray nozzle 54. This nozzle is, for example, pivotably mounted about vertical axis 16 so as to be reciprocally movable traversely or laterally across the direction of travel of pads 22 over drive sprockets 36. Pivotal movement of nozzle 54 is controlled by lever arm 56, connected to cam device 58. That cam device is driven in conjunction with conveyor 32 by drive motor 60. Various conventional belt and chain connections 62 can be employed to achieve that result.
It has been found to be particularly advantageous to align nozzle 54 such that it sprays the top surfaces of pads 22 immediately after the pads are bent to crack away manure and debris and to exposed the recessed portions. In that way, the side to side motion of the spray of water across the pads from nozzle 54 creates a wiping motion to, in effect, sweep off loosened manure and debris and penetrate all the way through to the base of the pad projections. Preferably, cleaning fluid is sprayed from nozzle 54 at 1250 to 1400 PSI at a rate of 2.2 gallons per minute. Cleaning fluid is supplied to nozzle 54 via pipe or line 64, connected to the exterior of washing cabinet 50.
The low pressure sheeting spray station is preferably located downstream from the high pressure wiping spray station, begins adjacent the pad bending station and includes low pressure nozzles 66. In the example shown by FIGS. 1-3, nozzles 66 are disposed at three locations A, B and C. At each such location, nozzles 66 are mounted in groups of six separate nozzles linearly aligned across the width of conveyor 32, the end nozzle of each such group being shown in FIG. 2. Thus, the cleaning fluid coming out of those nozzles creates a sheet of spray across pads 22 as they move along conveyor 32 past nozzles 66. Cleaning fluid is, for example, supplied to nozzles 66 via a common pipe or line 68, connected to the exterior of washing cabinet 50.
To improve the cleaning efficiency, nozzles 66 can be specially oriented with respect to pads 22. In FIG. 2, nozzles at location A are arranged near drive sprockets 36 to cause the spray to impact the top surfaces of pads 22 almost tangentially while the pads are still somewhat bent and the interior recesses more exposed. Further downstream at location B, nozzles 66 are arranged to cause the spray to strike the top surfaces of pads 22 nearly perpendicularly or orthogonally while the pads are in their normal, planar configuration. Further yet downstream at location C, nozzles 66 are arranged to cause the spray to strike the bottom surfaces of pads 22 at an acute angle against the direction of travel of the pads along conveyor 32, again while the pads are in their normal planar configuration.
Circulation system 90 supplies and recycles the cleaning fluid. This system includes a high pressure fluid pump 92, a high pressure fluid reservoir or tank 94 connected to pump 92, a high pressure fluid pipe or line 96 connected to line 64. The cleaning fluid is preferably water with a conventional anti-foaming soap or disinfectant mixed therein. Also, it has been found to be advantageous for the cleaning fluid supplied to high pressure nozzle 54 to be heated to approximately 200 degrees Fahrenheit. To achieve that fluid heating, tank 94 can be provided with an internal heater or a coil heater can be mounted along line 96. The initial supply of cleaning fluid and any additional fluid needed in operation can be provided by any conventional pipe connection to high pressure pump 92 or to a supply reservoir 98 disposed in fluid communication with that pump.
It has been found to be particularly advantageous, however, to recycle most of the spent cleaning fluid during operation. To achieve that recycling, circulation system 90 includes funneling shield 100, below washer cabinet 50, to receive manure, debris and spent cleaning fluid washed off of pads 22. This shield is formed, for example, from a screen or filtering layer which permits excess cleaning fluid to pass through the shield, but retains manure and debris. Shield 100 is preferably configured as a funnel to direct such manure and debris toward a lower central region 102 containing an auger or like conveyor 104 for removing accumulated manure and debris from apparatus 10. To increase the rate and/or volume of fluid that can be filtered through the screen of shield 100, the funnel configuration can include a series of downward steps toward region 102. Also, to decrease the amount of cleaning fluid discarded with the manure by auger 104, the walls of region 102 can also be formed from a screen or filtering material and a plurality of holes 103 can be disposed in the radially inner portions of the blades of auger 104. In this way it has been found that the volume of non-recyclable cleaning fluid can limited to at least approximately 2.1 gallons per minute.
Recirculating water tank 106 is disposed below shield 100 to receive the portion of the spent cleaning fluid that can be reused, although initially the fluid in this tank can be clean and unused. That tank is connected to recirculating pump 108 which provides cleaning fluid via pipe or line 110 to line 68 and low pressure nozzles 66. In preferred embodiments, this recycled cleaning fluid is provided to nozzles 66 at approximately 25 PSI.
Since pads 22 travel past locations A, B and C in an inverted or upside down position, manure, debris and cleaning fluid tends to fall of the top surfaces of the pads toward shield 100. As a result, pads 22 tend to "drip dry" during that length of conveyor 32 in the reverse of the way dirt, debris, etc. tends to accumulate on the pads. As the cleaned pads exit washing cabinet 50, rods 42 terminate and the pads are no longer closely retained to the support surfaces of conveyor 32. Instead, pads 22 fall onto plate 112, closely spaced from that conveyor, and are dragged forward by lugs 40 toward pad stacking system 120.
Stacking system 120 reorients the pads to the upright position and stacks the pads for easy removal and reinstallation in the nests. This system includes bin 122, having an open front end 124 from which the pads can be removed. Bin 122 is, for example, disposed with respect to the end of plate 112 such that the leading edge of the pads drops down into bin 122 as the conveyor moves the pads forward. Continued movement of the pads forward causes the pads to flip over inside the bin such that the top surfaces of the pads are again upright and each new pad lands upon the top of the stack. Thus, the pads can be returned to a clean stack in the same order and orientation as taken from the dirty stack. Open sides 126 of bin 122 allow the drying process to continue once the pads are stacked.
Apparatus 10 can be made sufficiently compact so as to be portable by mounting on frame 130. Wheels 132 are disposed on frame 130 to facilitate movement from one poultry house to another.
Although the present invention has been described above in detail with respect to preferred embodiments, the same is by way of illustration and example only, and is not to be taken as a limitation of the full scope of the present invention. Those of skill in the art will now realize that various modifications and refinements of the present invention to particular situations can be made without departing from the scope of the invention. Accordingly, the spirit and scope of the present invention are limited only by the terms of the claims below.
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A method and apparatus is provided wherein poultry nest pads are moved on a conveyor between a plurality of cleaning stations, involving first bending the pads prior to wetting in order to separate debris and dried manure by cracking and breaking from the projections of the pad and to further expose the internal pad recesses, then spraying the pads with a cleaning fluid at high pressure in a wiping motion across the bent pad, and then spraying with a sheet of cleaning fluid at low pressure across the top and bottom surfaces of the pad while it is in an inverted orientation over a tank or receptacle for receiving the debris, manure and spent cleaning fluid. That receptacle includes an auger for removing the settled manure and debris. A filtering and recirculation system is incorporated with the receptacle for reusing at least a portion of the spent cleaning fluid. The conveyor is arranged to remove individual pads from a stack of dirty pads, support the pads through the cleaning stations and return the pads to a stack of clean pads. The entire apparatus can be mounted on a wheeled stand for transport to the poultry house to be serviced.
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RELATED APPLICATIONS
This is a non-provisional application based upon an earlier filed provisional application Ser. No. 60/248,918 filed Nov. 15, 2000.
BACKGROUND OF THE INVENTION
The present invention generally relates to elevator car door opening and closing apparatus. More specifically the present invention relates to an elevator car door opening apparatus wherein the active door operating mechanism is carried upon the elevator car and car door and an inexpensive, landing door unlocking and opening mechanism is attached to the landing door. A mechanical elevator car door locking mechanism is included which is inherently disabled when the car is within a reasonable distance of a landing site but which otherwise only permits the doors to be opened by an amount insufficient for passengers, within the car, to exit.
PRIOR ART
Heretofore complex and expensive landing door opening mechanisms have been attached to the landing door at each individual landing site. An example of such a mechanism may be found in U.S. Pat. No. 5,690,188, for an “Elevator Door System” issued to Takakusaki et al. on Nov. 25, 1997 wherein simple, inexpensive car door opening roller assemblies are placed on the car doors and complex, expensive, vane assemblies are placed on each landing site door. This arrangement can prove very costly in a high rise building having a large number of floors served by multiple elevators since the expensive vane assemblies must be provided on each and every landing site door.
BRIEF SUMMARY OF THE PRESENT INVENTION
The present invention overcomes the shortcomings of the referenced prior art by placing relatively inexpensive landing door opening roller assemblies on the landing doors and placing a more efficient clutch assembly on the elevator car door that engages the landing door roller assembly when the car doors are opened thereby opening both car and landing doors simultaneously in a more efficient and economical manner. Therefore, the more expensive clutch assembly need only be provided on the elevator car and not on each and every landing site door; a definite economical advantage in high rise buildings having a large number of landing sites served by one or more elevator cars.
The present invention teaches a new and improved clutch assembly, attached to the elevator car door comprising an assembly of mechanical links that form an expanding and collapsing mechanical parallelogram that is linked to the car door opening mechanism. The mechanical parallelogram is configured such that two parallel sides thereof provide a pair of vertically oriented gripping links that move laterally toward or away from each other as the mechanical parallelogram expands or collapses. A cam wheel, operated by the door opening mechanism, expands and/or collapses the mechanical parallelogram.
As the elevator car approaches and stops at a landing site, a pair of rollers attached to the landing door's locking mechanism enters the slot between the vertically oriented gripping links of the mechanical parallelogram. As the elevator doors begin to open, by action of the car door opening mechanism, the cam wheel is caused to rotate thereby collapsing, or closing, the vertical gripping links upon the landing door rollers coupling the landing door to the elevator car door and unlocking the landing doors. With the landing doors unlocked and coupled to the elevator car doors, the car doors and landing doors are opened simultaneously by the car door opening mechanism.
By reversing the elevator car door opening mechanism, the elevator car doors and the landing doors are simultaneously closed and the gripping links are expanded or opened, by the reverse rotation of the cam wheel, thereby releasing their grip upon the landing door rollers whereby the landing doors are again locked and the elevator car is free to move on to another landing site.
In the event of an emergency such as an unexpected electrical power failure, the door opening system, as taught and disclosed herein, further provides a simple and economical way to prevent the opening of the elevator car doors, by onboard passengers, beyond a predetermined amount if the elevator car is not within reasonable distance of a landing zone.
If the elevator car is not within a reasonable distance of a landing site the landing door locking and unlocking rollers will not be between the vertical gripping links of the mechanical parallelogram. Therefore, if the passengers, in a stalled elevator car, push the car doors open, the gripping links, of the mechanical parallelogram will close or collapse toward each other farther than possible when the landing door locking and unlocking rollers are present. The additional travel of the mechanical parallelogram gripping links may be advantageously used to mechanically activate, by appropriate mechanical linkage, a car door latch mechanism that will limit the amount of car door separation.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 presents a view looking downward on the top of a typical elevator car, embodying the present invention, stopped at a landing site.
FIG. 2 presents an elevational, view of a pair of elevator car doors in the closed configuration and embodying the present invention.
FIG. 3 presents an elevational view of a pair of elevator car doors in the open configuration and embodying the present invention.
FIG. 4 presents a pictorial view of the elevator door power drive assembly of the present invention.
FIG. 5 presents an elevational view of the right side car door embodying the present invention.
FIGS. 5A through 5C illustrates the operation of an elevator car door safety latch.
FIG. 6 presents an enlarged elevational view of the door opening clutch assembly shown in FIG. 5 .
FIG. 7 presents an exploded view of the elements comprising the car door opening clutch assembly as illustrated in FIGS. 5 and 6.
FIG. 8 presents a plan view of the landing door opening rollers about to be engaged by the elevator door opening clutch assembly.
FIG. 9 presents an elevational view taken along line 9 — 9 in FIG. 6 .
FIG. 10 presents an elevational view taken along line 10 — 10 in FIG. 6 .
FIG. 11 presents an elevational view taken along line 11 — 11 in FIG. 1 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 presents a top view of a typical elevator car 10 positioned at a typical landing site and embodying the present invention. As illustrated, in FIG. 1, the elevator car doors 12 and 13 are in alignment with landing doors 14 and 15 respectively. A door opening clutch assembly 18 , attached to each car door 12 and 13 , is in engaging alignment with a pair of landing door unlocking and opening roller assemblies 21 .
When car 10 stops at a given landing, car doors 12 and 13 are opened by means of clutch assemblies 18 which, because of their engagement with roller assemblies 21 on landing doors 14 and 15 also unlock and open landing doors 14 and 15 .
Referring now to FIG. 2, car doors 12 and 13 are illustrated in their closed position. A door opening power drive assembly 40 is affixed to the top of car 10 . Referring now to FIG. 4, drive assembly 40 preferably comprises an electric motor 42 coupled to a speed reducing torque multiplier 44 preferably having a speed reduction ratio of 29 to 1. Although any speed reducing apparatus may be used it is preferable that a “cyclo” or cyclodial type speed reducer be used. A suitable cyclo speed reducer has been found to be Cyclo Speed Model CNHX-4100Y-29 marketed by Sumitomo Machinery Corporation of America. The cyclo speed reducer operates by the action of an eccentric cam mounted on the input shaft of the speed reducer. The eccentric cam rotates within a bore inside a cyclodial disc forcing the cyclodial disc to roll inside a ring gear housing. As the input shaft, and the eccentric cam, rotate, the cyclodial disc advances a given distance in the opposite direction thereby producing a speed reduction. The amount of speed reduction is determined by the specific design of the cyclodial disc and the ring gear housing. The primary advantage of the cyclodial speed reducer is that it has no elements operating in shear as in a typical geared speed reducer. In a cyclodial speed reducer all moving elements operate in compression. Thus a valuable benefit is realized, namely long life and no catastrophic failure is possible. Further, because of the rolling action, the cyclo speed reducer is more quiet than speed reducers using gears. This is particularly important for a device mounted on top of an elevator car where because of its box like structure, can amplify sounds to the passengers within the car.
Attached to output shaft 46 of speed reducer 44 is a typical door actuating arm 48 having a typical counter weight 41 attached thereto as illustrated. However, any other traditional drive assembly, such as the belt drive assemblies as illustrated in U.S. Pat. Nos. 4,926,975 and 5,690,188, may be used in combination with the present invention.
The continuing detailed description of the present invention will be further described as it applies to the right hand elevator door 13 and its associated landing door 15 . However, it is to be understood that the invention, hereinbelow, may be equally applied to the left hand door 12 , as also illustrated in the figures, by one skilled in the relevant art.
Referring now to FIGS. 2, 5 , and 6 , door drive link 20 is pivotally attached to pivot pin 43 of actuating arm 48 of power drive assembly 40 . Link 20 is pivotally attached to door opening link 22 at pivot 23 . Door opening link 22 is pivotally attached to the car body at pivot 24 . Link 22 is also pivotally attached to rotatable cam link 60 , of clutch assembly 18 , at pivot 51 . Rotatable cam link 60 is pivotally attached to clutch mounting plate 62 by pivot pin 54 . Clutch mounting plate 62 is typically attached to door 13 , as illustrated in FIG. 5, by any convenient means. FIG. 7 provides an exploded view of clutch assembly 18 as applied to door 13 .
To open doors 12 and 13 , power drive assembly 40 is energized whereby actuating arm 48 rotates counterclockwise, as viewed in FIG. 2, thereby causing link 20 to translate to the left whereby link 22 rotates, counterclockwise about pivot 24 dragging door 13 to its open position as illustrated in FIG. 3 . To close doors 12 and 13 , the process is simply reversed.
Referring now to FIGS. 2, 3 , 5 , 6 , 7 , 9 and 10 . Clutch assembly 18 , preferably, comprises a base or mounting plate 62 which is affixed to the hoist side of elevator door 13 . Pivotally attached to base plate 62 are a pair of laterally disposed, diagonal links 71 and 72 . Diagonal links 71 and 72 are pivotally attached to base plate 62 by pivot pins 74 and 76 respectively such that links 71 and 72 are free to rotate in a plane parallel to the plane of base plate 62 . Pivotally attached to the opposite ends of diagonal links 71 and 72 are vertical links 78 and 79 as illustrated in FIG. 6 . Thus links 71 , 72 , 78 , and 79 form a movable parallelogram whereby the theoretical area, therein, may be expanded and/or collapsed. Link 79 is provided a cam follower, or roller, 77 projecting into the plane of rotation of links 71 and 72 . Similarly vertical link 78 includes pin 73 extending into the plane of rotation of links 71 and 72 .
Cam wheel 60 is pivotally attached to base plate 62 by pivot pin 54 whereby cam link 60 is free to rotate within the plane of links 71 and 72 between base plate 62 and vertical links 78 and 79 as illustrated in FIGS. 9 and 10. Cam wheel 60 has two cam surfaces 63 and 64 . Both cam surfaces 63 and 64 are of a circular configuration concentric about pivot 54 with surface 64 being of a larger radius than surface 63 . A camming ramp, or step, 66 acts as a transition from surface 63 to surface 64 . Extending radially outward from cam surface 63 is arm 61 . The function of cam surfaces 63 and 64 , ramp 66 , and arm 61 will be described more fully below.
When car doors 12 and 13 are in there respective closed position, as illustrated in FIG. 2, all elements of clutch assembly 18 , on car door 13 , are positioned as shown in FIGS. 5 and 6. Cam arm 61 is in engagement with pin 73 on vertical link 78 thereby preventing tension spring 65 from collapsing the collapsible parallelogram formed by links 71 , 72 , 78 , and 79 . Cam follower 77 , on vertical link 79 , is in engagement with, or slightly removed from cam surface 63 and immediately adjacent to ramp 66 between cam surfaces 63 and 64 .
As car door 13 begins to open, by virtue of the horizontal force applied by link 22 through cam wheel 60 and pivot 54 , cam wheel 60 begins to rotate clockwise on door 13 (counterclockwise on door 12 ) see FIG. 2 . As cam wheel 60 rotates clockwise, cam arm 61 rises releasing its hold on pin 73 and ramp 66 engages cam follower 77 , on vertical link 79 , and with the assistance of tension spring 65 , forces vertical link 79 downward and vertical link 78 upward thereby causing vertical links 78 and 79 to move laterally toward one another by action of the collapsing parallelogram formed by links 71 , 72 , 78 , and 79 .
Referring now to FIGS. 1, 8 and 11 . If elevator car 10 is in a landing zone, or safely close to a landing, door unlocking and opening rollers 26 and 27 , of roller coupling assembly 21 , will be positioned between vertical links 78 and 79 of clutch assembly 18 as illustrated. As shown in FIG. 11, rollers 26 and 27 are typically positioned side by side with roller 26 rigidly affixed to assembly 21 while roller 27 is permitted to move laterally approximately one quarter of an inch. When coupling assembly 21 is positioned between vertical links 78 and 79 each roller, 26 and 27 , is typically provided approximately one quarter of an inch clearance between roller surface and vertical links 78 and 79 respectively. Thus when the collapsing parallelogram formed by links 71 , 72 , 78 , and 79 closes upon rollers 26 and 27 vertical link 79 need only translate one quarter of an inch to engage roller 26 however, vertical link 78 must not only translate one quarter of an inch to engage roller 27 but it must also translate an additional quarter of an inch pushing roller 27 to its lateral stop to firmly grip coupling assembly 21 . Therefore, in order to provide the additional travel required by vertical link 78 lateral links 71 and 72 are eccentrically pivoted about pivots 74 and 76 respectively, whereby link 78 will move faster and laterally further than link 79 by virtue of the longer pivot radius about pivots 74 and 76 .
As roller 27 is pushed toward roller 26 by vertical link 79 door unlatching link 30 is caused to move vertically thereby unlatching door locking lever 34 permitting the door to open.
When elevator car doors 12 and 13 close, by action of power drive 40 , cam wheel 60 , on door 13 , will rotate counterclockwise, as viewed in FIGS. 5 and 6, whereby cam arm 61 will engage pin 73 , on vertical link 78 , and by overcoming the force of tension spring 65 force vertical link 78 downward causing vertical links 78 and 79 to separate releasing their grip upon door opening rollers 26 and 27 and thereby returning clutch assembly 18 to its closed door configuration permitting elevator car 10 to move on to another landing. Roller 27 being pivotally biased to separate from roller 26 , because of the weight of link 30 upon lever arm 36 , will separate from roller 26 thereby causing the landing door locking lever 34 to engage and lock the landing door from being forced open.
In the event Elevator car 10 stops outside a landing zone, for example as a result of a power failure, elevator car doors 12 and 13 might be pushed open by passengers inside the car by overcoming the resisting torque of power drive assembly 40 . However, it is desirable that car doors 12 and 13 be pushed open only to a given position to permit air ventilation within the car. Clutch 18 further acts to limit the car door opening as described in greater detail below.
FIG. 5 illustrates an optional feature that may be added to the present invention. Attached to a door suspension assembly 32 of car door 13 by pivot 58 is latching arm 56 . Latching arm 56 is connected to vertical link 78 of clutch assembly 18 by link 52 as illustrated.
Referring additionally to FIGS. 5A, 5 B, and 5 C. If car 10 stops outside a landing zone, rollers 26 and 27 , of landing door coupling assembly 21 , will not be positioned between vertical links 78 and 79 of clutch assembly 18 . Thus if car doors 12 and 13 are forced open, clutch assembly 18 will function as described above whereby cam wheel 60 will rotate clockwise, by action of links 22 , and 20 , and actuating arm 48 of power drive assembly 40 whereby arm 61 of cam wheel 60 will rotate clockwise and upward, as viewed in FIGS. 5 and 6, thereby releasing its hold upon pin 73 . Vertical links 78 and 79 , now being unrestricted, and being drawn together by action of tension spring 65 may close more fully than when roller coupling assembly 21 is therebetween.
Upon collapse of the parallelogram formed by links 71 , 72 , 78 , and 79 , vertical link 78 is permitted to move further upward than it would if a landing door coupling assembly 21 was therebetween, thereby, similarly, forcing latching link 52 further upward causing latch 56 to rotate counterclockwise about pivot 58 . As door 13 moves further, latching link 56 progressively rotates downward, as illustrated in FIGS. 5A, 5 B, and 5 C until latch 56 travels over center, as illustrated in FIG. 5C, whereby latch 56 will engage bracket 57 attached to door rail 59 thereby preventing further opening of door 13 .
Preferably vertical links 78 and 79 also includes roller engaging plates 68 and 69 , respectively, having diverging end flanges as illustrated in the figures. The diverging end flanges, of plates 68 and 69 serve to guide rollers 26 and 27 , of roller coupling assembly 21 , there between, see FIGS. 8 and 11, when the elevator car is reengaging the hoistway rollers 26 and 27 after manual disengagement for maintenance purposes.
Although the preferred embodiment as disclosed herein teaches an elevator having two car doors with two associated landing doors wherein a separate clutch assembly is included for each car door, the clutch assembly as described and claimed herein may also be effectively used on an elevator car having a single car door with a single associated landing door. Further the clutch assembly, as taught and claimed herein, may be used on an elevator car having two car doors wherein a single clutch assembly is positioned on one “master” door and the second car door is “slaved” to the master door and operated by means such as cables, gears or mechanical linkages.
It should be further understood, by those skilled in the art, that various other changes, modifications, omissions and/or additions in form and detail of the preferred embodiment taught herein may be made therein without departing from the spirit and scope of the claimed invention.
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An elevator car door opening and closing apparatus is taught having a clutch assembly carried by each car door for coupling with a landing door locking and unlocking assembly whereby the car and landing doors open and close simultaneously. The clutch assembly includes a four bar mechanical expanding and collapsing parallelogram linkage which engages, unlocks, and opens the landing door. Mechanical linkage is also attached to the parallelogram linkage whereby the elevator car doors may only be forced opened a limited amount if the car is stalled between landing sites.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This is a divisional application of U.S. application Ser. No. 10/888,893, filed on Jul. 9, 2004, which is hereby incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] The present invention relates generally to switching the frequency of electrical power provided by power modules and, more particularly, to systems and methods for the reduction and elimination of air pollutants by providing electrical power by power modules.
[0003] Electrical generators are commonly used for temporarily generating electricity for small loads at facilities that are remote or mobile. One current disadvantage with many such generators is that they use diesel fuel, which creates a very high quantity of air pollution. A commonly used type of diesel fuel is bunker fuel, which is one of the most air polluting fuels that can be used. Additionally, such generators commonly lack catalytic converters and other pollution control devices to minimize air pollution.
[0004] Another disadvantage of current generators is that they are built for a specific installation or use. In other words, such electrical generators are single voltage and single frequency systems and cannot be used at multiple sites that may have different voltage and frequency requirements.
[0005] The limited use of generators is evident in many environments, such as the marine environment. There is a lack of uniformity in electrical equipment used internationally. Some on-board electrical equipment may function with 50 or 60 Hz alternating current (AC). The same electrical equipment may need a voltage of 110, 220, 380, 400, 480, or even 600 volts. For a ship traveling internationally, its ability to connect to an onshore generator (which can vary from country to country) will be limited to the electrical compatibility between the generator and onboard equipment (which can also vary from country to country based on the ship's origin). Thus, the ability of a port to provide electrical power to the ship's onboard equipment will be limited to the electrical compatibility between the generator and onboard equipment.
[0006] Providing a range of voltage generation or frequency generation has required using more than one generator and more than one transformer. However, it is unfeasible to equip a port with multiple generators and multiple transformers. Doing so would require much space, huge investment costs, and increased safety risks.
[0007] Another problem is that a ship may berth at different locations of the same port depending on the type and size of cargo. Installation of an extensive electrical cable network would be required to connect a stationary generator or electrical source at a berth for ships at various locations within a port.
[0008] One attempt to provide a solution to the above problems is disclosed in U.S. Pat. No. 6,644,247 to Campion (“Campion”). A frequency switching system for portable power modules includes a turbocharger operatively connected to a motor and has interchangeable components that allow selecting a first or second turbocharger configuration. Frequency output may be varied by interchanging turbochargers, and voltage switching is accomplished by operating a voltage switch. To switch electrical frequencies, the design described in the Campion patent requires connecting and disconnecting integral portions of the frequency switching system. For example, the design described in the Campion patent involves switching frequency by disconnecting a first driving portion of a turbocharger from an exhaust duct, disconnecting the first driving portion from a turbocharger bypass, disconnecting the first driving portion from an exhaust gas manifold, disconnecting the first driving portion from a driven portion, and making connections between a second driving portion and corresponding locations previously disconnected from the first driving portion. Thus, much mechanical work is required to change the frequency output.
[0009] Besides the mechanical concerns in changing frequency output, Campion lacks effective methods for reducing air pollution and/or taking advantage of pollution control incentives offered by environmental regulatory agencies. Those agencies often offer financial incentives for reducing air pollution. For example, if an electrical power plant reduces air pollution by adopting technology that reduces emissions, then the environmental regulatory agency may issue the operator of the electrical power plant with pollution credits. A pollution credit is an incentive for reduction in air pollutants that may be used by the polluter to offset excess air pollutants at another facility. A pollution credit may be bought, sold, banked, or traded. For example, if the operator of the electrical power plant has another facility that is environmentally regulated, then the operator may use the pollution credits earned from the electrical power plant to offset pollution “penalties” for the other facility. If the operator of the electrical power plant desires to not use the pollution credits, then the operator may sell the pollution credits to operators of other facilities who can, in turn, use the credits to offset their penalties.
[0010] As can be seen, there is a need for an improved apparatus and methods for providing electrical power to varying electrical equipment having varying frequency and voltage needs, needing minimal use of space and capital equipment, being portable, being easily switchable between electrical frequencies and electrical voltages, and providing reduced air pollution.
SUMMARY OF THE INVENTION
[0011] In one aspect of the present invention, a method for changing a frequency of electrical power provided by a power module comprises determining a first frequency of electrical power provided by the power module; engaging a first governor to maintain the first frequency of electrical power provided by the power module; determining a second frequency of electrical power provided by the power module; and engaging a second governor to maintain the second frequency of electrical power provided by the power module.
[0012] In an alternative aspect of the present invention, a method for changing a voltage of electrical power provided by a power module comprises adjusting voltage of the electrical power provided by the power module with a voltage regulator; and wherein the voltage is adjusted independently of frequency of the electrical power.
[0013] In another aspect of the present invention, a method for providing electrical power from a first location to a second location comprises operating a motor; driving an electrical generator connected to the motor; selecting a first electrical frequency; controlling the electrical generator with a first governor and a second governor; engaging the first governor to maintain the first electrical frequency of electrical power; selecting a first electrical voltage; and delivering electrical power, at the first electrical frequency and the first electrical voltage, via a cable connected between the electrical generator and a power connection box.
[0014] In yet another aspect of the present invention, a method for providing power from a port to a ship electrical system comprises operating a motor positioned within a container; driving an electrical generator positioned within the container and driveably connected to the motor; selecting a first electrical frequency; controlling the electrical generator with a governor; controlling the rotational speed of the electrical generator with a speed controller; selecting a first electrical voltage; selecting a second electrical frequency; and delivering power, at the second electrical frequency and the selected first electrical voltage, via a cable connected between the electrical generator and a power connection box.
[0015] In a further aspect of the present invention, a method for providing power from a port to a ship comprises operating a gaseous fuel motor positioned within a container; driving a constant speed, variable load electrical generator positioned within the container and driveably connected to the gaseous fuel motor; selecting a first electrical frequency; controlling an electrical frequency produced by the electrical generator with a first governor; selecting a second electrical frequency; selecting a first electrical voltage; regulating the first electrical voltage with an adjustable voltage regulator; controlling the second electrical frequency produced by the electrical generator with a second governor; delivering power, at the second electrical frequency and the first electrical voltage, via a cable connected between the electrical generator and a power connection box.
[0016] In a still further aspect of the present invention, an apparatus for providing temporary power from a generator to an electrical system comprises a container; a gaseous fuel motor positioned within the container; a constant speed, variable load electrical generator driveably connected to the gaseous fuel motor; a first governor to maintain a first electrical frequency of electrical power provided by the constant speed, variable load electrical generator at the first electrical frequency; a second governor to maintain a second electrical frequency of electrical power provided by the constant speed, variable load electrical generator at the second electrical frequency; and a first speed controller and a second speed controller for controlling the rotational speed of the electrical generator.
[0017] In yet a still further aspect of the present invention, a power module for providing switchable power comprises a container; a motor positioned within the container; a generator connected to the motor; a first governor to maintain a first frequency of electrical power provided by the generator at the first frequency; a second governor to maintain a second frequency of electrical power provided by the generator at the second frequency; and an adjustable voltage regulator to adjust a voltage of the power provided by the generator.
[0018] In a still further aspect of the present invention, an electrical power network comprises a ship; a dock adjacent the ship; a gaseous fuel motor at the dock; a generator connected to the gaseous fuel motor; a first governor to maintain a first electrical frequency of electrical power provided by the generator at the first electrical frequency; a second governor to maintain a second electrical frequency of electrical power provided by the generator at the second electrical frequency; a first speed controller and a second speed controller for controlling the rotational speed of the generator; an adjustable voltage regulator to adjust a voltage of the power provided by the constant speed, variable load electrical generator; a power connection box; a generator cable for delivering the electrical power to the power connection box; and a cable connected between the power connection box and a vessel electrical system.
[0019] These and other aspects, objects, features and advantages of the present invention, are specifically set forth in, or will become apparent from, the following detailed description of an exemplary embodiment of the invention when read in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] FIG. 1 is a schematic of an electrical power network, according to an embodiment of the present invention;
[0021] FIG. 2 is a block diagram of an apparatus for providing electrical power from one location to another location, according to an embodiment of the present invention;
[0022] FIG. 3 is a partial sectional view of a power module, according to an embodiment of the present invention;
[0023] FIG. 4 is a partial, perspective view of a motor and generator of the power module of FIG. 3 ;
[0024] FIG. 5 is an enlarged view of the portion of the motor within section A of FIG. 4 ;
[0025] FIG. 6 is a side view, along line 6 - 6 of FIG. 5 ;
[0026] FIG. 7 is a plan view, in isolation, of a linkage system, according to another embodiment of the present invention;
[0027] FIG. 8 is a side view, along line 8 - 8 of FIG. 7 ; and
[0028] FIG. 9 is a flow diagram of a method for providing electrical power to a location, according to an embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0029] The following detailed description is of the best currently contemplated modes of carrying out the invention. The description is not to be taken in a limiting sense, but is made merely for the purpose of illustrating the general principles of the invention, since the scope of the invention is best defined by the appended claims.
[0030] The present invention is useful for switchable power delivery with selectable frequency and voltage settings. “Switchable power” is intended to refer to electrical power that is capable of being changed in frequency and/or voltage without mechanically connecting or disconnecting portions of a generator or motor. Additionally, the invention is useful for reducing pollution by using cleaner fuels for generating electricity and emissions controls for a motor driving a generator. The invention is useful for generating electrical power during electrical outages, or for providing auxiliary power supply. One such use is for marine vessels such as ships, boats, barges, and other watercraft that require auxiliary electrical power of a particular frequency and voltage while the vessel is berthed. The invention is also useful for providing power to vehicles, such as aircraft or trucks.
[0031] Prior art service generators may use bunker fuel, while the present invention may use a cleaner fuel, such as natural gas, liquefied natural gas, liquefied petroleum gas, and the like for generating electricity. The air pollution that is otherwise generated from bunker fuel is effectively reduced by instead using cleaner burning fuel motor of the present invention such that the pollution reduction may be 99% for No x and CO and 100% for PM 10 (particulate matter).
[0032] Internationally, electrical systems often have different standard electrical frequencies (e.g., 50 Hz and 60 Hz) and standard electrical voltages (e.g., 110, 220, 380, 400, 480, and 600 volts). To build a power plant at a first stationary or non-stationary (moveable) location to provide electrical power to a second stationary or non-stationary (moveable) location, multiple generators and transformers have been needed at great capital expense to provide different electrical frequencies and different electrical voltages.
[0033] In contrast, the present invention can use one generator with two governors and two speed controllers to select a desired electrical frequency and/or a desired electrical voltage. Instead of disconnecting, assembling, and re-connecting generator components as has heretofore occurred (such as disconnecting a driving portion from an exhaust system to change a turbocharger), selecting frequencies and voltages may be accomplished by merely activating a governor to open and close a fuel valve to regulate motor rotation to set frequency and adjusting a voltage regulator to set output voltage, according to the present invention.
[0034] In more specifically describing the present invention, and as can be appreciated from FIG. 1 , the present invention provides an electrical power network 10 for providing electrical power from a first location 34 to a second location 44 . The electric power network 10 may comprise a power module 30 , which may be situated at the first location 34 . The first location 34 may, as an example, be a dock 60 in a port. The network 10 may further include a fuel tank 40 to supply fuel to the power module 30 . The fuel tank 40 may supply natural gas, liquefied natural gas, liquefied petroleum gas, propane, ultra low sulphur diesel (“California diesel”), and the like. The power module 30 may supply electrical power, via a generator cable 50 , to a power connection box 250 . A cable 52 of the network 10 may be connected from the power connection box 250 to supply electrical power to the second location 44 which may, for example, be a ship 20 docked at a berth. An electrical system 54 may be a type of electrical equipment known in the art for distributing electric power at the second location 44 , such as onboard the ship 20 .
[0035] The electrical power network 10 may also include a machine 80 , such as a crane, for raising and lowering the power module 30 and transporting the power module through a lateral distance D, and thereby move the power module 30 from one location to another. For example, the machine 80 may move the power module 30 from a truck (not shown) to the first location 34 . Besides being moveable by the machine 80 , the portable power module 30 may be moveable, such as by a forklift (not shown) and trailerable, such that the portable power module 30 may be transported, such as by a standard 18-wheel truck and trailer (not shown), from one location to another location.
[0036] As shown in the block diagram in FIG. 2 , the power module 30 may comprise a motor 100 , which may be positioned within a container 90 . The motor 100 may be, for example, a gaseous fuel motor or a turbocharged after-cooled engine. The motor 100 may be driveably connected to drive a generator 110 , which may be, for example, a constant speed, variable load electrical generator.
[0037] A first governor 200 and a second governor 210 may control the production of electric power from the generator 110 by controlling the rotational velocity of the generator 110 . The first and second governors 200 , 210 can be well-known governors and may be, for example, a type manufactured by the Woodward Company of Fort Collins, Colo., USA. The governors 200 , 210 may be of the electro-mechanical type that operate by extending a rod to contact a fuel valve (such as a butterfly valve) of the motor 100 , and thereby open and close the fuel valve. The opening and closing of the fuel valve can regulate the fuel supply to the motor 100 , and thereby regulate the rotational speed of the generator 110 . In turn, the electrical frequency produced by the generator 110 is regulated (i.e., selected). The governors 200 , 210 may be calibrated to regulate fuel supply in relation to motor 110 speed such that increasing and decreasing fuel supply rate respectively increases and decreases the motor 110 speed.
[0038] One governor (for example, first governor 200 ) may be used to set the generator 110 to a first frequency (e.g., 50 Hz) and a second governor (for example, second governor 210 ) to set the generator 110 to a second frequency (e.g., 60 Hz). For example, the first governor 200 may be calibrated to supply fuel to run the motor 100 at 1000 rpm, which may correspond (depending upon the type of motor 100 and generator 110 ) to the generator 110 producing electricity at 50 Hz. Likewise, the second governor 210 may be calibrated to supply fuel to run the motor 100 at 1200 rpm, which may correspond to the generator 110 producing electricity at 60 Hz. In another example, the first governor 200 may be calibrated to set motor 100 speed to 1600 rpm to produce 50 Hz electricity and the second governor 210 may be calibrated to set motor 100 speed to 1800 rpm to produce 60 Hz electricity.
[0039] The generator 110 output electrical frequency may be switched by, for example, turning off the first governor 200 and turning on the second governor 210 , to change the electrical frequency from a first frequency to a second frequency (for example, from 50 Hz to 60 Hz). Likewise, generator 110 output electrical frequency may be switched by turning off the second governor 210 and turning on the first governor 200 , to change the electrical frequency from a second frequency to a first frequency (for example, from 60 Hz to 50 Hz).
[0040] A first speed controller 220 and, optionally, a second speed controller 230 may control the rotational speed of the generator 110 , by controlling actuation of the governors 200 , 210 . The present invention may operate with only the first speed controller 220 or with both the first speed controller 220 and the second speed controller 230 . The first and second speed controllers 220 , 230 may be digital electronic controllers of a type well known in the prior art.
[0041] The first speed controller 220 may be associated with the motor 100 , the first governor 200 , and the second governor 210 when independent controlling of the first governor 200 and the second governor 210 is not desired or when the second speed controller 230 is malfunctioning. For example, when independent controlling is not needed, the first speed controller 220 may send instructions to deactivate the first governor 200 and activate the second governor 210 . The first speed controller 220 may receive feedback from the motor 100 to send corresponding instructions to the first governor 200 and the second governor 210 . For example, if the first speed controller 220 senses a decrease in rpm of the motor 100 , the first speed controller 220 may send instructions to the first governor 200 and the second governor 210 to open a fuel valve to increase the fuel supply to the motor 100 , which would increase the motor speed.
[0042] Alternatively, the first speed controller 220 may be associated with the motor 100 and the first governor 200 , while the second speed controller 230 may be associated with the motor 100 and the second governor 210 when independent controlling of the first governor 200 and the second governor 210 is desired. When the first speed controller 220 and the second speed controller 230 are both used, then the first speed controller 220 may receive feedback from the motor 100 to send corresponding instructions to the first governor 200 and the second speed controller 220 may receive feedback from the motor 100 to send corresponding instructions to the second governor 210 . For example, if the first speed controller 220 senses a decrease in rpm of the motor 100 , the first speed controller 220 may send instructions to the first governor 200 to open a first fuel valve (not shown) to increase the fuel supply to the motor 100 , which would increase motor speed. Meanwhile, the second speed controller 230 may send instructions to the second governor 210 to open the first fuel valve, and second fuel valve (not shown) when two fuel valves are desired to be operated, to increase the fuel supply to the motor 100 , which would increase the motor speed.
[0043] An adjustable voltage regulator 240 may be used (manually or automatically) to adjust the generator 110 output electrical voltage to varying amounts, which for example may be set to a value within a group consisting of, for example, ordinarily used voltages, such as 110, 220, 380, 400, and 480 volts. Desirably, the electrical voltage may be adjusted to a value within the range from about 380 volts to about 480 volts, depending on the voltage needed for equipment to be powered. The generator 110 output electrical voltage may be at values other than the ordinarily used voltages of 110, 220, 380, 400, and 480. The generator 110 output electrical voltage may be selected to be any voltage that can be safely delivered. The adjustable voltage regulator 240 may be a rheostat type, such as an adjustable voltage regulator manufactured by the Basler Electric Corporation of Highland, Ill., USA.
[0044] In still referring to FIG. 2 , the generator cable 50 may connect an electric cable spool 120 to the power connection box 250 . The power connection box 250 may permit intermediate connection among various electrical cables to connect to various electrical systems, for example, permitting the generator cable 50 to be connected to the cable 52 , which may be connected to the vessel electrical system 54 .
[0045] With reference to FIG. 3 , the power module 30 may comprise a container 90 . The container 90 may comprise wheels 92 for ground transport and struts 94 for supporting the container 90 when stationary. The container 90 may be a shipping container of a standard type known in the maritime and trucking industries. The electric cable spool 120 for storing lengths of generator cable 50 may be positioned within the container 90 . A louvered vent 140 , which may provide ventilation for combustion air and cooling of the interior of the container 90 , may also be positioned within the container 90 . A switch gear 130 may be used to monitor electricity produced from the generator 110 to the second location 44 (shown in FIGS. 1 and 2 ), such as measuring and reporting amperage, voltage, and frequency. As an example, the switch gear 130 may be of a type made by General Electric Corporation of a brand known as the Zenith Paralleling Switchgear. Exhaust from the motor 100 may exit the container 90 through an exhaust pipe 96 . A catalytic converter (not shown) may be affixed to the container 90 and the exhaust pipe 96 .
[0046] In FIG. 4 , the motor 100 and the generator 110 may be attached to a fan 150 for cooling the motor 100 . A first carburetor 202 and an optional second carburetor 204 may be used to meter fuel for combustion within motor 100 . The first carburetor 202 and the second carburetor 204 may be of the type well known in the art to include a butterfly valve (not shown). The first and second carburetor 202 , 204 may be opened and closed by the first governor 200 . Likewise, the first and second carburetor 202 , 204 may be opened and closed by the second governor 210 .
[0047] Although not shown, it should be understood that the present invention may comprise other arrangements among the first governor 200 , the second governor 210 , the first carburetor 202 , and the second carburetor 204 .
[0048] A base 160 may support the motor 100 and the generator 110 . The base 160 may comprise steel skid rails, such as I-beams. The motor 100 and the generator 110 may be bolted onto the base 160 with spring isolators for vibration isolation during operation. The base 160 may be secured to the container by bolting or welding into the interior of the container.
[0049] FIG. 5 , which is an enlarged view of Section A of FIG. 4 , depicts one arrangement among the governors 200 , 210 and the carburetors 202 , 204 . The first governor 200 and the second governor 210 may each comprise an extension rod 206 , which may be connected to a tie rod 208 . The tie rod 208 may be connected to a valve rod 212 , which may rotate to open and close each carburetor 202 , 204 .
[0050] The relative movement of the extension rod 206 , the tie rod 208 , and the valve rod 212 is represented in FIG. 6 , which is a view, along line 6 - 6 of FIG. 5 . Upon actuation of the first governor 200 (such as by the first speed controller 220 , not shown), the extension rod 206 may extend along direction B. Extension of the extension rod 206 may cause rotation of the tie rod 208 along direction C. The valve rod 212 may then rotate along the same direction C. The valve rod 212 may be connected to a butterfly valve (not shown) within the first carburetor 202 to open and close the butterfly valve to start or stop the flow of fuel within the motor 100 .
[0051] Continuing with FIG. 6 , the first governor 200 may be used to open or close the first carburetor 202 . To open the first carburetor 202 , the extension rod 206 may extend, along direction B, for example, away from the first governor 200 . The tie rod 208 may then rotate along direction C, for example, clockwise. The valve rod 212 may then rotate, along direction C, for example, clockwise to open the first carburetor 202 . Likewise, to close the first carburetor 202 , the extension rod 206 may move, along direction B, towards the governor 200 , moving the tie rod 208 , along direction C, for example, counterclockwise. The valve rod 212 may then move counterclockwise to close the first carburetor 202 .
[0052] Another embodiment of the present invention is shown in FIG. 7 as a linkage system 214 , in isolation, of one arrangement among the governors 200 , 210 and the carburetors 202 , 204 . The first governor 200 and the second governor 210 may each be connected to a governor arm 216 , which may be connected to a linkage tie rod 218 . The linkage tie rod 218 may be connected to a connector rod 222 . Each connector rod may be connected to a linkage rod 260 . A translation rod 224 may be connected to a vertical rod 226 . The vertical rod 226 may be connected to a carburetor rod 228 , which may rotate to open and close the carburetors 202 , 204 .
[0053] The relative movement within the linkage system 214 is represented in FIG. 8 , which is a view, along line 8 - 8 of FIG. 7 . The governors 200 , 210 may act in unison. Upon actuation of the first governor 200 and the second governor 210 (such as by the first speed controller 220 , not shown), the governor arm 216 may move along direction D. Movement of the governor arm 216 may cause movement of the linkage tie rod 218 along direction E. The connector rod 222 may then move along direction F to rotate the linkage rod 260 to along the same direction F. The translation rod 224 may then move along direction G to cause vertical rod 226 to move along direction H. Next, the carburetor rod 228 (moving, for example, in direction J) may be connected to a butterfly valve (not shown) within each carburetor 202 , 204 to open and close the butterfly valve to start or stop the flow of fuel within the motor 100 (not shown).
[0054] It can be seen in FIG. 9 that the present invention also provides a method 300 for providing power, for example, from a port to a ship. The method 300 may comprise a step 310 of operating a motor 100 , which may be positioned within a container 90 for ease of transportation. Thereafter, the method 300 may comprise a step 320 of driving an electrical generator 110 , which may be positioned within the container 90 . The electrical generator 110 may be driveably connected to the motor 100 . The electrical generator 110 may be positioned within the container 90 , along with the motor 100 , to facilitate portability such that a machine 80 may move the container 90 and that the container 90 may be moved by truck (or other vehicle) without separately moving the electrical generator 110 and the motor 100 . Next, the method 300 may continue with a step 330 of selecting a first electrical frequency, based on a previous setting for electrical frequency. Step 340 may comprise controlling the first electrical frequency with a first governor 200 . Next, a step 350 may comprise controlling the rotational speed of the electrical generator 110 with a first speed controller 220 to maintain the first frequency. Thereafter, a step 360 may comprise selecting a second electrical frequency based on the needed frequency for the equipment to be powered. Thereafter, the method 300 may comprise a step 370 of selecting a first electrical voltage based on the needed voltage for the equipment to be powered and a step 380 of regulating the first electrical voltage with an adjustable voltage regulator to maintain the selected first electrical voltage. A step 390 may comprise controlling the second electrical frequency produced by the electrical generator 110 with a second governor 210 . Thereafter, a step 400 may comprise delivering power, at the second electrical frequency and the first electrical voltage, via a cable 50 connecting the electrical generator 110 and a power connection box 250 from where electrical power compatible with a vessel electrical system (not shown) may be delivered to the vessel electrical system (not shown) to power the vessel's services.
[0055] 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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The present invention provides a method and apparatus for providing temporary electrical power to stationary locations and moveable locations. For example, vessel marine power systems may be directed to the reduction and elimination of air pollutants produced when using a ship's generator while at dock. The power system is modular, portable, and generates electricity over a wide range of voltages and frequencies.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
Crochet Needle Storage and Dispensing Device.
2. Description of the Prior Art
In crocheting it is common practice to employ a number of needles of various sizes. Such needles during the crocheting operation may be easily lost or mislaid.
The primary object of devising the present invention is to supply a light weight portable device in which crochet hook defining needles of various sizes may be stored when not in use, but any one of the needles being readily dispensed from the device for use by a simple manual operation.
Another object of the invention is to maintain a number of crochet hook defining needles in a confined space, but one in which the needles may be readily dispensed, and due to the needles being maintained in the confined space when not in use the probability of them being lost or mislaid is substantially eliminated.
SUMMARY OF THE INVENTION
The invention which is used in storing a number of crochet hook defining needles of various sizes and selectively dispensing any one of these needles, includes a cylindrical housing that has a first end portion and a second opened end. The first end portion includes an inwardly extending tubular member that defines both a longitudinally extending cam surface and a portion of circular transverse cross section. The cam surface is radially aligned with a longitudinal slot in the housing. The tubular member has a first inwardly extending body shoulder defined therein. A needle holding assembly is provided that includes first and second generally circular members and tubular means that extend therebetween. The tubular means includes a second body shoulder intermediately disposed therein. The first generally circular member includes a number of circumferentially spaced resilient clips that removably engage longitudinal sections of the needles adjacent the first ends thereof. The second generally circular member includes a number of circumferentially spaced longitudinally extending sockets that are aligned with the clips and removably engage second ends of the needles. The assembly is disposed within the housing and serves to removably support the needles. The tubular means of the assembly rotatably and slidably engages the portion of the tubular member of circular transverse cross section. A compressed helical spring is provided that at all times tends to move the assembly away from the tubular member. Stop means are provided that extend between the first and second body shoulders and allow the spring to move the assembly and needles to a first position in the housing where the assembly may be rotated without the needles contacting the cam surface.
A cam is provided that closes the second end of the housing and is rigidly secured to the assembly. The cap has a plurality of indicia thereon, each of which indicia when longitudinally aligned with the slot visually indicate the particular one of the needles that is in a dispensable condition in the housing. The dispensable needle is dispensed through the slot when the assembly and cap are manually forced toward the first end of the housing to bring the hook defining end of the dispensable needle into sliding pressure contact with the cam surface. After the needle is dispensed the spring means automatically return the assembly to the first position after the cap and assembly cease having a manual force exerted thereon.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a perspective view of the device which may be used to store a number of crochet hook defining needles, and selectively dispensing any one of the needles therefrom;
FIG. 2 is a longitudinal cross sectional view of the device taken on the line 2--2 of FIG. 1, with the device being in a first needle storing position;
FIG. 3 is the same longitudinal cross sectional view as shown in FIG. 2, but with the device being disposed in a second position whereupon a needle is dispensed therefrom;
FIG. 4 is a transverse cross sectional view of the device taken on the line 4--4 of FIG. 2; and
FIG. 5 is a second transverse cross sectional view of the device taken on the line 5--5 of FIG. 2.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The invention L as may best be seen in the drawings includes a cylindrical housing M in which a needle holding and needle dispensing assembly N is movably supported. The assembly N has a cap P rigidly secured thereto and the cap having a number of indicia Q imprinted thereon. When one of the indicia Q is transversely aligned with a longitudinal slot 20 in the housing, the indicia indicates which of the needles situated in the housing may be dispensed therefrom by causing the invention to move from a first to a second position. The needles are visually indicated in FIGS. 4 and 5 and identified by the letters E, F, G, H, I, J, K, O and OO that are used in trade to identify them as to size. The needles are generically identified in FIGS. 2 and 3 by the letter R rather than the specific letters previously mentioned.
The housing M as can best be seen in FIGS. 1, 2 and 3, includes a cylindrical shell 10 that has a first end portion 12 and a second open end 14. The first end portion 12 includes an inwardly extending tubular member 16 that defines a longitudinal cam surface 18, and the tubular member including a portion 16a that is of circular transverse cross section. A longitudinal slot 20 is formed in the shell 10. The portion 16a as can best be seen in FIG. 2 includes a first body shoulder 16b.
The needle holding and needle dispensing assembly N includes a first generally circular member 22 that has a first tube 24 extending downwardly from substantially the center thereof as can be seen in FIG. 2. The member 22 is illustrated as including a number of circumferentially spaced radially extending legs 26 with each of the legs having a clip 28 on the outer end thereof. The clip 28 is of varying width in order that the clip may engage needles R of different transverse cross sections as shown in FIGS. 2, 4 and 5.
The assembly N also includes a second generally circular member 30 that has a tubular stub 38 projecting downwardly from the center thereof and this stub having an inwardly extending lip 30b. The second generally circular member 30 also has a second tube 32 extending upwardly therefrom as shown in FIG. 2. The second generally circular member 30 is illustrated as being defined by a number of circumferentially spaced radially extending second legs 34 which legs on the outer extremity thereof support tubular sockets 36. The sockets 36 are of various transverse cross sections to removably engage the ends of the needles R that are of different transverse cross sections. The first tube 24 has a first free end 38 shown in FIG. 2 that has a non-circular interior that slidably engages a first non-circular end 42 of the second tube 32. The first end 42 has a second shoulder 40 defined therein.
A compressed helical spring 44 is provided as shown in FIGS. 2 and 3 that is situated within the first tube 24 and is in abutting contact with the first shoulder 16b and second shoulder 40. An elongate screw 46 extends through openings in the first and second shoulder 16b and 40, with the screw including a head 46a that is in abutting contact with the second shoulder 40. The upper end of the screw is engaged by a nut 48 that is in abutting contact with the first body shoulder 16b when the invention is in the first position illustrated in FIG. 2. The screw 46 extends through a tubular spacer 50, which spacer has a flanged end 52 that is situated above the first body shoulder 16b and in abutting contact therewith. The cap P as may best be seen in FIGS. 2 and 3 includes a circular plate 54 that has a hub 54a extending upwardly therefrom, which hub has an internal circumferentially extending recess therein that is engaged by the lip 30b. The plate 54 has a cylindrical side wall 54b extending upwardly from the peripheral edge therof, and the side wall extending upwardly over the lower portion of the shell 10. A retainer 56 extends upwardly into the tubular stub 38 and forces the lip 30b of the stub into engagement with the hub 54a whereby the cap P is removably but nonrotatably supported on the stub 30a. The cylindrical side wall 54b has the indicia Q marked thereon, with each indicia being so related to one of the needles R supported on the assembly N, that when that particular indicia is longitudinally aligned with the slot 20, the indicia will indicate which one of the needles R is in a position to be pivoted outwardly through the slot 20. After the invention L has had the needles R disposed therein, the needles may be selectively dispensed therefrom by aligning the appropriate one of the indicia Q with the slot 20. The cap P is now moved upwardly relative to the housing, with the upper end of the needle R that is aligned with the slot 20 being forced into pressure contact to pivot the upper end of the needle outwardly through the slot to the position shown in FIG. 3. Due to the resiliency of the material defining the second legs 34, the needle while still disposed in one of the sockets 36 is easily lifted therefrom.
The use and operation of the invention has been described previously in detail and need not be repeated.
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A light weight, portable device for removably storing a number of needles of various transverse cross section but of substantially the same length, which needles have crochet hooks defined on first ends thereof, and the device capable of being used to selectively dispense any desired one of the needles therefrom by a simple manual operation.
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FIELD OF THE INVENTION
[0001] The present invention relates to the preparation of lithium hydroxide which is substantially dust free. More particularly, there is provided coated lithium hydroxide monohydrate crystals which are dust free and suitable for producing industrial grease.
BACKGROUND OF THE INVENTION
[0002] Lithium hydroxide monohydrate produces a small amount of dust which is always present when being handled or poured. This dust is extremely choking and irritating to humans even in trace amounts. Large amounts of lithium hydroxide monohydrate are used in industrial grease manufacturing and the choking dust has been a major problem in its use.
[0003] Lithium hydroxide has also been used in closed-cycle oxygen systems such as the atmosphere which is found in closed places as submarines or in re-breathing appliances which are used in anesthesia or emergency oxygen equipment because it will react with carbon dioxide. In a rebreather system is it necessary that the carbon dioxide be 4% or less than the entire atmosphere inasmuch as a greater amount of carbon dioxide will result in a deleterious effect upon the person in the breathing apparatus. The use of lithium hydroxide has been complicated by the fact that anhydrous lithium hydroxide pellets tend to crumble and create noxious dust.
[0004] U.S. Pat. No. 3,607,040 to Hevert et al has solved the problem of preventing the crumbling and dust formation of pellets by treating anhydrous lithium hydroxide with polyvinyl alcohol and then calcining the resultant mixture to remove any water. The problem with the use of polyvinyl alcohol is that a unitary treatment of lithium hydroxide is not possible for both powder and pellets since polyvinyl alcohol is not used in the production of grease.
[0005] U.S. Pat. No. 2,629,652 to Schecter et al discloses forming porous, anhydrous, non-dusting granules of lithium hydroxide for use in closed space ventilation systems by pressing lithium hydroxide having a water content of between 40 and 45% under pressure of 18,000 to about 25,000 psi to form a cake, breaking the cake into granules and then heating the granules to a moderate elevated temperature. The dust problem is solved because the fine particles which cause dust are physically separated from the granules.
[0006] U.S. Pat. No. 2,846,308 to Baxendale disclosed the treatment of alkali hydroxides, which includes lithium hydroxide, with an ester or an organic acid or an ester or an inorganic acid in liquid form to reduce the hydroscopic properties of the alkali hydroxide for use as photographic developers. About 1 to 15% by weight of a lower alkyl acid ester which is liquid and can generate a volatile alcohol is utilized.
[0007] U.S. Pat. No. 5,948,736 to Smith et al discloses the coating of lithium monohydrate crystals with fatty acids, esters or triglycerides thereof which require heating to properly coat.
[0008] It is an object of the invention to provide a method for reducing the dust when handling lithium hydroxide monohydrate powders and granules without heating.
[0009] It is another object of the invention to provide a pourable dust-free lithium hydroxide monohydrate powder.
[0010] It is yet another object of the invention to provide a pourable lithium hydroxide monohydrate powder which can be directly utilized to produce an industrial grease.
SUMMARY OF THE INVENTION
[0011] In accordance with the present invention the above and other objects are accomplished by coating the surface of lithium hydroxide particles and granules with about 0.2 to 1.5% by weight of paraffinic oil, particularly a saturated hydrocarbon oil or a saturate napthenic oil.
[0012] Fumed silica in an amount of about 0.01 to 1% weight percent may be added to the composition to enhance flowability.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0013] In one aspect an embodiment of the present invention lithium monohydrate can be made substantially dust free and pourable by the method of adding about 0.2 to 1.5% by weight of a coating of paraffinic oil.
[0014] Prefereably, the coating is formed by admixing the lithium hydroxide at ambient temperatures. The paraffinic oils which may be used are those which have a starting boiling point of at least 150° C. and a primary boiling point of over about 200° C. The paraffin oils are the saturated hydrocarbon oils and saturated napthenic oils including mineral oils of different viscosities.
[0015] The paraffinic oils have the advantage over prior coating compositions because they tend to spread evenly at ambient temperatures and do not require heat and subsequent cooling.
[0016] These oils are similar and with the base stock oils which are used to make the grease. The coating composition can be applied to the particles in any suitable manner such as by dusting, spraying, grinding or dipping. The coating composition can be mixed with the lithium hydroxide in a tumbler, mixer or other similar apparatus. A solid coating agent may also be dissolved in a suitable solvent sprayed over the lithium hydroxide particles and the solvent then removed in a conventional manner.
[0017] In accordance with another embodiment of the invention 0.01 to 1% by weight of composition of fumed silica can be added to improve pourability.
[0018] The following examples are illustrative of the practice of the method of the present invention. It will be understood, however, that it is not to be construed as in any way limitative of the full scope of the invention since various changes can be made, without departing from the spirit of the teaching contained herein, in the light of the guiding principles which have been set forth above. All percentages herein stated are based on weight except where noted.
EXAMPLE 1
[0019] 100 lbs. of lithium hydroxide monohydrate were tumbled in a closed mixer and 0.7 lbs of a white mineral oil (paraffin oil boiling point greater than 230° C.) was sprayed on it as it was tumbled. The material was bagged and sealed. When the bag was reopened and the contents poured out, no choking sensation was noted which would definitely have occurred if the mineral oil coating had not been applied.
Comparative Example 1
[0020] 100 lbs. of lithium hydroxide monohydrate were tumbled in a closed mixer and 1.8 lbs. of a white mineral oil (paraffin oil boiling point greater than 230° C.) was sprayed on it as it was tumbled. The material was bagged and sealed. When the bag was reopened and the contents poured out, no choking sensation was noted which would definitely have occurred if the mineral oil coating had not been applied. Although the material poured out of the bag satisfactorily, it was caking and somewhat lumpy due to the extra oil.
EXAMPLE II
[0021] 100 lbs of lithium hydroxide monohydrate were tumbled in a closed mixer and 0.5 lbs of a light mineral oil (paraffin oil boiling point greater than 230° C.) was sprayed on it as it was tumbled. The material was bagged and sealed. When the bag was reopened and the contents poured out, no choking sensation was noted which would definitely have occurred if the mineral oil coating had not been applied. If desired, about 0.1 to 1% by weight of fumed silica may be added.
EXAMPLE III
[0022] Preparation of Lithium Grease
[0023] 5 grams of coated dust free lithium hydroxide from Example 1 was added to about 50 grams of water to make up a solution of lithium hydroxide. This solution was added slowly to a stirred mixture of 33.6 grams Cenwax A and Jesco 750 Pale Oil heated at 95° F. over 2 hr. The water was allowed to escape without undue foaming. The solution was heated an additional hour to ensure full reaction. The grease mire was heated to 150° and then cooled with stirring. The lubricant (grease) had a ½ scale 60 stroke penetration of 270 under the reaction displayed very little foaming and was easy to control.
[0024] In lieu of Cenwax A and Jesco 750 Pale Oil, other waxes and oils which are standard in the industry can be used.
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The present invention provides a method for forming dust free lithium hydroxide monohydrate. The method contains the step of coating the lithium hydroxide with 0.2 to 1.5% by weight of paraffinic oils.
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CROSS-REFERENCE TO RELATED APPLICATION
The invention described and claimed hereinbelow is also described in German Patent Application DE 10 2007 062 333.1 filed on Dec. 21, 2007. This German Patent Application, whose subject matter is incorporated here by reference, provides the basis for a claim of priority of invention under 35 U.S.C. 119(a)-(d).
BACKGROUND OF THE INVENTION
The present invention relates to a method for transmitting multiturn modulo control axis data, a related participant in a communication system, a related computer program, and a related computer program product.
BACKGROUND INFORMATION
Automation tasks that are performed by shaftless machines are usually carried out with the aid of a “control axis”. A control axis typically provides angular position information or speed information as a reference which represents the cycle time of the machine. The control axis position represents the position of a vertical shaft.
The control axis information is typically calculated and distributed in a controller (a “virtual control axis”), but it may also originate from a mechanically installed position sensor, a “control axis sensor” (a “real control axis”). The control axis position is transmitted to drives and to further controllers.
Several known solutions for designing this communication exist in the field of field busses, such as Profibus, Profinet, CIPmotion, CAN Bus, SERCOS interface, etc. The control axis information is transmitted, e.g. as a numerical value via the communication system to the recipients which may be actuators (drives) or controllers which may, in turn, forward the information to actuators connected thereto. The transmission of the control axis position from the controller to the particular recipients must take place in a synchronized manner, so that the particular processing steps take place in an accurately timed manner.
“Modulo axes” are endlessly moving axes, i.e. their position value is unlimited. In contrast, absolute axes have a finite position range within which they move. The depiction of the position of modulo axes is provided with an overrun, the “module value”.
In the case of a modulo control axis, the control axis position is reset after one pass or cycle, and starts anew, wherein, e.g. position 360° corresponds to position 0°. The recipients of the control axis position must know the “module value” of the control axis, e.g. 360° in the example described above, in order to be able to process the jump in position, the “modulo overrun”.
If one processing run or cycle, e.g. one rotation of a print roller, is always carried out per one rotation of the control axis, this is referred to as a single-turn control axis. A multiturn solution is preferred whenever one processing run of a processing device includes several control axis revolutions. This may be the case, e.g. for a machine module which performs manufacturing and packaging, in the case of which one single product is manufactured per one revolution of the control axis, but, at another station, several individual products are packaged to form a single unit. The processing cycle of the packaging machine therefore includes several revolutions of the control axis.
It is known, in order to operate machine configurations of this type, to transmit the control axis position as a control axis revolution counter value. A transmission method of this type is known, e.g. by the name CIPmotion. In this transmission method, information related to the control axis position is transmitted in a synchronous manner together with the information related to the modulo value of the (single) control axis. A revolution counter of the control axis is also transmitted. This revolution counter does not include a settable module value, however; instead, its modulo overrun takes place at the numerical limit (e.g. 32 bit). It is therefore a relatively complex undertaking to implement a multiturn application for processing runs which have a different number of control axis revolutions when CIPmotion is used.
Another system for transmitting multiturn control axis information is known by the name SYNAX, in which a transmission method based on the “SERCOS interface” standard is used for transmission. In a SYNAX system, different module values are supported for the devices that are attached, it being possible for the control axis position that is defined and that will be transmitted to include several revolutions (e.g. 0° to 720°). It is provided that different control axes are generated for different recipients. In the example described above, a parametrized modulo value of 360° and a control axis position of 0° to 360° would be transmitted to the machine module to be created, while, for the packaging machine module, e.g. a modulo value of N×360°, parametrized, and a control axis position of 0° to N×360° would be transmitted, in order to package N individual products in one container. It is known to transmit N as a “control axis cycle”.
In the transmission method used in SYNAX, a transmission channel is provided for cyclic, real time-capable data transmission, and a transmission channel is provided for acyclical data transmission. In cyclical data transmission, only the control axis position is transmitted in real time. If the multiturn modulo value must be changed, the pertinent information is separated from the control axis position, either in the acyclic channel or via a multiplex transmission in the cyclic channel. The point in time when the transmission takes place is therefore not definitely known, i.e. the information about the control axis position and the associated (multiturn) modulo value are not present in the recipients in a reliably consistent manner. It is therefore common to halt production, transmit the new multiturn modulo value to the particular recipients, correct the control axis position, if necessary, and to restart production. Time is lost when this takes place. In addition, waste is typically produced when the processing units are braked and then reaccelerated. In addition, it is often necessary to deactivate the recipients (e.g. by removing a drive release). Depending on the process being carried out, this may result in disruptions, e.g. a taut web becoming slack, which, in turn, causes disruptions when the machine is restarted.
SUMMARY OF THE INVENTION
The object of the present invention, therefore, is to provide an improved method for transmitting multiturn modulo control axis information.
This object is attained via a method for transmitting multiturn modulo control axis data, a related participant in a communication system, a related computer program, and a related computer program product having the features of the invention. Advantageous developments are the subject matter of the description that follows.
The applicable multiturn modulo value is transmitted in one data telegram simultaneously with the control axis position in the multiturn format. This automatically results in data consistency of the multiturn control axis position and the associated multiturn modulo value. There is no need to ensure the consistency using complex mechanisms. It is understood that the multiturn modulo value may also be designed as a modulo revolution counter for multiplication with a single control axis revolution.
A participant—according to the present invention—of a communication system is set up to carry out a method according to the present invention, and it includes the necessary means therefor.
It is preferable for a participant to monitor the control axis modulo value that is transmitted in the data telegram, and, if a change in the control axis module value is detected, the participant adjusts its axle position based on the control axis modulo value and the previous control axis module value. It is therefore possible to reparametrize participants during on-going production, since they automatically detect a change in the modulo value and correct their axle or drive position accordingly in order to continue operation using the control axis position value that is based on the new modulo value.
The control axis position value is advantageously transmitted together with the associated control axis modulo value in one data telegram in the at least one real-time data transmission channel. The multiturn modulo value (or a corresponding numerical value, e.g. a module revolution counter) is transmitted simultaneously with the transmission of the control axis position in the multiturn format. Data consistency of the multiturn control axis position and the corresponding multiturn modulo value of the control axis results automatically. There is no need to ensure the consistency using complex mechanisms.
Expediently, at least one non-real-time data transmission channel is provided between the participants in the communication system, the at least one control axis position value being transmitted together with the associated control axis modulo value in the at least one non-real-time data transmission channel. A change in the multiturn modulo value for a certain participant may be advantageously carried out via a non-real-time channel using a defined sequence. A control axis position which may have been changed is transmitted along with the new multiturn modulo value. Via the defined sequence, it is ensured that the multiturn modulo value and the internal control axis position actual value become effective simultaneously as a consistent data pair, and that they may be processed correctly by the participant, since the change in the multiturn modulo value and the adjustment of the control axis position which may need to be carried out take place at the same time.
As an alternative, the conversion may take place using a command that reports a change, with the result that monitorings or calculations that may be taking place in the participant are preferably shut off. After the command, the multiturn modulo value and the control axis position are transmitted. When the command has come to an end, the participant jumps to the new values and reactivates the monitoring and/or calculation.
According to a preferred embodiment, the communication system uses data transmission based on the “SERCOS interface” standard, and, in particular, based on “SERCOS III”. A SYNAX network may be used in particular as the communication system. For example, up to two control axes per motion control controller may be calculated in SYNAX 200. Individual machine modules or complete machine units may be integrated easily and in a transparent manner in linked and synchronized production processes. The cascadable multiturn control axes are transmitted to the servo drives as setpoint position values having digital accuracy. Using the SERCOS interface as the drive bus (IEC 61491/EN 61491) ensures that transmission to the individual drives of the machine units takes place without disruption. The Sercos interface defines cyclical, synchronous, and equidistant data communication between a communication master (typically: MC control) and a plurality of communication slaves (typically: drives or decentralized I/O stations). The data that are sent from the master to the slaves in a cyclic manner are contained in the master data telegram (MDT) and in one (Sercos III) or several (Sercos II) drive data telegrams (AT), wherein, according to the present invention, the at least one control axis position value is transmitted together with the associated value in one data telegram.
The present invention also relates to a computer program having program code means which are suited to carrying out a method according to the present invention when the computer program is run on a computer or a related arithmetic unit, in particular in a participant—according to the present invention—of a communication system.
The computer program product that is provided according to the present invention includes program code means that are stored on a computer-readable data storage device and that are suited to carrying out a method according to the present invention when the computer program is run on a computer or a related arithmetic unit, in particular in a participant—according to the present invention—of a communication system. Suitable data storage devices are, in particular, diskettes, hard drives, Flash drives, EEPROMs, CD-ROMs, DVDs, etc. It is also possible for a program to be downloaded from computer networks (Internet, intranet, etc.).
Further advantages and embodiments of the present invention result from the description and the attached drawing.
It is understood that the features mentioned above and to be described below may be used not only in the combination described, but also in other combinations or alone, without leaving the scope of the present invention.
The present invention is depicted schematically with reference to an exemplary embodiment in the drawing, and it is described in detail below with reference to the drawing.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a schematic depiction of a transmission of multiturn modulo control axis data according to the prior art;
FIG. 2 shows a first embodiment of a transmission—according to the present invention—of muliturn modulo control axis data; and
FIG. 3 shows a second embodiment of a transmission—according to the present invention—of multiturn modulo control axis data.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIGS. 1 through 3 illustrate one possibility from the prior art and two possibilities according to the present invention of changing a control axis modulo value from its initial parametrized value of 720° to 360°, and of correcting the control axis position accordingly. The change should take place after control axis position 604°.
FIG. 1 shows a schematic illustration of a related control axis data transmission in the prior art. The transmission shown may take place using the “SERCOS interface” standard on a SYNAX network. A time t is plotted on an x-axis 11 in a diagram 10 . A first data transmission channel CH 1 and a second data transmission channel CH 2 are shown in the diagram. Data transmission channel CH 1 is designed as a real-time data transmission channel, and data transmission channel CH 2 is designed as a non-real time data transmission channel. Data telegrams 12 which include control axis position values are transmitted in a cyclic manner in real-time data transmission channel CH 1 . The cyclic data transmission is depicted via the equidistant placement along x-axis 11 . Initially, control axis position values of 600° to 604° are transmitted in a cyclic manner using data telegrams 11 .
To reparametrize the related participant in the communication system, as desired, production is halted after control axis position value 604°, i.e. the controller release of the axes is withdrawn from the recipients. Control axis position values that are received after that are not processed by the recipients.
After production has been halted, a data telegram 12 which includes a new control axis modulo value is transmitted in non-real-time data transmission channel CH 2 . The new control axis modulo value is 360°. Since the transmission in non-real-time data transmission channel CH 2 does not take place in a secured or real-time manner, a waiting period of sufficient length must occur in order to ensure that data telegram 13 has been received by all appropriate participants in the communication system. After data telegram 13 with new control axis modulo value 360° has been received by the related participants, they parametrize control axis modulo value 360°. The control axis position is corrected accordingly, and the transmission then takes place with corrected control axis position value 245° via real-time data transmission channel CH 1 after the necessary waiting period has expired. Before transmission takes place, the recipients are reactivated by setting the controller release of the axes.
FIG. 2 shows a diagram 20 of a first embodiment of a transmission—according to the present invention—of multiturn modulo control axis data. In the transmission depicted in FIG. 2 , the control axis position values are transmitted along with the associated control axis modulo value in a data telegram 22 in real-time data transmission channel CH 1 . In particular, control axis position values 600° through 604° are transmitted together with associated control axis modulo value 720°, wherein control axis position values 245° through 248° are transmitted after conversion with associated control axis modulo value 360°. The participants in the communication system therefore receive a control axis position value simultaneously with the associated control axis modulo value in one data telegram via the real-time data transmission channel. The correct control axis position value with the correct associated control axis modulo value is therefore reliably available at any time, thereby making it possible to reparametrize the participants in the communication system during production without the need to halt production.
Every associated participant detects the change in the control axis modulo value from 720° to 360° and adapts its axle position automatically, e.g. the angular position of a print axle, to the new modulo value. This means that axle positions=360° remain unchanged, and axle positions between 360° and 720° are corrected by 360°. The control axis position is corrected in the same manner, so that transmission is continued with corrected control axis position value 245°.
FIG. 3 shows a schematic depiction of a second embodiment of the transmission—according to the present invention—of multiturn modulo control axis data, in a diagram 30 . In the transmission of multiturn modulo control axis data depicted, the control axis position values are transmitted during production in data telegrams 12 in real-time data transmission channel CH 1 . According to the solution according to the present invention, which is depicted, corrected control axis position value 245° is transmitted together with associated control axis modulo value 360° in a data telegram 33 in non-real-time data transmission channel CH 2 in order to reparametrize the appropriate participants in the communication system. The transmission of data telegram 33 takes place in real time before the desired instant of conversion, thereby ensuring that data telegram 33 will be received by the particular participants in the communication system before the instant when conversion takes place.
The related participants in the communication system obtain the information from data telegram 33 that was received stating that new control axis modulo value 360° must be parametrized when control axis position value 245° is received. In the next step, the data telegram with control axis position value 245° is therefore transmitted to the related participants in the communication system in real-time data transmission channel CH 1 after the data telegram with control axis position value 604°, and the related participants carry out the desired reparametrization.
Via the embodiments of the present invention described, transmission of multiturn modulo control axis data takes place between the participants in a communication system, thereby making it possible to reparametrize the control axis under operating conditions and without halting production.
It is understood that only one particularly preferred embodiment of the present invention is depicted in the figures shown. Any other type of embodiment is also feasible, without leaving the scope of the present invention.
LIST OF REFERENCE NUMERALS
10 Schematic depiction of the data transmission in the prior art
11 x-axis t
12 , 13 Data telegram
20 , 30 Schematic depiction of data transmission according to the present invention
22 , 33 Data telegram
CH 1 Real-time data transmission channel
CH 2 Non-real-time data transmission channel
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The present invention relates to a method for transmitting multiturn modulo control axis data which includes at least one control axis position value (600°-604°; 245°-248°) and an associated control axis modulo value (720°; 360°) in one communication system which includes at least two participants, at least one real-time data transmission channel (CH 1 ) being provided for the cyclic transmission of data between the participants; the at least one control axis position value (600°-604°; 245°-248°) is transmitted together with the associated control axis modulo value (720°; 360°) in one data telegram ( 22; 33 ).
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This invention was made with Government support under Grant No. NSF-90-10908, awarded by the National Institute Science Foundation. The Government has certain rights in this invention.
This is a division of application Ser. No. 07/899,431, filed Jun. 16, 1992, now abandoned.
BACKGROUND OF THE INVENTION
The drive towards higher density data storage on magnetic media has imposed a significant demand on the size and sensitivity of magnetic heads. This demand has been met, in part, by thin film inductive and magnetoresistive heads which can be fabricated in very small sizes by deposition and lithographic techniques similar to those used in the semiconductor industry. Thin film inductive heads are subject to the same problems as their core-and-winding predecessors of extreme sensitivity to gap irregularities and stray fields which result in output signal losses. Thin film magnetoresistive heads, on the other hand, rely on changes in the material's resistance in response to flux from the recording media and do not require precise gap modeling. For these reasons, inter alia, magnetoresistive elements are increasingly preferred over inductive heads for reading data stored at high densities on magnetic media.
A figure of merit for magnetoresistive (MR) elements is ΔR/R, which is the percent change in resistance of the element as the magnetization changes from parallel to perpendicular to the direction of the current. Current magnetoresistance elements are made from permalloy (81% Ni/19% Fe), which, at room temperature has a ΔR/R of about 3%. For improved response, a higher value of ΔR/R is desirable.
Recently, it has been found that magnetic layered structures with anti-ferromagnetic couplings exhibit giant magnetoresistance (GMR) in which, in the presence of a magnetic field, ΔR/R can be as high as 50%. The GMR phenomenon is derived from the reorientation of the single domain magnetic layers. For optimum properties, the thickness of the multilayers must be less than 3 nm, and ΔR/R increases with the number of pairs of thin film layers. Thus, these multilayers provide significant challenges for production because of the precision with which the thicknesses and other features, such as interface roughness, must be maintained for the many iterations of the pairs of magnetic and non-magnetic films. Several studies have shown that GMR oscillates in magnitude as a function of the thickness of the non-magnetic layers, increasing the concern about thickness control. These layered structures are also subject to output noise from magnetic domains, and, since their outputs are nonlinear, the devices must be biased to obtain a linear output. Most reported work has been on Fe/Cr superlattices, however, Co/Cr, Co/Cu and Co/Ru superlattices have also been found to exhibit GMR.
The extreme sensitivity to layer thickness places significant limitations on practical and economical application of GMR to data. recording and other potential uses. It would be desirable to provide a method for forming GMR materials which is relatively insensitive to thickness and does not require multiple layers, and where the material is not subject to output noise caused by domains or to the nonlinearities of the layered structures. It is to such a method and material that the present invention is directed.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide heterogeneous alloys which exhibit giant magnetoresistance.
It is a further object of the present invention to provide a method for forming such alloys.
In the preferred embodiment, a single layer film is sputtered onto a substrate at room temperature from separate targets, one target being a ferromagnetic material, the other being a non-ferromagnetic or weakly-magnetic material. The film is annealed for a predetermined time in order to induce phase separation between the magnetic clusters and the non-magnetic matrix, and to form stable clusters of a size such that each magnetic particle, or cluster, comprises a single domain and has no dimension greater than the mean free path within the particle.
Other deposition and film-forming techniques may be used including sputtering from a single composite target, evaporation, metal pastes, mechanically combining the magnetic and non-magnetic materials or implanting the magnetic materials (ions) into the non-magnetic matrix.
While a distinct interface needs to be maintained between the magnetic and non-magnetic components of the film, the film can be formed from materials which are either immiscible or miscible under equilibrium conditions. In the latter case, deposition conditions can be controlled to assure that the desired interfaces are formed between the magnetic and non-magnetic components of the film.
BRIEF DESCRIPTION OF THE DRAWINGS
Understanding of the present invention will be facilitated by consideration of the following detailed description of a preferred embodiment of the present invention, taken in conjunction with the accompanying drawings, in which like reference numerals refer to like parts and in which:
FIG. 1 is a plot of resistance ratio with applied magnetic fields for the inventive film; and
FIG. 2 is a plot of resistance ratio with temperature.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
A single layer film comprising a magnetic material and a non-magnetic, or weakly-magnetic, material (hereinafter collectively identified as "non-magnetic") is deposited on a substrate by d.c. magnetron co-sputtering from separate targets. The sputter deposition is performed at low pressures, in the 10 -7 torr range. The film is formed with the non-magnetic film providing a matrix within which magnetic particles or clusters are precipitated. After deposition, the sample may be annealed to control the size of the particles. The ideal particles must be large enough to avoid superparamagnetism (thermally-activated magnetization reversal at room temperature), but small enough that their dimensions do not exceed the mean free path within the particles, and so that they remain a single magnetic domain. In an actual sample there will be some variation in particle size within a given film, with some particles smaller than, and others larger than, the "ideal". The average particle size in such a sample should possess the desired relationships to domain and mean free path.
A number of other deposition or film-forming techniques may also be used, including evaporation, pastes or mechanically-formed metals, e.g., heated and compressed by high pressure rollers. Magnetic materials may also be implanted into a non-magnetic matrix. Any of these or similar techniques can then be followed by heat processing to assure formation of the desired magnetic precipitates.
By precipitating small magnetic particles in a non-magnetic matrix, an increased surface area of magnetic material is made available for the electron scattering that is responsible for magnetoresistance (MR). This dependence upon available surface area indicates that the magnetic and non-magnetic materials must remain separate with distinguishable interfaces. This requirement follows the explanations of MR in multilayered structures that the electrons are scattered at the interfaces, where spin dependent scattering predominates. The need for distinct interfaces between the magnetic and non-magnetic materials does not, however, limit the choice of materials to those that are mutually insoluble. While the materials can be immiscible under equilibrium conditions, they can also be miscible, with the materials being kept separate by controlling deposition conditions.
In initial evaluations, "cobalt-copper (Co--Cu) films were prepared by d.c. magnetron sputtering from separate copper and cobalt targets onto a silicon wafer having 100 orientation. A 3.5 minute pre-sputter step was performed prior to deposition. Background pressure was 6×10 -7 torr. The deposition step of approximately 100 minutes at room temperature with the substrates rotated above the targets at one revolution per second provided a 3,000 Åfilm.
Sputter rates were adjusted to yield films of 12, 19 and 28 atom percent cobalt. These samples exhibited GMR at 10° K. with MR negligible at room temperature, indicating a superparamagnetic behavior due to a highly disordered state and fine grain size. The samples were annealed to increase grain size, to achieve phase separation between cobalt and copper, and to form stable cobalt particles. After annealing, the 19 Co and the 28 Co samples show the largest MR changes. Their MR curves had the shape shown in line C of FIG. 1. The maximum MR occurred at the coercive force, H c , which was approximately 500 Oe at 10° K. for all annealed 19 Co and 28 Co samples. Remanence/saturation (M r /M s ) ratios were greater than 0.3 at 10° K. for all annealed samples. Both H c and M r /M s decreased with increased temperature at measurement and annealing time. The magnetic behavior of the annealed samples was associated with the precipitation of cobalt-rich particles in a copper-rich matrix.
FIG. 2 shows ΔR/R versus temperature for as-deposited and annealed 19 Co and 28 Co specimens. Saturation fields for the MR coincided with the saturation fields for magnetization. The MR ratio increased with decreasing annealing temperature and time (except for the as-deposited 28 Co).
As annealing times and temperatures increase, the average Co-rich particle sizes also increase, with corresponding decrease in MR. Larger Co particles have several adverse effects on MR: 1) the surface/volume ratio decreases, reducing the spin-dependent interfacial scattering relative to bulk-scattering processes; 2) the particles become larger than the mean-free path within the particles; and 3) the particles are no longer. single domains such that the interaction of the conduction electron spins with the varying magnetization distribution in the particles produces a state in which the conduction electron spin channels are mixed. Also seen in FIG. 2 is the rapid relaxation rate of MR with increasing temperature, which is attributable to superparamagnetism.
The GMR in the heterogeneous copper-cobalt alloys may be analyzed in the same manner as the copper-cobalt multilayers. Assuming a random distribution of cobalt particles with average radius r Co in a copper matrix, and adopting a spin-dependent scattering model at the surface of cobalt particles and within the cobalt particles, the conductivity can be written as: ##EQU1## where n is the number of electrons; e is the electron charge, m is the electron mass, and Δ.sup.σ is the average scattering matrix. The phenomenological input for Δ.sup.σ is:
Δ.sup.σ =Δ.sub.Cu +Δ.sub.CO.sup.σ +Δ.sub.S.sup.σ (2)
where ##EQU2## and c is the Co concentration; λ Cu and λ Co are the mean free paths of Cu and Co, respectively; ξ is the scattering strength for surfaces; P Co and P S are the spin dependent ratios for scattering within the Co particles and at their surfaces, respectively. Thus Equation (1) is the sum of scattering in Cu, Co, and at the interfaces between them. Since ##EQU3## Equation (2) is substituted into Equation (1), and Equation (3) becomes: ##EQU4## with ± referring to spin up and down, and ##EQU5##
In Co/Cu multilayers, the principal spin dependent scattering is from the interfacial term (P S =0.5 P Co =0.2, ξ=0.3) [16]. Thus, if P Co= 0, Equation (4) reduces to ##EQU6## Equation (5) correctly predicts the inverse dependence of MR on the particle size, in accordance with the surface/volume ratio consideration noted above.
A consideration in the development of magnetoresistive films for practical applications is that the applied saturation field be as low as possible while still achieving the maximum ΔR/R. It is well known that soft ferromagnetic materials provide greater MR with lower applied fields. Materials which may be used as softer magnetic particles include those which are well known in the recording industry for their use in inductive heads, including iron, cobalt-iron, and permalloy.
Another factor which will influence the efficiency of the saturation field in inducing magnetoresistance is the shape of the magnetic particles. A demagnetizing field will be generated by a spherical particle such that an additional field must be overcome by the applied saturation field. By controlling the shape of the particles during deposition, disc-like particles can be formed which possess lower demagnetization fields while still having large surface areas. Preferably, the plane of the disc-like particles will be oriented parallel to the field. Such an effect can be achieved by control of deposition parameters or by post-deposition anneal under a magnetic field.
For practical applications, a robust material such as silver may be desirable for use as the non-magnetic matrix. Cobalt and silver are immiscible under equilibrium conditions. After annealing one hour at 200° C., the ΔR/R at room temperature for a sample of 33 atom-% Co in silver was measured at 21.5%. An advantage of using silver is its relatively high environmental stability, i.e., minimal corrosion or oxidation, and such an alloy system is much easier to prepare and control than multilayers. Silver is further suited for use in such an application because none of the magnetic elements are soluble in silver. Other possible matrix materials include ruthenium, gold and chromium, among others. It is also desirable to supplement or substitute the cobalt, which is a hard magnetic material, with softer magnetic materials.
The above-described method eliminates the need for use of multilayers for achieving giant magnetoresistance. The single layer film of the present invention possesses several advantages over the prior GMR materials in that it is easier to control fabrication, its output may be linear, and there are no domains so that there are no domain walls to produce noise. It is anticipated that the inventive film will significantly enhance the fabrication of MR heads, making such films more practical and economical than those of the current technology.
It will be evident that there are additional embodiments which are not illustrated above but which are clearly within the scope and spirit of the present invention. The above description and drawings are therefore intended to be exemplary only and the scope of the invention is to be limited solely by the appended claims.
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A single layer film is deposited onto a substrate at room temperature from two sources, one source being a magnetic material, the other being a non-magnetic or weakly-magnetic material. The film is annealed for predetermined time in order to induce phase separation between the magnetic clusters and the non-magnetic matrix, and to form stable clusters of a size such that each magnetic particle, or cluster, comprises a single domain and has no dimensions greater than the mean free path within the particle.
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BACKGROUND OF THE INVENTION
[0001] In the downhole hydrocarbon recovery industry elastomeric seals are used to seal annular areas between concentric tubulars. To prevent axial extrusion of the elastomeric seals at high temperatures and high pressures, backups are employed. Backups are radially expanded to fill the annular area during deployment and are radially retracted during tripping thereof. Although a typical backup can adequately prevent a seal from extruding thereby, each backup can only backup one end of one seal, thereby requiring two backups per seal. With each backup having a separate actuation, two actuations are needed to back up the two ends of a single seal. The industry would be receptive of systems that permit a reduction in the number of actuations required to backup multiple seals.
BRIEF DESCRIPTION OF THE INVENTION
[0002] Disclosed herein is a downhole backup system. The system includes, a tubular positionable within a downhole structure such that an annular space exists between the tubular and the downhole structure, and a plurality of wedges that are radially movably positioned within the annular space, each of two opposing ends of the plurality of wedges are configured to completely cover the annular space at all possible radial positions of the plurality of wedges.
[0003] Further disclosed herein is a method of backing up seals at a downhole tool. The method includes, moving a plurality of wedges radially, and covering perimetrical gaps between adjacent wedges on both longitudinal ends with wings disposed at the plurality of wedges.
[0004] Further disclosed herein is a method of occluding a downhole annular space. The method includes, radially moving a plurality of wedges positioned in the downhole annular space, and occluding the downhole annular space at both opposing ends of the plurality of wedges.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] The following descriptions should not be considered limiting in any way. With reference to the accompanying drawings, like elements are numbered alike:
[0006] FIG. 1 depicts a perspective view of a downhole dual backup 10 disclosed herein;
[0007] FIG. 2 depicts a cross sectional view of the downhole dual backup of FIG. 1 ; and
[0008] FIG. 3 depicts a perspective view of a wedge of the downhole dual backup of FIG. 1 .
DETAILED DESCRIPTION OF THE INVENTION
[0009] A detailed description of one or more embodiments of the disclosed apparatus and method are presented herein by way of exemplification and not limitation with reference to the Figures.
[0010] Referring to FIGS. 1-3 , the downhole dual backup 10 includes, a plurality of wedges 14 , positioned perimetrically adjacent to one another, between a pair of ramps 18 . One or more biasing member(s) 22 , disclosed herein as tension springs (three being illustrated), surround the wedges 14 and bias the wedges 14 radially inwardly. Each wedge 14 has one wing 26 , 28 on each end that extends perimetrically beyond edges 30 , 31 of the wedges 14 , respectively. The wing 26 on a first end 32 extends in a direction opposite to the direction of the wing 28 on a second end 36 , although designs having the wings 26 , 28 extending in the same direction are possible. Each wedge 14 also has a surface 40 on the first end 32 and a surface 44 on the second end 36 . The wedges 14 are configured such that the wing 26 on the first end 32 of one wedge 14 slidably engages with the surface 40 on the first end 32 of an adjacent wedge 14 . Similarly, the wing 28 on the second end 36 of one wedge 14 slidably engages with the surface 44 on the second end 36 of an adjacent wedge 14 .
[0011] The foregoing allows the wedges 14 to provide two continuous perimetrical supports 50 , 54 regardless of a specific radial position the wedges 14 . As such, elastomeric members 58 , shown herein as seals (not shown in FIG. 2 ), are prevented from extruding through annular openings between an outer dimension 62 of the ramps 18 and an inner surface of a downhole structure, such as a liner, casing or open hole (not shown), for example, within which the backup 10 is positioned. These two continuous perimetrical supports 50 , 54 are best seen in FIG. 2 at radial dimensions greater than the outer dimension 62 . Since the dual backup 10 has the two continuous perimetrical supports 50 , 54 , two ends 64 , 65 , of two different seals 58 , can be backed up with just one of the dual backups 10 . A surface 66 , on the wing 26 , creates a portion of the first perimetrical support 50 and the surface 40 forms another portion of the first perimetrical support 50 . As such, the perimetrical support 50 is stepped by a thickness 70 of the wing 26 as viewed while proceeding around a perimeter thereof. The wing 26 provides a portion of the perimetrical support 50 that would be unsupported by perimetrical clearance between the edges 30 and 31 if the wing 26 were not present. Similarly, a surface 44 on the wing 28 creates a portion of the second perimetrical support 54 and the surface 44 forms another portion of the second perimetrical support 54 . The wings 26 , 28 extend sufficiently to overlap with the surface 40 , 44 at all radial positions of the wings 26 , 28 , the radial movement of which will be described below.
[0012] Axial movement of the ramps 18 causes radial movement of the wedges 14 . As the ramps 18 move toward one another by a linear actuator (not shown), for example, angled surfaces 78 and 82 , of the ramps 18 , engage with angled surfaces 86 , 88 of the wedges 14 , respectively. This engagement causes the wedges 14 to simultaneously move radially outwardly causing the springs 22 to lengthen in the process. The lengthening of the springs 22 increases the radial inward bias the springs 22 provide to the wedges 14 . Alternately, axial movement of the ramps 18 away from one another allows the wedges 14 to move radially inwardly under the biasing load of the springs 22 .
[0013] Alignment features 92 in the ramps 18 , shown herein as slots (although protrusions or other details could be employed), engage with complementary features 96 in the wedges 14 , shown herein as tabs, to maintain substantially equal angular spacing between the wedges 14 as the wedges 14 move radially. This assures that the perimetrical distance between adjacent wedges 14 remains uniform and the wings 26 , 28 cover the clearances between edges 30 and 31 at all radial positions of the wedges 14 .
[0014] By assuring that the wings 26 , 28 overlap with the surfaces 40 , 44 the full perimetrical supports 50 , 54 also form barriers that restrict the ingress of contamination to the backup 10 that could adversely affect the radial actuation of the wedges 14 . The elastomeric members 58 , by being on both axial ends of the dual backup 10 , further protect the backup 10 from contamination. This prevention of ingress of contamination coupled with the fact that there is no plastic deformation of the components during actuation of the dual backup 10 the dual backup 10 is capable of an indefinite number of cycles without degradation. Additionally, the dual back up is fully reusable.
[0015] While the invention has been described with reference to an exemplary embodiment or embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the claims. Also, in the drawings and the description, there have been disclosed exemplary embodiments of the invention and, although specific terms may have been employed, they are unless otherwise stated used in a generic and descriptive sense only and not for purposes of limitation, the scope of the invention therefore not being so limited. Moreover, the use of the terms first, second, etc. do not denote any order or importance, but rather the terms first, second, etc. are used to distinguish one element from another. Furthermore, the use of the terms a, an, etc. do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced item.
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A downhole backup system including, a tubular positionable within a downhole structure such that an annular space exists between the tubular and the downhole structure, and a plurality of wedges that are radially movably positioned within the annular space, each of two opposing ends of the plurality of wedges are configured to completely cover the annular space at all possible radial positions of the plurality of wedges.
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This is a continuation of application Ser. No. 08/381,058 filed on Jan. 31, 1995, now abandoned.
TECHNICAL FIELD
The invention relates generally to battery operated devices and, more particularly, to a system for reducing power consumption in such devices.
BACKGROUND OF THE INVENTION
Portable personal computers (PCs) were first introduced in the early 1980s and have since enjoyed great commercial success and consumer acceptance. As the portable PC market has grown, users have begun to demand lighter weight, lower volume PCs which can be used for longer periods of time between battery charges. Meeting these demands has proved challenging in view of the fact that most portable PCs now support peripheral devices previously available only on desktop PCs. The additional peripherals greatly increase overall power consumption, making it difficult to achieve an optimal level of functionality while maintaining an acceptable battery life. Furthermore, although for reasons other than maximizing battery life, it has become desirable to more efficiently manage power consumption of desktop PCs in order to minimize overall operating costs.
Because many of the components and peripheral devices of both desktop and portable PCs consume a great deal of power even when they are not active, power management systems have been developed which cause each component or peripheral device to operate in the lowest power consumption mode with respect to present demands on the system. For example, U.S. Pat. No. 4,980,836 to Carter et al. discloses a power management system for a portable PC system in which the hard disk unit, the floppy disk unit, the keyboard, the serial ports and the printer are monitored for I/O activity to determine whether the system is active and a timer is reset upon each access to any of the monitored devices. If the timer counts down to zero, the system is deemed inactive and is placed in a reduced power consumption mode, in which power is removed from the hard disk unit, the floppy disk unit, the LCD and miscellaneous circuitry and clocks. To bring the system out of the reduced power consumption mode, a user depresses a switch to initiate a wakeup operation.
Since Carter, improvements in the basic power management system have been introduced which include options such as blanking the liquid crystal display (LCD) or monitor screen after a preselected period of I/O inactivity or turning off the hard disk drive motor alter the hard disk drive has not been accessed for a preselected period of time. Furthermore, there may be provided more than one reduced power consumption mode. For example, there may be a "STANDBY" mode, in which certain components, such as the LCD and the hard disk drive motor, are caused to enter a reduced power consumption mode but the processing speed of the central processing unit (CPU) is not affected, and a "SLEEP" mode, in which nearly all of the functions of the PC are slowed or halted, including the CPU. From the standpoint of power consumption, the SLEEP mode is substantially equivalent to turning the PC off, except that no data is lost.
It may be desirable in many cases to monitor each of a selected group of PC components and cause that component to operate in a reduced power consumption mode if it has not been accessed during a preselected time period. Therefore, what is needed is a system for efficiently monitoring each of a plurality of PC I/O and peripheral devices individually and causing the device to operate in one or more reduced power consumption modes, depending on the type of device, if it is determined that the device has not been accessed during a preselected time period.
SUMMARY OF THE INVENTION
The foregoing problems are solved and a technical advance is achieved by method and apparatus for reducing power consumption in battery operated devices, namely, PCs. In a departure from the art, a power management system of the present invention individually monitors each of several I/O and peripheral devices of a PC for activity during a predefined activity period, as delimited by a periodic timer associated with the device. Upon the expiration of the associated timer, a determination is made whether the device was active during the expired activity period. If so, the device is caused to continue to operate in a full power mode; otherwise, it is caused to operate in its next lowest reduced power consumption mode.
In a preferred embodiment, a PC embodying features of the present invention comprises a power management microcontroller electrically connected via a system bus to at least one I/O, or peripheral, device to be power managed. Also connected to the microcontroller and the I/O device is an I/O activity interrupt generator for monitoring the system bus for I/O device activity and generating an I/O interrupt to the microcontroller upon detection of same. The power management microcontroller includes a power management unit (PMU), comprising appropriate hardware and/or software for implementing the power management functions of the present invention, registers or memory devices for storing an activity state variable (ASV) and a power state variable (PSV), respectively, for each I/O device to be power managed by the PMU, and a periodic timer associated with each I/O device to be power managed by the PMU, it being understood that the periodic timers may be implemented using hardware timers or a combination of hardware and software for generating periodic timer interrupts. The microcontroller controls the power consumption mode of each I/O device (i.e., ON/FULL POWER, STANDBY, SUSPEND, OFF) in accordance with the current state of its ASV and PSV as follows.
In general, an ASV has two states, which are IDLE and BUSY. A PSV has two or more states, depending on the type of I/O device with which it is associated and the number of reduced power consumption modes in which the device is operable. With respect to a particular I/O device, when the PC is first turned on, its ASV is set to IDLE, to indicate there has been no I/O activity, its PSV is set to 0, corresponding to an ON, or FULL POWER, mode of the I/O device, and the I/O device is caused to operate in FULL POWER mode. At this point, the periodic timer associated with the I/O device also starts to run. As previously indicated, the I/O activity interrupt generator monitors the system bus for I/O device activity and, upon detecting that an I/O device is active, the interrupt generator generates an I/O activity interrupt to the microcontroller. In addition, the interrupt generator sets an internal flag associated with the active I/O device such that subsequent activity of the I/O device does not result in the generation of an interrupt. Upon the receipt by the microcontroller of an I/O activity interrupt, the ASV is set to BUSY, to indicate the occurrence of I/O activity.
Upon the expiration of the associated timer, as indicated by the generation of a periodic timer interrupt to the microcontroller, the state of the ASV is checked. If the ASV is set to BUSY, indicating that I/O activity occurred during the previous period, the device remains in FULL POWER mode, as it is apparently active. Alternatively, if the ASV is set to IDLE, indicating that there was no I/O activity during the period, the PSV is checked to determine the mode of operation of the device and, if the device is not already in its lowest reduced power mode, the PSV is incremented and the device is caused to operate in its next lowest reduced power consumption mode, as indicated by the incremented value of the PSV. In addition, regardless of the states of the ASV and PSV, the internal flag of the interrupt generator associated with the I/O device is reset.
In an alternative embodiment, in which the power management microcontroller is used to power manage multiple I/O devices, for example, DEVICE1 and DEVICE2, the microcontroller includes, in addition to the PMU, two ASV registers, designated ASV1 and ASV2, and two PSV registers, designated PSV1 and PSV2, respectively corresponding to DEVICE1 and DEVICE2. In addition, the timer is implemented using a read/write countdown register loaded with a variable TIMER, the value of which controls the period of the timer for generating interrupts. In this embodiment, ASV1 and ASV2 are initiated to 0 (IDLE) and PSV1 and PSV2 are initialized to 0 on power up of the PC. Upon each detection of an I/O activity interrupt, the ASV and PSV of the corresponding device are set to the current value of TIMER and 0, respectively, and the device is caused to operate in a full power mode, it being noted that the I/O interrupt generator is at no time disabled in this alternative embodiment. Upon each detection of a timer interrupt, execution proceeds as described above, except that the value of TIMER is adjusted by subtracting the greater of the value of ASV 1 and ASV2 from TIMER.
A technical advantage achieved with the invention is that each of several I/O and peripheral devices of a PC can be monitored individually and caused to operate in successive reduced power consumption modes in an orderly fashion, thereby reducing the overall power consumption of the PC.
A further technical advantage achieved with the invention is that each device is systematically cycled through its reduced power consumption modes until it has been placed in the lowest such mode, typically "OFF," or accessed.
Another technical advantage achieved with the invention is that, using the alternative embodiment, the time lag inherent in the use of a static time period may be significantly reduced or eliminated.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A is a block diagram of a PC for implementing a power management system embodying features of the present invention.
FIG. 1B is a block diagram of the power management microcontroller of FIG. 1A.
FIG. 2 is flowchart of the operation of the power management system of FIG. 1A.
FIG. 3 is a state diagram of the power management system of FIG. 1A.
FIG. 4 is a block diagram of a PC for implementing an alternative embodiment of the power management system of the present invention.
FIGS. 5A and 5B are a flowchart of the operation of the alternative embodiment of the power management system of FIG. 4.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
In FIG. 1A, a PC including a power management system embodying features of the present invention is designated by reference numeral 10. The PC 10 comprises a power management microcontroller 12, a CPU 13, memory 14, an I/O activity interrupt generator 15, and at least one I/O device 16 all electrically interconnected in a conventional manner via a system bus 17.
Referring to FIG. 1B, the power management microcontroller 12 is illustrated in greater detail. As illustrated, the microcontroller 12 includes a power management unit (PMU) 18, comprising appropriate hardware (including memory) and/or software for implementing the power management functions of the present invention, as will be described. Connected to the PMU 18 are a periodic timer 19 associated with the I/O device 16 for generating to the PMU 18 a timer interrupt at periodic intervals, and registers or other appropriate storage devices 22a, 22b, for storing an activity state variable (ASV) and a power state variable (PSV), respectively, or indicating the activity and power states of the I/O device 16. In a particular embodiment, the timer 19 is implemented by programming a hardware register, typically a countdown register, to generate a periodic interrupt at a desired frequency, although it should be understood that the timer 19 may be implemented using hardware or a combination of hardware and software for generating periodic timer interrupts. As will be described in greater detail with reference to FIGS. 2 and 3, the microcontroller 12 controls the power consumption mode of the I/O device 16 (i.e., FULL POWER, STANDBY, SUSPEND, OFF) in accordance with the current state of the ASV and the PSV stored in the registers 22a, 22b.
It should be understood that, although not shown, the PC 10 may include any number of I/O devices, such as the I/O device 16, to be power managed. Accordingly, for each such I/O device, the PC 10 will include an associated timer, such as timer 19, and ASV and PSV registers, such as the registers 22a, 22b, corresponding to the state and power consumption mode of the managed I/O device. Alternatively, the PC 10 may include a single timer and a single set of ASV and PSV registers 22a, 22b, for the entire system, in which case all of the I/O devices will be power managed simultaneously.
In general, the ASV has two states, which are IDLE and BUSY, while the PSV has two or more states, depending on the type of I/O device 16 and the number of reduced power consumption modes in which the device is operable. For example, a particular type of display device may have n power consumption modes, where n is greater than two (2), as shown in Table I below:
TABLE I______________________________________PSV Value Device Power Mode______________________________________0 ON/FULL POWER1 STANDBY2 SUSPENDn OFF______________________________________
In a preferred embodiment, as shown in Table I, the Device Power Modes are arranged in order of decreasing power consumption and in an inverse relationship with the value of the PSV, such that as the value of the PSV increases, the power consumption mode of the device decreases.
Alternatively, the I/O device 12 may be a hard disk drive having only two power modes, as shown below in Table II:
TABLE II______________________________________PSV Value Device Power Mode______________________________________0 ON/FULL POWER1 OFF______________________________________
Although described with greater specificity below with reference to FIGS. 2 and 3, the overall operation of the power management functions of the system 10 may be generally described as follows. At the outset, it should be observed that, although the operation of the power management system will be described with respect to a single I/O device, i.e., the I/O device 16, the below described functions may occur with respect to each I/O device to be power managed. Accordingly, when the PC 10 is first turned on, the ASV in the register 22a is set to IDLE, to indicate there has been no I/O activity, the PSV in the register 22b is set to 0, corresponding to an ON, or FULL POWER, mode of the I/O device 16, and the I/O device 16 is caused to operate in its FULL POWER mode. At this point, the periodic timer 19 also starts to run.
Responsive to the detection by the I/O activity interrupt generator 15 of I/O device 16 activity, the generator 15 generates an I/O activity interrupt to the microcontroller 12 and sets an internal flag associated with the I/O device 16. In accordance with a feature of the present invention, so long as the internal flag is set, the generator 15 will not generate an I/O activity interrupt responsive to detection of I/O device 16 activity. Responsive to detection by the PMU 18 of an I/O activity interrupt from the generator 15, the ASV is set to BUSY, to indicate the occurrence of I/O activity during the period, the PSV is set to 0 and the device is caused to operate in FULL POWER mode, corresponding to PSV=0. Upon the expiration of the current period, as indicated by the timer's 19 generating a periodic timer interrupt to the PMU 18, the state of the ASV is checked. If the ASV is set to BUSY, indicating that I/O activity occurred during the previous period, the value of PSV and the power consumption mode of the device 16 remain unchanged and the ASV is set to IDLE. Alternatively, if the ASV is set to IDLE, indicating that there has been no I/O activity during the previous period, the PSV is checked to determine the power consumption mode of the device and, if the device is not already in its lowest reduced power consumption mode, (i.e., if the PSV is not set to its maximum value), the PSV is incremented and the device is caused to operate in its next lowest reduced power consumption mode, that is, the mode corresponding to the incremented value of the PSV.
Referring now to FIG. 2, the functions implemented by the microcontroller 12 and PMU 18 for power managing the device 16 will be described in greater detail. It should be understood that appropriate instructions for execution by the microcontroller 12 for implementing the below described functions are stored in a memory device (not shown) associated with or incorporated into the microcontroller 12. Execution begins in step 200 when the PC 10 is powered on by a user. In step 202, the ASV is set to IDLE and the PSV is set to 0. In step 204, the internal flag of the interrupt generator 15 is reset, to enable the generation of an I/O activity interrupt. In step 206, a determination is made whether an I/O activity interrupt has been detected by the PMU 18. If in step 206 it is determined that an I/O activity interrupt has been detected, execution proceeds to step 208, in which the ASV is set to BUSY and the PSV is set to 0. In addition, the device 16 is set to a power consumption mode associated with the value of the PSV, in this case, ON/FULL POWER. Execution then proceeds to step 210, in which the internal flag of the interrupt generator 15 is set, thereby disabling the generation of I/O activity interrupts responsive to subsequent I/O device 16 activity.
Execution then proceeds to step 212, in which a determination is made whether a timer interrupt has been received by the PMU 18. Moreover, if in step 206, it is determined that an I/O activity interrupt has not been received, execution proceeds directly to step 212. If in step 212 it is determined that a timer interrupt has not been received, execution returns to step 204; otherwise, execution proceeds to step 214. In step 214, a determination is made whether the ASV is set to IDLE. If it is determined that the ASV is set to IDLE, execution proceeds to step 216, in which a determination is made whether the PSV is set to its maximum value, which, as demonstrated above with reference to Tables I and II, will vary according to the number of power consumption modes in which the device 16 is operable. If it is determined that the PSV is not set to its maximum value, in step 218, the PSV is incremented by one (1) and the device 16 is caused to operate in the corresponding reduced power consumption mode.
It should be clear that the combination of steps 216 and 218 effect the following result: if the device 16 is not already in the lowest possible power consumption mode (step 216), the device 16 will be caused to operate in its next lowest possible power consumption mode (step 218). Execution then proceeds to step 220. If in step 214, it is determined that the ASV is not set to IDLE, or if in step 216, it is determined that the PSV is set to its maximum value, execution proceeds directly to step 220. In step 220, the ASV is reset to IDLE and execution returns to step 204.
FIG. 3 shows a state diagram of the PC 10 during a power management operation in which the device 16 is operable in n reduced power consumption modes, wherein n is greater than two (2), as shown in Table I above. Referring to FIGS. 1 and 3, upon power up, the PC 10 is in a state 300, in which the ASV is set to IDLE, the PSV is set to 0, and the device 16 is ON (FIG. 2, steps 200, 202). Upon the detection by the microcontroller 12 of an I/O activity interrupt, the PC 10 transitions to a state 302, as indicated by a line 304, in which the ASV is set to BUSY, the PSV is set to 0, and the device 16 remains ON (FIG. 2, steps 206, 208). Upon the generation by the timer 19 of a periodic timer interrupt, while the PC 10 is in the state 304, the PC 10 transitions back to the state 302, as indicated by a line 308 (FIG. 2, steps 212, 214, 220).
Upon the generation by the timer 19 of a periodic timer interrupt while the PC 10 is in the state 302, the PC 10 transitions to a state 310, as indicated by the line 312, in which the ASV is set to IDLE, the PSV is set to 1, and the device 16 is caused by the microcontroller 12 to operate in its first reduced power consumption mode, for example, "STANDBY" (FIG. 2, steps 212-220). Upon the generation by the timer 19 of a periodic timer interrupt while the PC 10 is in the state 310, the PC 10 transitions to a state 314, as indicated by a line 316, in which the ASV is set to IDLE, the PSV is set to 2, and the device 16 is caused by the microcontroller 12 to operate its second reduced power consumption mode, for example, "SUSPEND" (FIG. 2, steps 212-220).
This process continues, with the PC transitioning to states corresponding to lower reduced power consumption modes responsive to upon the generation of a periodic timer interrupt, until the PC 10 transitions to a state 318, as indicated by a line 320, in which the ASV is set to IDLE, the PSV is set to n, and the device 16 is caused to operate in its lowest reduced power consumption mode, which is "OFF" (FIG. 2, steps 212-220). In the embodiment illustrated in FIG. 3 (and Table I), "n" is the maximum value for the PSV. Accordingly, upon the occurrence of subsequent periodic timer interrupts while the PC 10 is in the state 318, the PC 10 transitions back to the state 318, as indicated by the line 322 (FIG. 2, steps 212-216, 220).
It should be obvious from the above that, assuming the device 16 has n possible reduced power consumption modes (including OFF and excluding ON), upon each occurrence of a periodic timer interrupt while the ASV is set to IDLE, the PSV will incremented by one and the device 16 will caused by the microcontroller 12 to enter the next lowest possible power consumption mode until the PSV has been incremented to n and the device 16 has been caused to operate in its lowest reduced power consumption mode (typically OFF). At that point, the device 16 will continue to operate in this lowest power consumption mode until the generation by the device 16 of an I/O activity interrupt, as at which point, the device 16 is returned to its FULL POWER mode and the ASV and the PSV are set to BUSY and 0, respectively.
Referring again to FIG. 3, upon the generation by the device 16 of an I/O activity interrupt while the PC 10 is in one of the states 310, 314 or 318, the PC 10 transitions to the state 304, as shown by lines 324, 326 or 328, respectively (FIG. 2, steps 206, 208).
Referring to FIG. 4, in an alternative embodiment of the present invention, the system is modified to advantageously power manage multiple I/O devices. As shown in FIG. 4, a PC 400 includes first and second I/O devices, respectively designated by reference numerals 402 and 404, respectively, interconnected with a power management microcontroller 412, CPU 413, memory 414, and an I/O activity interrupt generator 415 via a system bus 417. Similar to the power management microcontroller 12 (FIG. 1), the microcontroller 412 includes a PMU 418 and a timer 419. In addition, as described, but not shown, above in connection with FIGS. 1 and 2, the PMU 418 is connected to a set of ASV registers 422a and a set of PSV registers 422b for storing a respective ASV and PSV for each of the devices 402, 404. For purposes of clarity, the device 402 will be alternatively referred to herein as DEVICE1, with its corresponding ASV and PSV being designated ASV1 and PSV1. Similarly, the device 404 will be alternatively referred to herein as DEVICE2, with its corresponding ASV and PSV being designated ASV2 and PSV2.
In the preferred implementation of the embodiment shown in FIG. 4, the timer 419 comprises a programmable mad/write countdown register in which is stored a TIMER variable for controlling the frequency with which timer interrupts are generated by the timer 419. In addition, it should be recognized that the generator 415 generates individual I/O activity interrupts for each of the devices 402, 404, responsive to detection of activity thereof, respectively. As will be described, in this alternative embodiment, the generator 415 is not selectively enabled and disabled; rather, it remains in a constantly enabled state.
The operation of the alternative embodiment of the present invention will be described in greater detail with reference to FIGS. 5A and 5B. Execution begins in step 500 when the PC 400 is powered on by a user. In step 502, ASV1 and ASV2 are set to IDLE, which in this embodiment is represented by a logic 0, and PSV1 and PSV2 are also set to 0. In step 504, a determination is made whether the generator 415 has generated an I/O activity interrupt corresponding to DEVICE1 (hereinafter "DEVICE1 interrupt"). If so, execution proceeds to step 506, in which ASV 1 is set to the current value of TIMER, PSV1 is set to 0, and DEVICE1 is caused to operate in FULL POWER mode. Execution then proceeds to step 508. If in step 504, the generator 15 has not generated a DEVICE1 interrupt, execution proceeds directly to step 508. In step 508, a determination is made whether the generator 415 has generated an I/O activity interrupt corresponding to DEVICE2 (hereinafter "DEVICE2 interrupt"). If so, execution proceeds to step 510, in which ASV2 is set to the current value of TIMER, PSV2 is set to 0, and DEVICE2 is caused to operate in FULL POWER mode.
In step 512, a determination is made whether the timer 419 has generated a timer interrupt, which will occur when the timer 419 has counted down from the value of TIMER to zero. If not, execution returns to step 504; otherwise, execution proceeds to step 514. As previously indicated, the generator 415 is not disabled responsive to generation of an I/O activity interrupt; therefore, the values of ASV1 and ASV2 may be changed more than once before a timer interrupt is generated in step 512. In step 514, a determination is made whether ASV1 is set to 0 (IDLE). If so, execution proceeds to step 516, in which a determination is made whether PSV1 is set to its maximum value, as described above with reference to step 216 (FIG. 2). If not, execution proceeds to step 518. In step 518, PSV1 is incremented by 1 and DEVICE1 is caused to operate in the corresponding reduced power consumption mode as described above with reference to step 218 (FIG. 2).
Execution then proceeds to step 520. If in step 514, it is determined that ASV1 is not set to 0 (IDLE) or if in step 516, it is determined that PSV1 is set to its maximum value, execution proceeds directly to step 520. In step 520, a determination is made whether ASV2 is set to 0 (IDLE). If so, execution proceeds to step 522, in which a determination is made whether PSV2 is set to its maximum value. If not, execution proceeds to step 524, in which PSV2 is incremented by 1 and DEVICE2 is caused to operate in the corresponding reduced power consumption mode. Execution then proceeds to step 526. If in step 520 it is determined that ASV1 is not equal to 0 or if in step 522 it is determined that PSV2 is not set to its maximum value, execution proceeds directly to step 526. In step 526, the variable TIMER for controlling the period of the timer 419, is set to equal the maximum time period minus the greater of ASV1 and ASV2. It should be recognized that if both DEVICE1 and DEVICE2 were idle during the period (ASV1=ASV2=0), the value of TIMER will be the maximum time period.
In this manner, the frequency with which timer interrupts are generated is appropriately dynamically adjusted according to the activity of the devices being managed. Accordingly, the time lag inherent in the use of a static time period is effectively eliminated, as the timer 419 period will be adjusted to the smallest period necessary to ensure effective power management. For example, a hard disk may be programmed to spin down after 15 seconds of inactivity and the timer programmed to generate timer interrupts every 5 seconds. Using a static time period, if the disk is accessed one millisecond (1 ms) after the timer interrupt, the disk will spin down 20 seconds minus 1 ms after the last access, rather than 15 seconds thereafter, as it is supposed to do. This problem is eliminated by the use of a dynamic time period, as implemented in the alternative embodiment, which is adjusted to compensate for this occurrence.
It is understood that the present invention can take many forms and embodiments. The embodiments shown herein are intended to illustrate rather than to limit the invention, it being appreciated that variations may be made without departing from the spirit or the scope of the invention. For example, the PMU 18 may comprise a conventional "System Management Mode" unit of a microcontroller, as is well known in the art. Alternatively, the PMU 18 may comprise specialized software and hardware for implementing the above-described functions. Moreover, any number of I/O and/or peripheral devices may be power managed using the above-described power management system. Still further, the timer 419 may be implemented using a countup timer, in which case the value of TIMER would be adjusted by adding the value of the lesser of ASV1, ASV2 to TIMER.
Although illustrative embodiments of the invention have been shown and described, a wide range of modification, change and substitution is intended in the foregoing disclosure and in some instances some features of the present invention may be employed without a corresponding use of the other features. Accordingly, it is appropriate that the appended claims be construed broadly and in a manner consistent with the scope of the invention.
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A system for reducing the amount of power consumed by a battery operated computer device is disclosed. A microcontroller continuously monitors the activity of at least one I/O device and sets an activity state variable (ASV) associated with the I/O device accordingly. Upon each the expiration of a preselected time period, the microcontroller examines the state of the ASV to determine whether the I/O device was active during the expired time period. If so, the I/O device is caused to operate in a full power mode; otherwise, the I/O device is caused to operate in a reduced power consumption mode. In one embodiment, the I/O device is capable of operating in more than one reduced power consumption mode, in which case, responsive to a determination that the I/O device was not active during the expired time period, the I/O device is caused to operate in the next lowest power consumption mode. In an alternative embodiment, the frequency with which timer interrupts are generated is automatically adjusted after the expiration of each time period.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.K. Patent Application No. 1111624.1, filed Jul. 7, 2011; U.K. Patent Application No. 1111625.8, filed Jul. 7, 2011; U.K. Patent Application No. 1207922.4, filed May 5, 2012; U.K. Patent Application No. 1207923.2, filed May 5, 2012; the contents of which are incorporated herein in their entireties.
FIELD OF THE INVENTION
[0002] The present invention relates to compositions and methods for improving visual performance in a human subject, and to methods of making the composition.
BACKGROUND OF THE INVENTION
[0003] The central retina, known as the macula, is responsible for color and fine-detail vision. A pigment, composed of the carotenoids, lutein (L), zeaxanthin (Z), and meso-zeaxanthin (MZ), accumulates at the macula where it is known as macular pigment (MP). MP is a blue light filter and a powerful antioxidant, and is therefore believed to protect against age-related macular degeneration (AMD), which is now the most common cause of blind registration in the western world. Various scientists have proposed that macular pigments may enhance visual performance (VP), but there does not appear to be any persuasive experimental evidence supporting such hypotheses.
[0004] MZ-containing compositions have been disclosed as useful in the treatment of age-related macular degeneration (AMD), see for example U.S. Pat. No. 6,329,432. Supplements containing each of L, Z and MZ are known, and sold for the intended purpose of treating and/or preventing eye disorders such as AMD. One example of such a supplement is sold under the trade mark MacuShield®, and contains the three MP carotenoids L, Z and MZ in the amounts of 10 mg, 2 mg and 10 mg respectively, per dose.
[0005] WO 03/063848 discloses the use of a compound, such as lutein, zeaxanthin, mesozeaxanthin or mixtures thereof, for the manufacture of a composition for improving visual performance of a subject in conditions of darkness. The document is, however, rather unusual in that it does not contain any experimental evidence or data to support the alleged use. The person skilled in the art would therefore be rather skeptical of the disclosure and certainly could not derive any expectation of success therefrom.
[0006] EP 1 920 711 discloses a method of assessing visual performance which, in effect, involves measuring or determining the amount of macular pigment (such as lutein, zeaxanthin or mesozeaxanthin) present in the subject's eye (i.e. measuring macular pigment optical density, MPOD). If the level of MPOD is low, the document suggests administering a composition comprising lutein and/or zeaxanthin, which is purported to lead to an improvement in visual performance. However, the document does not disclose any actual experimental data to show that improving the level of macular pigment can produce an improvement in visual performance. Again therefore, the person skilled in the art would treat the disclosure of the document with some caution and could not derive any expectation of success therefrom.
SUMMARY OF THE INVENTION
[0007] “Dietary supplement” means an addition to the diet in a pill, capsule, tablet, powder or liquid form, which is not a natural or conventional food, and which effectively increases the function of tissues or organs, or increases the level or concentration of a substance in the body, or improves performance of tissues or organs.
[0008] The inventors have discovered that consumption of a dietary supplement containing lutein alone has little effect in the MP of subjects who exhibit an abnormally low concentration of MP in the central portion of the retina. In contrast, consumption of a dietary supplement comprising MZ alone can return MP levels in the central portion of the retina substantially to normal, but has little effect on MP levels outside the central portion. Consumption of a combined supplement, containing relatively high amounts of MZ, but also Z and L, cannot only normalize MP levels in the central region of the retina, but also augment MP levels outside the central region of the retina.
[0009] For present purposes, the ‘central region’ of the retina means that central portion of the retina which has an eccentricity of 0.25° or less, as determined by optical coherence tomography (OCT) and/or fundus photography.
[0010] In a first aspect the invention provides a composition comprising MZ for use as a dietary supplement, food additive or the like for oral consumption improving the visual performance of a human subject. In preferred embodiments, the subject is a subject without age-related macular degeneration (AMD).
[0011] For the purposes of the present specification, a subject is considered to be without AMD if they have a score of 1-3 in the AREDS (Age-Related Eye Disease Study) 11-step maculopathy grading system (Klein et al., 1991 Ophthalmology 98, 1128-1134).
[0012] In a second aspect, the invention provides a method of improving the visual performance of a human subject in need of such improvement, the method comprising the step of administering to the subject an effective amount of a composition comprising MZ. As explained below, the composition will preferably also comprise lutein and/or zeaxanthin. The composition will preferably be administered orally, typically as a dietary supplement or food additive. In preferred embodiments the method is performed on a subject without AMD.
[0013] An effective amount of the composition for a particular subject can readily be determined by non-inventive routine trial and error, in view of the guidance given in the present specification. Low doses can be given initially and the dosage increased until an improvement in visual performance is detected. The subject's visual performance can be tested in any of a number of convenient methods, as elaborated below.
[0014] For present purposes, MZ is understood to refer to the compound (trans, 3R, 3′S meso)-zeaxanthin, having the structure shown in FIG. 1 . Also included within the term “MZ” are esters of MZ, for example the acetate, laurate, myristate, palmitate, linoleate, linolenate and arachidonate esters, and esters with omega 3 fatty acids.
[0015] A human subject is considered not to be experiencing AMD if, following examination by a retinologist, there are no signs of any of the following characteristics normally associated with AMD including: soft drusen, hyper- and/or hypo-pigmentary changes at the macula (early AMD), or geographic atrophy or choroidal neovascularisation (advanced AMD).
[0016] The composition will preferably comprise MZ at a concentration of at least 0.001% w/w up to 20% w/w. In one embodiment, a preferred concentration of MZ may be in the range 3-10% w/w. However, the person skilled in the art will appreciate that the precise concentration of MZ in the composition of the invention is not critical: a beneficial effect on the visual performance of the subject can be obtained by consuming larger doses of a composition comprising lower concentrations of MZ and vice versa. A typical effective average daily dose of MZ to be consumed by a normal human adult subject will typically be in the range 0.1 mg to 100 mg per day, more conveniently in the range 1 to 50 mg per day, and preferably in the range 5-25 mg per day.
[0017] The composition may conveniently be in unitary dosage form e.g. as a tablet, capsule or the like. Conveniently, but not necessarily, the composition may be packaged in a foil blister pack, of the sort known to those skilled in the art. Desirably one or two of the doses are taken each day, the amount of MZ in the doses being adjusted accordingly.
[0018] The composition of the invention will desirably comprise not only MZ, but also lutein and/or zeaxanthin. Most preferably the composition will comprise MZ, lutein and zeaxanthin, which may be collectively referred to as macular carotenoids. Conveniently, but not necessarily, MZ will be present in the composition at a greater concentration or the same concentration as lutein or zeaxanthin. The percentage of either MZ or lutein in the composition can range from 10% to 90% (of macular carotenoid pigment present in the formulation). The percentage of zeaxanthin can typically range from 5 to 45% (of macular carotenoid pigment in the formulation). A particularly favored composition has an MZ: lutein: zeaxanthin ratio of 10:10:2 (or 45%, 45%, 10%).
[0019] The three macular carotenoids may be combined or preferably manufactured as such in single formulation. The composition of the invention may be in any formulation suitable for oral consumption by a human subject, including a tablet, capsule, gel, liquid, powder or the like. The macular carotenoids may be granulated for example as microcapsules before inclusion in the formulation. The composition may conveniently comprise conventional diluents, especially vegetable oils such as sunflower, safflower, corn oil and rape seed oils, excipients, bulking agents and the like which are well known to those skilled in the art. Such substances include calcium and/or magnesium stearate, starch or modified starch.
[0020] Other conventional formulating agents may be present in the composition, including any one or more of the following non-exclusive list: acidity regulators; anticaking agents (e.g. sodium aluminosilicate, calcium or magnesium carbonate, calcium silicate, sodium or potassium ferrocyanide), antioxidants (e.g. vitamin E, vitamin C, polyphenols), colorings (e.g. artificial colorings such as FD&C Blue No. 1, Blue No. 2, Green No. 3, Red No. 40, Red No. 3, Yellow No. 5 and Yellow No. 6; and natural colorings such as caramel, annatto, cochineal, betanin, turmeric, saffron, paprika etc.); color retention agents; emulsifiers; flavors; flavor enhancers; preservatives; stabilizers; sweeteners and thickeners.
[0021] The above-mentioned compositions containing MZ can be an added to a preparation containing essential vitamins and minerals; for example a one a day tablet/capsule containing all RDAs of the vitamins and minerals required by man; or dietary products which are fortified by vitamins and minerals; or together with omega 3 fatty acids.
[0022] Macular carotenoids containing MZ can be fed to hens and the eggs therefrom can provide an excellent source of MZ for human consumption
Visual Performance
[0023] Visual performance is a state, condition or parameter, not an abnormality or a disease. Thus there is a range of values in normal subjects without the presence of any underlying retinal or macular disease. However, like all other human conditions, improvements in VP are considered beneficial and desirable.
[0024] There are many different measures of “visual performance” known to those skilled in the art.
[0025] For present purposes, improving “visual performance” means producing a detectable improvement in one or more of the following in the subject: contrast sensitivity; visual acuity, preferably best corrected visual acuity; glare disability; discomfort glare; ocular straylight; photostress recovery; and S-cone sensitivity. Preferably the improvement in visual performance created by consumption of the composition of the invention comprises an improvement in one or more of: contrast sensitivity, best corrected visual activity, or glare disability.
[0026] Preferably consumption of the composition of the parameters of visual performance, more preferably in two or more, and most preferably a detectable improvement in three or more of the aforementioned visual performance parameters.
[0027] The various parameters of visual performance listed above are described in more detail below.
(i) Contrast Sensitivity Function
[0028] Contrast is the difference in visual properties that make an object (or its representation in an image) distinguishable from other objects and the background. In visual perception of the real world, contrast is determined by the difference in the color and brightness of the object and other objects within the same field of view. Contrast Sensitivity is a measure of a subject's sensitivity to changes in contrast; it is a measure of how much contrast is required to accurately detect a target as distinct from its background.
[0029] By altering the size (spatial frequency) of a target, and the luminance of the background, it is possible to test Contrast Sensitivity function, which is very much reflective of real-world vision, where the most important determinants of vision are contrast, size and luminance. Contrast Sensitivity function can be assessed using the Functional Acuity Contrast Test (FACT), which is designed to test contrast sensitivity at varying spatial frequency settings, as disclosed by Loughman et al., 2010 Vision Res. 50, 1249-1256). Letter Contrast Sensitivity may be measured using the commercially available “Thomson Chart”.
(ii) Visual Acuity
[0030] Visual acuity is a simple and intuitive way of assessing visual performance It is a useful measure of vision because it relates directly to the need for spectacles (i.e. if an individual is long or short sighted, the introduction of spectacle lenses typically creates a predictable improvement in visual acuity). Also, it tends to be adversely affected by ocular disease and therefore abnormal visual acuity can be a sign of developing abnormality.
[0031] Despite its widespread use and popularity, it is not the best technique for the assessment of vision because (a) it tends not to relate well with vision in conditions different to the brightly lit, high contrast test environment, and (b) it only evaluates performance at the high spatial frequency (i.e. small letter size) end of the spectrum. Typically best corrected visual acuity (“BCVA”) is assessed using a high contrast (close to 100%, i.e. black letters on a white background) letter chart, after the subject's vision has been corrected with corrective lenses to the best level possible. The subject's task is to read the smallest possible letter size they can recognize. The visual performance is quantified using a standard notation (e.g. Snellen notation; where 20/20 or 6/6 vision is accepted as normal human vision). Improvements in BCVA imply a benefit in visual acuity in general.
[0000] (iii) Glare Disability
[0032] Glare disability is a term used to describe the degradation of visual performance typically caused by loss of retinal image contrast. Glare disability is often caused, for example, by surface light reflections, or bright light sources such as car headlights, and typically is a consequence of increased forward light scatter within the eye. New bi-xenon high intensity discharge (“HID”) car headlights contain more “blue” light and are often considered as a cause of additional glare disability compared to older headlight sources.
[0033] This is of particular importance to macular pigment investigations because of the optical filtration properties of macular pigment. Macular pigment acts as a short wavelength (blue) light filter. Its prereceptoral and central location facilitate the optimization of visual performance with respect to glare because intraocular forward light scatter is short wavelength (blue) light dominated.
[0034] Glare disability can be assessed using the Functional Acuity Contrast Test (FACT), as disclosed by Loughman et. al., 2010 Vision Res. 50, 1249-1256.
(iv) Discomfort Glare
[0035] Discomfort glare results in an instinctive desire to look away from a bright light source or difficulty in seeing a task. It refers to the sensation one experiences when the overall illumination is too bright e.g. on a snow field under bright sun.
[0036] Macular pigment has the capacity to diminish the effects of discomfort glare because (a) it filters the blue component which contains most energy; less light and less energy therefore reach the photoreceptors to affect performance, and (b) macular pigment also has dichroic properties which means it has the capacity to filter plane polarized light. Plane polarized light is light reflected from a surface (e.g. snow covered ground, water etc) into the eye. It is unidirectional so the energy is concentrated and therefore has increased effect on vision. This is why skiers, anglers and the like wear polarized sunglasses to reduce such discomfort glare.
[0037] Discomfort glare is assessed using a discomfort rating scale as disclosed by Wenzel et al., 2006 Vision Res. 46, 4615-4622.
(v) Ocular Straylight
[0038] Ocular straylight is a parameter that is relatively new in clinical practice after being studied for many years in experimental settings. It concerns the part of the incident light that is scattered by the ocular media and does not participate in the normal image formation on the retina. Instead, this light creates a more or less homogeneous haze over the retinal image. Several pathologies are known to increase retinal straylight considerably, which may lead to symptoms such as loss of contrast sensitivity, disability glare, and halos. This will reduce a patient's quality of vision in everyday life, for example while driving at night and recognizing a person against a light source, but has only a very limited effect on visual acuity as measured during an ophthalmic examination.
[0039] As macular pigment absorbs the dominant short wave scattered component, it has the capacity to significantly reduce the amount of ocular straylight, and therefore further enrich visual performance particularly under circumstances of glare.
[0040] Ocular stray light is assessed using the Oculus C-Quant as disclosed by van Bree et al., 2011 Ophthalmology 118, 945-953.
(vi) Photostress Recovery
[0041] Photostress Recovery testing is a method of assessing visual performance by timing the recovery of visual function after adaptation to an intense light source. The test involves exposing the macula to a light source bright enough to bleach a significant proportion of the visual pigments. Return of normal retinal function and sensitivity depends on the regeneration of the visual pigments. The test essentially provides an indirect assessment of macular function.
[0042] Photostress recovery is assessed using a macular automated photostress test using the Humphrey Perimeter as disclosed by Loughman et. al., 2010 Vision Res. 50, 1249-1256.
[0000] (vii) S-cone Sensitivity
[0043] S-cones are the “blue” sensitive cones i.e. their peak sensitivity is to short wavelengths. Typically, a person with high levels of macular pigment would be expected to demonstrate low S-cone sensitivity, as the macular pigment is minimizing the amount of blue light striking the photoreceptors. Combining a test of S cone sensitivity with a photostress test can provide information on the direct effects of macular pigment on the actual sensitivity of those cones most affected by glare.
[0044] S-cone sensitivity is assessed using the short-wavelength automated perimetry program (SWAP) on the Humphrey Perimeter as described by (Davison et. al., Optom. Vis. Sci. 2011 vol. 88).
[0000] (viii) Assessment of VP by Questionnaire
[0045] Another method of testing for improvement in visual performance is the use of a questionnaire to score the subject's own assessment of their visual performance. In preferred embodiments of the invention therefore, a detectable improvement in visual performance is determined by an increased score in a subjective assessment questionnaire following a suitable period of weeks or months of consumption of the composition, as compared to a control assessment questionnaire completed prior to commencing consumption of the composition.
[0046] A suitable questionnaire is disclosed by Charalampidou et al., Arch. Ophthalmol. 2011 (May 9 th , Epublication ahead of print), in which is described a 30-part, non validated, “Visual Function in Normals” questionnaire (VFNq30), which was designed to assess subjective visual performance improvement. The design was based in part on a previously-validated visual activities questionnaire (Sloane et al., “The Visual Activities Questionnaire: Developing an instrument for assessing problems in everyday visual tasks. Technical Digest, Non-invasive Assessment of the Visual System, Topical Meeting of the Optical Society of America 1992), but adapted to suit a normal, young and healthy population sample. This questionnaire allows the subject to quantify their visual performance using three separate metrics: situational analysis (SA) which requires the subject to rate their visual performance in specified daily life situations; comparative analysis (CA) which requires the subject to compare their perceived visual performance to that of their peers/family/friends; subject satisfaction score (SSS) which requires the subject to provide an overall estimate of their perceived quality of vision. Each of the three metrics above is computed to give a performance score for five different functional aspects of their vision: acuity/spatial vision: glare disability; light/dark adaptation; daily visual tasks; and color discrimination.
Time to Achieve an Improvement of VP
[0047] Obviously, one does not expect any measurable, discernible or detectable improvement in the visual performance of a subject immediately after consuming the composition of the invention. The period of dietary supplementation required to produce a measurable improvement in visual performance will depend on several factors, including the average daily dose size of the macular carotenoids in the subject prior to commencing dietary supplementation, the subject's general health etc. Typically one would expect to require dietary supplementation with the composition of the invention for at least 8 weeks, and more preferably at least 3 or 6 months before measuring one or more visual performance parameters to test for any improvement therein.
[0048] The subject may need to consume the active composition of the invention at least once a week, more normally at least 3 times a week, and preferably daily.
PREFERRED EMBODIMENTS
[0049] In one embodiment of the invention, the composition may be consumed by subjects who have a deficiency in the amount of macular pigment in the central portion of their macula. By way of explanation the inventors have found that there exists a proportion of the population at large who may not be experiencing AMD (as herein defined), but who possess statistically significantly lower levels of macular pigment in the centre of the macula as determined by customized heterochromatic flicker photometry (cHFP) using the Macular Densitometer™. These subjects are described as having an atypical macular pigment distribution, referred to as a “central dip”. Using this technique, MP may be measured psychophysically by HFP. HFP is based on the fact that MP absorbs blue light. The subject may be asked to observe a target, within a test field, which is alternating in square wave counterphase between blue (460 nm) and green light (550 nm), i.e. flickering. They must adjust the luminance of the blue light to achieve null flicker, in other words, until the target becomes steady. The ratio of the amount of blue light required to achieve null flicker at the fovea may be compared to that required in the para-fovea (where MP is presumed to be zero), the logarithm of which is known as optical density. Using the Densitometer, MP can be measured at five points across the macula; 0.25°, 0.5°, 1°, 1.75° and 7°. The principle of HFP remains the same for each target. For those retinal eccentricities outside the fovea, i.e. 0.5°, 1°, 1.75° and 7°, the fixation point may be placed at the desired angular distance from a flickering disc. Three measurements may be taken at each loci and an average calculated. To minimize error in the HFP settings, care may be taken to optimize the flicker rate for each subject, otherwise known as critical flicker frequency (CFF). CFF is the frequency at which the subject can no longer perceive flicker in a 0.5° target at 550 nm. The CFF may be determined with a method of limits by which the flickering frequency is progressively decreased (or increased), until the subject reports a change from fusion to flicker (or flicker to fusion). Subjects with an atypical macular pigment distribution (“central dip”) may have an MPOD at 0.5° eccentricity which is greater than or equal to the MPOD at 0.25° eccentricity.
[0050] In another embodiment, the composition may be consumed by subjects who have statistically normal levels of macular pigment.
[0051] In another embodiment, the invention may provide a method of making a composition for human consumption, the composition to be consumed by a human subject for the purpose of improving visual performance, the method comprising the step of mixing an effective amount of MZ with an acceptable dietary diluent, excipient or carrier. The method may additionally comprise the addition of lutein and/or zeaxanthin to the diluent, excipient or carrier (or vice versa). Performance of the method may desirably result in manufacture of a composition having the preferred features set forth above. The method may additionally comprise the step of packaging the composition in a package together with instructions for consumption of the composition to effect an improvement in visual performance. Conveniently, the composition may be packaged in unitary dose form e.g. as a plurality of tablets, capsules or pills, which may be packaged loose (e.g. in a tub) or may be packaged individually (e.g. in a blister pack).
[0052] In one particular embodiment, the invention may provide a method of improving the visual performance of a human subject, the method comprising the steps of:
a) supplying a feed to egg-laying birds, such as hens or ducks, which feed comprises MZ, so as to cause the birds to lay eggs comprising MZ; b) collecting said eggs, and supplying the eggs, or at least part of the yolk thereof, in edible form to the subject.
[0055] Whole eggs may be provided raw for cooking by the subject. Alternatively the eggs may be processed and at least part of the yolks thereof provided to the subject, the MZ content of the eggs being concentrated in the yolk. Processing may involve, for example, shelling, cooking and drying the eggs.
[0056] Typically the composition of the invention may be consumed at least once a week, preferably at least twice a week, more preferably at least three times a week, and most preferably at least daily. In some embodiments the composition may be consumed more than once a day (e.g. once in the morning and once in the evening). The person skilled in the art will appreciate that the frequency of consumption can be adjusted to take account of the concentration of macular pigment carotenoids, especially meso-zeaxantion, present in the formulation. The method of the invention can be adjusted accordingly.
[0057] Consuming the composition of the invention, or performing the method of invention, over a sufficient period of time (typically at least 8 weeks, preferably at least 3 months, more preferably over at least 6 months, and most preferably for 12 months or more) may typically result in an increase in the level of macular pigment in a subject.
[0058] The amount of increase in the level of macular pigment carotenoids in the subject which is achieved by consumption of the composition may depend on, for example, the level of macular pigment carotenoids present in the subject's eyes prior to commencement of consumption of the composition. As described above, the inventors have found that there is a proportion of the population (about 10% or so) in Ireland which have abnormally low levels of macular pigment and an abnormal distribution of carotenoid pigments within the macula, and it is anticipated that similar subjects exist in other populations. Such people might be expected to exhibit a substantial increase in the level of macular pigment following long term (i.e. 6 months or more) consumption of the composition of the invention.
[0059] Significantly, however, and surprisingly, the inventors have also found that at least some parameters of visual performance (e.g. letter contrast sensitivity; glare disability) can be improved by consumption of the composition of the invention without necessarily a corresponding increase in the level of macular pigment.
[0060] In particular, the composition/method of the invention can produce a detectable improvement in the visual performance of a subject in conditions other than low light. For example, the composition/method of the invention can produce an improvement in the visual performance of a subject in conditions of illumination greater than 1 Cdm 2 ; more especially in photopic conditions (e.g. illumination levels greater than or equal to 3 Cdm −2 ).
[0061] More especially, the composition/method of the invention can produce an improvement in one or more of the following visual performance parameters: visual acuity, especially best corrected visual acuity (BCVA); contrast sensitivity (CS); and glare disability (GD). Suitable methods of measuring these visual performance parameters are known to those skilled in the art and are described in detail herein. Typically the method/composition of the invention will produce an improvement of at least 5%, preferably at least 8%, more preferably at least 10%, relative to the same parameter measured prior to consumption of the composition/performance of the method of the invention.
[0062] For the avoidance of doubt it is hereby explicitly stated that any feature of the invention described herein as preferable, advantageous, convenient, desirable, typical or the like may be present in any embodiments of the invention in isolation, or in any combination with any one or more other such features, unless the context dictates otherwise. In addition, features described in relation to one aspect of the invention will equally apply to the other aspects of the invention, unless the context dictates otherwise.
[0063] The content of all publications and citations mentioned in this specification is specifically incorporated herein by reference.
BRIEF DESCRIPTION OF THE DRAWINGS
[0064] The invention will now be further described by way of illustrative embodiment and with reference to the accompanying drawings, in which:
[0065] FIG. 1 is a schematic representation of the structural formulae for lutein, zeaxanthin and MZ;
[0066] FIG. 2 is a graph of corrected visual acuity against central macular pigment OD (arbitrary units) in a group of mixed normal and AMD subjects;
[0067] FIG. 3 is a graph of macular pigment OD (at 0.25° eccentricity) against time for subjects consuming various macular carotenoid compositions;
[0068] FIG. 4 is a graph showing the macular pigment OD measurement, at varying degrees of eccentricity, for particular subjects found to have atypical MPOD profiles, with a “central dip” (i.e. lower levels of macular pigment in the centre of the macula);
[0069] FIGS. 5 and 6 are graphs of MPOD (at 0.25 and 0.50° eccentricity respectively) against time, for subjects receiving one of three different macular carotenoid formulations;
[0070] FIGS. 7-9 are graphs of mean MPOD against retinal eccentricity for groups 1-3 respectively (see example 2), before and after an 8 week period of dietary supplementation with one of three different macular carotenoid formulations; and
[0071] FIG. 10 is a graph of MPOD against retinal eccentricity (mean of eight subjects; see example 5) before (circular symbols) or after (square symbols) 3 months of supplementation with a daily dose of 10 mg L, 10 mg MZ and 10 mg Z.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Example 1
[0072] Comparison of Macular Responses after Supplementation with Three Different Macular Carotenoid Formulations
Subjects and Recruitment
[0073] This study was conducted at the Institute of Vision Research, Whitfield Clinic, Waterford, Republic of Ireland. Seventy one subjects volunteered to participate in this study, which was approved by the local research ethics committee. Subjects were aged between 32 to 84 years and in good general health. The volunteers were divided into two groups: an AMD group and a normal group. 34 subjects had confirmed early stage AMD in at least one eye (AMD group; categorized and identified by either presence of drusen and/or pigmentary changes at the macula), and 37 subjects had no ocular pathology (normal group). Importantly, for the AMD group, significant efforts were made to identify patients with early AMD who were not currently taking carotenoid supplements.
Study Design and Formulation
[0074] L=Lutein MZ=mesozeaxanthin Z=Zeaxanthin
[0075] This study was a single blind, randomized-controlled clinical trial of oral supplementation with three different macular carotenoid formulations, as follows:
Group 1: High L Group
[0000]
(n=24 [normal group=12 and AMD group=12];
L=20 mg/day, Z=2 mg/day);
Group 2: mixed carotenoid group
(n=24 [normal group=13 and AMD group=11];
MZ=10 mg/day, L=10 mg/day, Z=2 mg/day);
Group 3: high MZ group
(n=23 [normal group=12 and AMD group=11];
MZ=18 mg/day, L=2 mg/day L).
All subjects were instructed to take one capsule (oil based) per day with a meal for 8 weeks. Compliance was assessed by tablet counting at each study visit.
Measurement of Macular Pigment Optical Density (MPOD)
[0083] The spatial profile of MP was measured using customized heterochromatic flicker photometry (cHFP) using the Macular Densitometer™, a cHFP instrument that is slightly modified from a device described by Wooten & Hammond (2005 Optometry & Vision Science 82, 378-386) and by Kirby et al., (2010 Invest. Ophthalmol. Vis. Sci. 51, 6722-6728.
[0084] Subjects were assessed at baseline, two weeks, four weeks, six weeks, and 8 weeks (V1, V2, V3, V4, and V5, respectively). MPOD was measured at the following eccentricities: at 0.25°, 0.5°, 1°, 1.75°, 3° but only results at 0.25°, the central part of the retina corresponding to the macula, are reported here.
[0085] Statistical Analysis The statistical software packages PASW Statistics 17.0 (SPSS Inc., Chicago, Ill., USA) and R were used for analysis and Sigma Plot 8.0 (Systat Software Inc., Chicago, Ill., USA) was used for graphical presentations. All quantitative variables investigated exhibited a typical normal distribution. We used the 5% level of significance.
Results
MPOD and Visual Acuity
[0086] There was a positive and statistically significant relationship between central MPOD (at 0.25°) and corrected visual acuity at baseline (r=0.303, p=0.008), as shown in FIG. 2 which is a graph of corrected visual acuity against MPOD (arbitrary units), showing the data points for individual subjects in the two groups prior to supplementation with one of the three carotenoid formulations. This finding suggests that central MP is significantly and positively related to visual performance.
[0087] Increase in MPOD over time
[0088] At an eccentricity of 0.25° the baseline MPOD was different for each group as follows; Group 1: 0.42±0.20 Group 2:0.44±0.18 Group 3: 0.49±0.21, with a mean of all groups of 0.45±0.20. To simplify the comparison all groups are drawn to start at the mean value. The study showed an increase in MPOD over time, as illustrated in FIG. 3 , which is a graph of MPOD at 0.25° eccentricity (arbitrary units) against time (timepoints 1 to 5, corresponding to 0, 2, 4, 6 & 8 weeks respectively). As seen in FIG. 3 , the biggest increase in central MPOD was achieved with the group 2 formulation (MZ=10 mg/day, L=10 mg/day, Z=2 mg/day) which was statistically significant different from groups 1 and 3. There was no statistical difference between group 1 and 3.
Conclusions
[0089] Surprisingly, the greatest effect on macular pigment was seen with the mixed carotenoid group (group 2) containing MZ 10 mg L10 mg Z 2 mg, whereas results with the other two groups were very similar. There appears to be synergism between MZ & L. That the high MZ group (group 3) was able to increase MP demonstrates that MZ can raise MPOD substantially without any contribution from the other carotenoids, but was less effective than MZ in combination with L.
[0000] Macular Carotenoid Supplementation in Subjects with ‘Central Dips’ in their Macular Pigment Spatial Profiles
[0090] The central retina, known as the macula, is responsible for color and fine-detail vision (Hirsh & Curcio 1989; Vision Res. 29, 1095-1101). A pigment of the two dietary carotenoids, lutein (L) and zeaxanthin (Z), and a typically non-dietary carotenoid MZ (MZ), (Johnson et al., 2005 Invest. Ophtalmol. Vis. Sci. 46, 692-702) accumulates at the macula, where it is known as macular pigment (MP). MP is a blue light filter (Snodderly et al., 1984 Invest. Opthalmol. Vis. Sci. 25, 660-673) and a powerful antioxidant (Khachik et al. 1997 Invest. Ophthalm. & Vis. Sci. 38, 1802-1811), and is therefore believed to protect against age-related macular degeneration (AMD), which is now the most common cause of blind registration in the western world (Klayer et al., 1998 Arch. Ophthalmol. 116, 653-658).
[0091] MZ and Z are the predominant carotenoids in the foveal region, whereas L predominates in the parafoveal region (Snodderley et al., 1991 Invest. Ophthalmol. Vis. Sci. 32, 268-279). The concentration of MZ peaks centrally, with an MZ: Z ratio of 0.82 in the central retina (within 3 mm of the fovea) and 0.25 in the peripheral retina (11-21 mm from the fovea) (Bone et al., 1997 Experimental Eye Research 64, 211-218). Retinal MZ is produced primarily by isomerization of retinal L, thus accounting for lower relative levels of L, and higher relative levels of MZ, in the central macula, and vice versa in the peripheral macula, and would also explain why MZ accounts for about one third of total MP.
[0092] The concentration of MP varies greatly amongst individuals (Hammond et al., 1997 Journal of the Optical Society of America A-Optics Image Science & Vision, 14, 1187-1196). Atypical MP spatial profiles (i.e. ‘central dips’) are present in some individual MP profiles. More importantly, it was confirmed that these ‘central dips’ were real and reproducible features of the MP spatial profile, when measured using customised heterochromatic flicker photometry (cHFP, a validated technique for measuring MP). The importance of such variations, if any, in the spatial profile of MP (e.g. the presence of a ‘central dip’) is not yet known, but may be related to the putative protective role of this pigment. For example, reduced MPOD at the centre of the macula (i.e. the presence of a ‘central dip’) may be associated with increased risk of developing AMD.
[0093] It has been shown that 12% (58 subjects out of a sample database of 484 subjects) of the normal Irish population had a reproducible ‘central dip’ in their MPOD spatial profile and that such a dip in the MP spatial profile is more common in older subjects and in cigarette smokers (two of the established risk factors for AMD).
Example 2
Supplementation of Formulations Containing Macular Carotenoids to Subjects with a “Central Dip” in their MP Profile
[0094] The study described in this example was performed with volunteer subjects from the above mentioned database (n=58) in the “central dip study”, who were identified, and confirmed, as having ‘central dips’ in their MP spatial profile (i.e. MPOD at 0.5 degrees of eccentricity was ≧MPOD at 0.25 degrees of eccentricity, see FIG. 4 ) and invited to participate in an 8-week supplementation trial with one of three different macular carotenoid formulations (see below).
Methods
Subjects and Study Design:
[0095] Fifty eight subjects with ‘central dips’ in their MP spatial profile (identified from a master MP database; n=484) were invited to take part in the study. Of the 40 subjects that agreed to come back for testing, 31 were confirmed as still having a ‘central dip’ (i.e. MPOD at 0.5 degrees of eccentricity was ≧MPOD at 0.25 degress of eccentricity) and were therefore enrolled into the 8-week supplementation trial.
[0096] All subjects signed an informed consent document and the experimental measures conformed to the Declaration of Helsinki. The study was reviewed and approved by the Research Ethics Committee, Waterford Institute of Technology, Waterford, Ireland. Inclusion criteria for participation in this study were as follows: MPOD at 0.5 degrees of eccentricity ≧MPOD at 0.25 degrees of eccentricity (i.e. evidence of a ‘central dip’ in the MP spatial profile); no presence of ocular pathology; visual acuity 20/60 or better in the study eye; not currently taking L and/or Z and/or MZ dietary supplements.
[0000] Subjects were randomly assigned into one of the three groups as follows;
Group 1: high L group (n=11), L=20 mg/day, Z=2 mg/day;
Group 2: mixed carotenoid group (n=10), MZ=10 mg/day, L=10 mg/day, Z=2 mg/day.
Group 3 the high MZ group (n=10), 18 mg/day MZ, 2 mg/day L).
[0097] All subjects were instructed to take one capsule per day with a meal for 8 weeks. MPOD, including its spatial profile, i.e. at 0.25°, 0.5°, 1°, 1.75°, 3°, was measured at baseline, four weeks and 8 weeks.
Measurement of Macular Pigment Optical Density
[0098] The spatial profile of MP was measured using cHFP using the Macular Densitometer™, as described in Example 1. In order to measure the spatial profile of MP, measurements were made at the following degrees of retinal eccentricity: 0.25°, 0.5°, 1°, 1.75°, 3° and 7° (the reference point) obtained using the following sized target diameters; 30 minutes, 1°, 2°, 3.5°, 1° and 2°,
Statistical Analysis
[0099] The statistical software package PASW Statistics 17.0 (SPSS Inc., Chicago, Ill., USA) was used for analysis and Sigma Plot 8.0 (Systat Software Inc., Chicago, Ill., USA) was used for graphical presentations. All quantitative variables investigated exhibited a typical normal distribution. Means±SDs are presented in the text and tables. Statistical comparisons of the three different intervention groups, at baseline, were conducted using independent samples t-tests and chi-square analysis, as appropriate. We used the 5% level of significance throughout our analysis.
Results
Change in MPOD Over 8-Week Supplementation Period
[0100] We conducted repeated measures ANOVA of MPOD, for all retinal eccentricities measured (i.e. at 0.25°, 0.5°, 1.0°, 1.75°, and 3°), over time (i.e. over the study period [baseline, 4 weeks and 8 weeks]), using a general linear model approach, with one between-subjects factor: treatment (Group 1, Group 2, Group 3) and age as a covariate. FIGS. 5 and 6 show the change in MPOD during the course of the trial for measurements at 0.25 and 0.5° eccentricity respectively. Table 1 presents repeated measures ANOVA results for each group separately and for each degree of retinal eccentricity. As seen in this Table, increase in MPOD at 0.25° and 0.5° was statistically significant in Group 2 (i.e. the mixed carotenoids group). Similarly, a significant increase in MPOD at 0.25° was seen in Group 3 (i.e. high MZ group). Of note, only the increase in MPOD at 0.25° in Group 2 remains significant after Bonferroni correction for multiple testing.
[0101] Change in the spatial profile of MPOD for each of Groups 1-3 is illustrated in FIGS. 7-9 respectively.
Conclusions
[0102] Only the two formulations containing MZ were able to correct the “central dip” and increase MP. Surprisingly, and contrary to expectation, the formulation containing L but without MZ had no effect on MPOD at any eccentricity.
[0103] The formulation containing mixed carotenoids (group 2) had a superior effect since it increased MP significantly at both 0.25 and 0.5 eccentricities. This is consistent with the result from the subjects who received a supplement with all three carotenoids without a central dip at the baseline (see Example 1) i.e. the greatest response was observed using a supplement containing each of MZ, L and Z.
[0000]
TABLE 1
Average MPOD values at each degree of eccentricity for all subjects
according to group & visit wise
Time
interaction
Group
MPOD
Baseline
4 wks
8 wks
(p-value)
Group 1
0.25
0.45 ± 0.20
0.48 ± 0.22
0.49 ± 0.21
0.112
Group 1
0.5
0.45 ± 0.23
0.46 ± 0.18
0.46 ± 0.23
0.509
Group 1
1
0.20 ± 0.18
0.27 ± 0.15
0.25 ± 0.13
0.234
Group 1
1.75
0.15 ± 0.09
0.15 ± 0.09
0.15 ± 0.09
0.986
Group 1
3
0.15 ± 0.11
0.16 ± 0.09
0.11 ± 0.08
0.265
Group 2
0.25
0.41 ± 0.27
0.50 ± 0.27
0.59 ± 0.30
0.000
Group 2
0.5
0.44 ± 0.26
0.46 ± 0.28
0.52 ± 0.28
0.016
Group 2
1
0.26 ± 0.23
0.29 ± 0.15
0.34 ± 0.10
0.417
Group 2
1.75
0.18 ± 0.10
0.19 ± 0.06
0.22 ± 0.06
0.218
Group 2
3
0.16 ± 0.12
0.14 ± 0.06
0.19 ± 0.11
0.448
Group 3
0.25
0.48 ± 0.16
0.55 ± 0.19
0.57 ± 0.18
0.005
Group 3
0.5
0.48 ± 0.15
0.48 ± 0.17
0.50 ± 0.15
0.786
Group 3
1
0.32 ± 0.12
0.31 ± 0.13
0.34 ± 0.12
0.596
Group 3
1.75
0.11 ± 0.09
0.12 ± 0.07
0.13 ± 0.08
0.743
Group 3
3
0.12 ± 0.08
0.15 ± 0.07
0.15 ± 0.07
0.522
Values represent mean ± standard deviation; n = 31; MPOD = macular pigment
optical density; 0.25° = MPOD measured at 0.25° retinal eccentricity; 0.5° = MPOD
measured at 0.5° retinal eccentricity; 1.0° = MPOD measured at 1.0° retinal
eccentricity; 1.75° = MPOD measured at 1.75° retinal eccentricity; 3° = MPOD
measured at 3.0° retinal eccentricity; Group 1: high L group; Group 2: combined
carotenoid group; Group 3: high MZ group; the p-values represent repeated measures
ANOVA for the 3 study visits (within-subject effects), with Greenhouse-Gesser
correction for lack of sphericity as appropriate.
Example 3
Comparison of Visual Performance in Subjects with Early Stage AMD after Supplementation with Three Different Macular Carotenoid Formulations
Subjects and Recruitment
[0104] This study was conducted with 72 subjects, many with early AMD. For details see Example 1.
Study Design and Formulation
[0105] The subjects with were divided into 3 groups (of 20-27 subjects) and given the following supplementations:
[0000] Group 1: L=20; Z=2 mg/day
Group 2: L=10; MZ=10; Z=2 mg/day
Group 3: MZ=17-18; L=2-3; Z=2 mg/day
[0106] These formulations, dissolved in 0.3 ml vegetable oil, were administered in soft gel capsules.
[0107] Visual Performance, using the techniques described previously above, was measured at baseline and at 3 and 6 months after supplementation. Statistical analyses were performed using a paired t test. Significant values were considered as P<0.05. Results are only given where at least one group was statistically significant.
Results:
[0108] Since there were no statistically significant improvements detected in VP after 3 months treatment, only results for 6 or 12 months are presented here (below):
1. Baseline Comparison Between Groups:
[0109]
[0000]
TABLE 2
Baseline Comparison
Group 2:
Group 1:
10 mg MZ;
Group 3:
20 mg L;
10 mg L;
18 mg MZ;
Variable
2 mg Z
2 mg Z
2 mg L
p
N
23
27
22
Age
67 ± 8
64 ± 9
72 ± 10
0.014
MPOD 0.25°
0.412 ± 0.19
0.482 ± 0.21
0.475 ± 0.20
0.411
BCVA
92 ± 21
97 ± 10
94 ± 8
0.362
[0110] The groups were statistically comparable at baseline with respect to MP and vision (assessed by Best Corrected Visual Acuity, “BCVA”). There was a significant difference between groups at baseline for age between Group 3 and the other two Groups. Group 1 and Group 2 were statistically similar with respect to age.
2. Best Corrected Visual Acuity (BCVA)
[0111] There was a baseline correlation (before supplementation) of a positive and statistically significant relationship between central MPOD (0.25) and BCVA, importantly this is in the AMD population (r−=0.368, p=0.002). There was no statistically significant change in BCVA in any group after 3 and 6 months.
[0112] A computer-generated LofMAR test chart (Test Chart 2000 Pro; Thomson Software Solutions) was used to determine BCVA at a viewing distance of 4 m, using a Sloan ETDRS letterset. BCVA was determined as the average of three measurements, with letter and line changes facilitated by the software pseudo-randomization feature. Best corrected visual acuity was recorded using a letter-scoring visual acuity rating, with 20/20 (6/6) visual acuity assigned a value of 100. Best corrected visual acuity was scored relative to this value, with each letter correctly identified assigned a nominal value of one, so that, for example, a BCVA of 20/20+1 (6/6+1) equated to a score of 101, and 20/20-1 (6/6-1) to 99.
3. MPOD Response
[0113] Table 3 below presents MP data for each Group and for each eccentricity measured, at baseline, six and twelve months after supplementation with macular carotenoids.
[0114] A statistically significant increase in MPOD at 12 months was observed only in groups 2 and 3, receiving the MZ-containing supplement.
[0000]
TABLE 3
MPOD
MPOD
MPOD
Group
Baseline
6 months
12 months
0.25
0.25
p
1:
0.42 ± 0.19
0.51 ± 0.20
0.57 ± 0.30
0.148
2:
0.48 ± 0.22
0.58 ± 0.21
0.63 ± 0.19
0.001
3:
0.52 ± 0.20
0.58 ± 0.22
0.57 ± 0.20
0.022
0.5
0.5
p
1:
0.32 ± 0.19
0.42 ± 0.18
0.46 ± 0.27
0.126
2:
0.39 ± 0.19
0.50 ± 0.18
0.52 ± 0.19
0.001
3:
0.41 ± 0.19
0.46 ± 0.19
0.45 ± 0.20
0.034
1.0
1.0
p
1:
0.22 ± 0.11
0.31 ± 0.15
0.32 ± 0.17
0.213
2:
0.25 ± 0.12
0.36 ± 0.17
0.37 ± 0.18
0.001
3:
0.26 ± 0.15
0.32 ± 0.14
0.33 ± 0.16
0.025
1.75
1.75
p
1:
0.13 ± 0.10
0.18 ± 0.11
0.20 ± 0.10
0.114
2:
0.14 ± 0.10
0.22 ± 0.12
0.24 ± 0.11
<0.001
3:
0.13 ± 0.11
0.21 ± 0.12
0.19 ± 0.10
0.063
4. Letter Contrast Sensitivity (Thomson Chart)
[0115] Table 4A presents letter contrast sensitivity data at baseline and six months after supplementation with macular carotenoids Measurements were made at 1.2, 2.4, 6.0, and 9.6 cpd. There was a statistically significant improvement only in Group 2 (10 mg MZ; 10 mg L; 2 mg Z) at 1.2, 2.4 and 9.6 cpd and not at all in the other two groups. This shows a greatly superior effect in Group 2.
[0000]
TABLE 4A
Letter contrast
Letter contrast
sensitivity
sensitivity
Group
Baseline
Six months
1.2 cpd
1.2 cpd
P
1:
1.68 ± 0.34
1.75 ± 0.30
0.091
2:
1.63 ± 0.24
1.80 ± 0.25
0.013
3:
1.68 ± 0.37
1.63 ± 0.25
0.322
2.4 cpd
2.4 cpd
p
1:
1.60 ± 0.33
1.66 ± 0.34
0.17
2:
1.59 ± 0.29
1.72 ± 0.33
0.049
3:
1.61 ± 0.35
1.63 ± 0.32
0.6
9.6 cpd
9.6 cpd
p
1:
1.1 ± 0.36
1.04 ± 0.41
0.194
2:
0.97 ± 0.32
1.11 ± 0.46
0.043
3:
0.94 ± 0.37
0.95 ± 0.43
0.901
[0116] Table 4B shows the letter contrast sensitivity (CS) at baseline and 12 months, for each of five spatial frequencies (1.2-15.15 cpd).
[0000]
TABLE 4B
Mean (±sd) letter contrast sensitivity (CS) values at baseline and at 12 months.
Group 1
Group 2
Group 3
cpd
Baseline
12 months
p
Baseline
12 months
p
Baseline
12 months
P
1.2
1.74 ± 0.31
1.86 ± 0.30
0.033
1.69 ± 0.24
1.88 ± 0.28
0.004
1.73 ± 0.30
1.89 ± 0.27
0.041
2.4
1.65 ± 0.32
1.79 ± 0.38
0.013
1.66 ± 0.28
1.79 ± 0.31
0.004
1.60 ± 0.30
1.85 ± 0.29
0.002
6.0
1.37 ± 0.29
1.42 ± 0.40
0.194
1.30 ± 0.29
1.38 ± 0.33
0.053
1.19 ± 0.43
1.55 ± 0.27
0.002
9.6
1.11 ± 0.28
1.09 ± 0.34
0.775
1.00 ± 0.32
1.10 ± 0.40
0.034
0.91 ± 0.45
1.19 ± 0.40
0.012
15.15
0.73 ± 0.33
0.73 ± 0.39
0.933
0.64 ± 0.37
0.73 ± 0.49
0.148
0.57 ± 0.46
0.83 ± 0.36
0.014
Abbreviations: cpd = cycles per degree
[0117] At 12 months the results were similar to 6 months in that letter contrast sensitivity increased in all groups for large objects (1.2 and 2.4 cpd) but only in groups 2 and 3 with smaller objects (6.0-15.5 cpd).
[0118] Table 4C reports the relationship between observed changes in MPOD (at 0.25° eccentricity) and observed changes in letter CS at 1.2 cpd. Of note, there were no statistically significant relationships between change in MP and change in letter CS, at any spatial frequency.
[0000]
TABLE 4C
Change in MPOD vs. change in letter CS
r
p
Group 1
0.262
0.294
Group 2
0.258
0.235
Group 3
−0.043
0.875
Colour Fundus Photographs
[0119] Colour fundus photographs were taken at every study visit using a Zeiss VisuCam™ (Carl Zeiss Meditec AG, Jena, Germany) and were graded stereoscopically at the Ocular Epidemiology Reading Center at the University of Wisconsin, USA. Photographs were graded using a modified version of the Wisconsin Age-Related Maculopathy Grading System. Early AMD was defined as the presence of drusen and/or pigmentary changes in at least one eye, confirmed by an on-site ophthalmologist in collaboration with graders at the University of Wisconsin. Each fundus photograph was evaluated, lesion-by-lesion, to determine maximum drusen size, type, area, and retinal pigmentary abnormalities. Overall findings were reported on an 11-step AMD severity scale. A change of two or more steps along the severity scale was defined as being clinically significant. Graded photographs were obtained for baseline and 12 months visits.
[0120] At baseline, there was no significant difference between the groups with respect to AMD grade (p=0.679) [Table 4D].
[0000]
TABLE 4D
AMD grading for entire groups and subgroups at baseline.
Entire group
Group 1
Group 2
Group 3
Grade
(n = 72)
(n = 23)
(n = 27)
(n = 22)
Sig.
1-3
16
(22.2%)
7
(30.4%)
6
(22.2%)
3
(13.6%)
0.679
4-5
28
(38.9%)
10
(43.5%)
8
(29.6%)
10
(45.5%)
6-7
19
(26.4%)
5
(21.7%)
8
(29.6%)
6
(27.3%)
8-9
4
(5.6%)
—
2
(7.4%)
2
(9.1%)
10-11
5
(6.9%)
1
(4.3%)
3
(11.1%)
1
(4.5%)
[0121] The changes in AMD grade between baseline and 12 months for each of the three groups are summarized in Table 4E. A change in the negative direction (i.e. −1, −2) indicates a progression along the AMD severity scale, whereas positive integers indicate regression (improvement) along the AMD severity scale. Between baseline and 12 months, there was no statistically significant difference between treatment groups with respect to change in AMD severity (p=0.223, Pearson chi-square test).
[0000]
TABLE 4E
Change in AMD grade (11-step scale) between baseline and 12 months.
Group
n
−2
−1
0
+1
+2
Sig.
1
16
1 (6%)
1 (6%)
10 (63%)
3 (19%)
1 (6%)
0.223
2
23
1 (4%)
2 (9%)
14 (61%)
4 (17%)
2 (9%)
3
15
2 (13%)
6 (40%)
4 (27%)
2 (13%)
1 (7%)
Total
54 (100%)
4 (7%)
9 (17%)
28 (52%)
9 (17%)
4 (7%)
Abbreviations: n = number of subjects; negative value indicates disease progression; a positive value indicates disease regression; 0 = no change in grade
[0122] Of note, table 4E shows that 86% of subjects exhibited no clinically significant change in the status of their AMD between baseline and 12 months, with 7% exhibiting deterioration and 7% exhibiting an improvement (note: a change in grade of two or more has been accepted as being clinically significant).
Discussion
[0123] The most interesting results were for letter contrast sensitivity. This test is only conducted in daylight and tests letters of different sizes. Results were at 6 months and 12 months were similar. There was no correlation between increase in MP and increase in this parameter indicating a neuro-physiological effects of macular carotenoids.
[0124] There was no significant change in AMD grade from baseline. Thus changes in contrast sensitivity were not related to effects on AMD pathology.
5. Contrast Sensitivity at Night (Assessed on the Fact Device)
[0125] Table 5 below presents log contrast sensitivity data assessed for night time, at baseline and six months after supplementation with macular carotenoids. Measurements were made at 1.5, 3.0, 6.0, 12 and 18 cpm. The statistically significant improvement in this measure of VP was present only in Group 2 at 1.5, 3.0, cpd and in Group 1 at 1.5 cpd showing a superior effect of group 2.
[0000]
TABLE 5
Night time contrast
Night time contrast
sensitivity
sensitivity
Group
Baseline
Six months
1.5 cpd
1.5 cpd
P
1:
1.53 ± 0.29
1.67 ± 0.26
0.124
2:
1.51 ± 0.27
1.66 ± 0.3
0.028
3:
1.44 ± 0.29
1.45 ± 0.34
0.911
3.0 cpd
3.0 cpd
p
1:
1.52 ± 0.25
1.8 ± 0.28
0.001
2:
1.62 ± 0.34
1.75 ± 0.41
0.01
3:
1.55 ± 0.40
1.6 ± 0.41
0.585
6. Contrast Sensitivity at Daytime (Assessed on the Fact Device)
[0126] Table 6 below presents log contrast sensitivity data assessed for day time at baseline and six months after supplementation with macular carotenoids. Measurements were made at 1.5, 3.0. 6.0, 12 and 18 cpm. The statistically significant improvement in this measure of VP was present in Group 2 at 1.5, 3.0, and 18 cpd and in Group 1 at 1.5 cpd showing a superior effect in group 2.
[0000]
TABLE 6
Daytime contrast
Daytime contrast
sensitivity
sensitivity
Group
Baseline
Six months
1.5 cpd
1.5 cpd
P
1:
1.41 ± 0.16
1.57 ± 0.26
0.03
2:
1.48 ± 0.23
1.6 ± 0.28
0.034
3:
1.41 ± 0.13
1.5 ± 0.28
0.238
3.0 cpd
3.0 cpd
p
1:
1.67 ± 0.21
1.75 ± 0.21
0.17
2:
1.7 ± 0.33
1.81 ± 0.34
0.018
3:
1.72 ± 0.18
1.77 ± 0.29
0.46
18 cpd
18 cpd
p
1:
0.62 ± 0.4
0.56 ± 0.41
0.497
2:
0.65 ± 0.38
0.77 ± 0.5
0.015
3:
0.57 ± 0.4
0.62 ± 0.43
0.704
7. Contrast Sensitivity at Night Time in the Presence of Glare (Assessed on the FACT Device)
[0127] Table 7 below presents Log contrast sensitivity data at night in the presence of glare at baseline and six months after supplementation with macular carotenoids. Measurements were made at 1.5, 3.0, 6.0, 12 and 18 cpd. There was a statistically significant improvement in this VP only in Group 2 at 18 cpd.
[0000]
TABLE 7
Night time contrast
Night time contrast
sensitivity
sensitivity
with glare
with glare
Baseline
Six months
Group
18 cpd
18 cpd
p
1:
0.34 ± 0.16
0.34 ± 0.16
0.136
2:
0.36 ± 0.13
0.47 ± 0.34
0.038
3:
0.36 ± 0.22
0.32 ± 0.08
0.588
8. Contrast Sensitivity at Day Time in the Presence of Glare (Assessed on the Fact Device)
[0128] Table 8 below presents Log contrast sensitivity data at day time in the presence of glare, at baseline and six months after supplementation with macular carotenoids. Measurements were made at 1.5, 3.0, 6.0, 12 and 18 cpd. The statistically significant improvement in this measure of VP was present in Group 2 at 1.5, 3.0, 6.0, and 18 cpd cpd and in Group 1 at 1.5, 3.0, and 6.0 cpd and in Group 3 at 6 cpd, showing a superior effect in group 2.
[0000]
TABLE 8
Daytime contrast
Daytime contrast
sensitivity with
sensitivity with
glare
glare
Group
Baseline
Six months
1.5 cpd
1.5 cpd
P
1:
1.5 ± 0.25
1.63 ± 0.21
0.001
2:
1.43 ± 0.25
1.68 ± 0.24
0.002
3:
1.42 ± 0.38
1.46 ± 0.36
0.351
3.0 cpd
3.0 cpd
p
1:
1.68 ± 0.22
1.85 ± 0.22
0.006
2:
1.71 ± 0.25
1.84 ± 0.25
0.007
3:
1.67 ± 0.35
1.71 ± 0.43
0.542
6.0 cpd
6.0 cpd
p
1:
1.46 ± 0.42
1.85 ± 0.22
<0.001
2:
1.46 ± 0.47
1.84 ± 0.25
<0.001
3:
1.36 ± 0.42
1.71 ± 0.43
0.001
18 cpd
18 cpd
p
1:
0.64 ± 0.46
0.59 ± 0.43
0.642
2:
0.53 ± 0.32
0.67 ± 0.51
0.018
3:
0.7 ± 0.47
0.66 ± 0.45
0.609
9. Contrast Sensitivity and Glare Disability Between Baseline and 12 Months
[0129] Data on contrast sensitivity (CS) and glare disability (GD) under mesopic (night-time) and photopic (daytime) conditions, at baseline and 12 months, are presented in Tables 9-12.
[0000]
TABLE 9
Log CS at baseline and 12 months under
mesopic conditions (FACT device)
Group
p
CS 1.5 cpd v1
CS 1.5 cpd v4
Group 1
1.59 ± 0.28
1.80 ± 0.22
0.007
Group 2
1.60 ± 0.27
1.76 ± 0.24
0.047
Group 3
1.53 ± 0.39
1.73 ± 0.25
0.124
CS 3 cpd v1
CS 3 cpd v4
Group 1
1.61 ± 0.25
1.82 ± 0.22
0.007
Group 2
1.68 ± 0.34
1.80 ± 0.26
0.058
Group 3
1.62 ± 0.42
1.85 ± 0.40
0.175
CS 6 cpd v1
CS 6 cpd v4
Group 1
1.18 ± 0.38
1.24 ± 0.53
0.521
Group 2
1.27 ± 0.40
1.38 ± 0.44
0.278
Group 3
1.20 ± 0.44
1.46 ± 0.50
0.060
CS 12 cpd v1
CS 12 cpd v4
Group 1
0.65 ± 0.14
0.79 ± 0.43
0.224
Group 2
0.67 ± 0.26
0.79 ± 0.24
0.080
Group 3
0.76 ± 0.25
0.89 ± 0.36
0.177
CS 18 cpd v1
CS 18 cpd v4
Group 1
0.40 ± 0.25
0.32 ± 0.08
0.207
Group 2
0.32 ± 0.07
0.36 ± 0.26
0.332
Group 3
0.36 ± 0.15
0.39 ± 0.24
0.476
Abbreviations: FACT = functional acuity contrast test; CS = contrast sensitivity; cpd = cycles per degree; v1 = baseline visit; v4 = 12 month visit
[0000]
TABLE 10
Log CS at baseline and 12 months under
photopic conditions (FACT device)
Group
p
CS 1.5 cpd v1
CS 1.5 cpd v4
Group 1
1.47 ± 0.25
1.63 ± 0.22
0.007
Group 2
1.56 ± 0.21
1.61 ± 0.24
0.478
Group 3
1.44 ± 0.22
1.63 ± 0.25
0.023
CS 3 cpd v1
CS 3 cpd v4
Group 1
1.70 ± 0.22
1.86 ± 0.11
0.002
Group 2
1.74 ± 0.33
1.86 ± 0.21
0.108
Group 3
1.78 ± 0.20
1.84 ± 0.24
0.402
CS 6 cpd v1
CS 6 cpd v4
Group 1
1.52 ± 0.30
1.59 ± 0.29
0.310
Group 2
1.52 ± 0.39
1.66 ± 0.39
0.064
Group 3
1.44 ± 0.45
1.62 ± 0.38
0.192
CS 12 cpd v1
CS 12 cpd v4
Group 1
1.01 ± 0.33
0.98 ± 0.35
0.709
Group 2
1.02 ± 0.36
1.21 ± 0.48
0.118
Group 3
0.99 ± 0.43
1.19 ± 0.48
0.164
CS 18 cpd v1
CS 18 cpd v4
Group 1
0.63 ± 0.39
0.54 ± 0.40
0.437
Group 2
0.59 ± 0.38
0.64 ± 0.48
0.687
Group 3
0.68 ± 0.48
0.76 ± 0.50
0.458
Abbreviations: FACT = functional acuity contrast test; GD = glare disability; cpd = cycles per degree; v1 = baseline visit; v4 = 12 month visit
[0000]
TABLE 11
Log GD at baseline and 12 months under
mesopic conditions (FACT device)
Group
p
GD 1.5 cpd v1
GD 1.5 cpd v4
Group 1
1.49 ± 0.37
1.52 ± 0.34
0.635
Group 2
1.44 ± 0.39
1.53 ± 0.35
0.365
Group 3
1.26 ± 0.44
1.53 ± 0.47
0.029
GD 3 cpd v1
GD 3 cpd v4
Group 1
1.57 ± 0.43
1.60 ± 0.32
0.728
Group 2
1.51 ± 0.38
1.70 ± 0.35
0.010
Group 3
1.39 ± 0.50
1.55 ± 0.49
0.346
GD 6 cpd v1
GD 6 cpd v4
Group 1
1.09 ± 0.37
1.04 ± 0.34
0.564
Group 2
1.18 ± 0.35
1.24 ± 0.43
0.581
Group 3
1.10 ± 0.40
1.20 ± 0.47
0.348
GD 12 cpd v1
GD 12 cpd v4
Group 1
0.66 ± 0.17
0.71 ± 0.18
0.343
Group 2
0.66 ± 0.17
0.80 ± 0.43
0.100
Group 3
0.77 ± 0.24
0.69 ± 0.22
0.115
GD 18 cpd v1
GD 18 cpd v4
Group 1
0.34 ± 0.16
0.30 ± 0.00
0.336
Group 2
0.34 ± 0.10
0.39 ± 0.37
0.483
Group 3
0.32 ± 0.08
0.36 ± 0.21
0.336
Abbreviations: FACT = functional acuity contrast test; GD = glare disability; cpd = cycles per degree; v1 = baseline visit; v4 = 12 month visit
[0000]
TABLE 12
Log GD at baseline and 12 months under
photopic conditions (FACT device)
Group
p
GD 1.5 cpd v1
GD 1.5 cpd v4
Group 1
1.60 ± 0.25
1.76 ± 0.23
0.006
Group 2
1.53 ± 0.19
1.74 ± 0.22
0.002
Group 3
1.51 ± 0.25
1.69 ± 0.42
0.058
GD 3 cpd v1
GD 3 cpd v4
Group 1
1.70 ± 0.26
1.89 ± 0.25
0.002
Group 2
1.78 ± 0.21
1.97 ± 0.18
0.001
Group 3
1.73 ± 0.20
1.84 ± 0.38
0.330
GD 6 cpd v1
GD 6 cpd v4
Group 1
1.54 ± 0.38
1.64 ± 0.35
0.358
Group 2
1.56 ± 0.43
1.69 ± 0.34
0.087
Group 3
1.46 ± 0.47
1.71 ± 0.38
0.048
GD 12 cpd v1
GD 12 cpd v4
Group 1
1.02 ± 0.42
1.05 ± 0.38
0.659
Group 2
0.97 ± 0.36
1.14 ± 0.35
0.169
Group 3
1.00 ± 0.44
1.11 ± 0.43
0.320
GD 18 cpd v1
GD 18 cpd v4
Group 1
0.64 ± 0.45
0.67 ± 0.48
0.752
Group 2
0.54 ± 0.34
0.81 ± 0.51
0.071
Group 3
0.75 ± 0.48
0.75 ± 0.52
0.993
Abbreviations: FACT = functional acuity contrast test; GD = glare disability; cpd = cycles per degree; v1 = baseline visit; v4 = 12 month visit
Discussion
[0130] Results at 12 months were similar to those at 6 months, in that the results were variable and difficult to interpret. Under mesopic (nighttime) conditions, contrast sensitivity only increased with large objects (1.5 and 3.0 cpd) in groups 1 and 2. For glare disability, group 1 did not change, whilst group 2 and 3 showed some change with large objects.
[0131] Under photopic (daylight) conditions, groups 1 and 3 only increased contrast sensitivity with large objects. With glare disability all groups increased only with large objects.
10. Changes in Visual Performance Parameters and Changes in MPOD
[0132] Table 13 reports the relationship between observed changes in MPOD (at 0.25° eccentricity) and observed changes in parameters of visual performance, namely CDVA and measures of mesopic and photopic contrast sensitivity, and mesopic and photopic glare disability, at 1.5 cpd. Of note, there were no statistically significant relationships between change in MP and change in visual performance in any of the groups (with the exception of a negative relationship between increases in MPOD and photopic CS at 1.5 cpd in Group 1 only).
[0000]
TABLE 13
r
p
Change in MPOD vs. change in CDVA
Group 1
−0.320
0.211
Group 2
−0.148
0.558
Group 3
−0.126
0.681
Change in MPOD vs. change in mesopic CS 1.5 cpd
Group 1
0.055
0.859
Group 2
−0.140
0.664
Group 3
0.041
0.906
Change in MPOD vs. change in photopic CS 1.5 cpd
Group 1
−0.705
0.007
Group 2
−0.106
0.743
Group 3
−0.122
0.720
Change in MPOD vs. change in mesopic GD 1.5 cpd
Group 1
0.318
0.289
Group 2
−0.106
0.743
Group 3
0.388
0.238
Change in MPOD vs. change in photopic GD 1.5 cpd
Group 1
−0.262
0.388
Group 2
−0.136
0.673
Group 3
−0.308
0.357
Abbreviations: MPOD = macular pigment optical density; CDVA = corrected distance visual acuity; L = lutein; Z = zeaxanthin; MZ = meso-zeaxanthin; CS = contrast sensitivity; cpd = cycles per degree; GD = glare disability.
Discussion
[0133] There was no correlation between increases in visual performance and increases in macular pigment, indicating a neuro-physiological effect of macular carotenoids.
[0000] Other Conclusions: Changes in VP were Only Statistically Significant after 6 Months or More
[0134] The methods reported here in contrast sensitivity were at varying spatial frequencies. Low spatial frequencies (e.g. 1.2 cpd) are indicative of very large objects (e.g. a car, a house), whereas, large spatial frequencies (e.g. 18 cpd) are indicative of small objects (e.g. a menu in a restaurant). The data lead to the following conclusions;
[0000] 1. The most important effect was on contrast sensitivity which is one of the most important measures of VP and it reflects how the patient actually perceives their own vision.
2. Statistical significance was reached across many spatial frequencies, which means the improvement detected has implications for general and real life vision.
3. There was a superior improvement in VP for the Group 2 intervention (i.e. 10 mg MZ; 10 mg L; 2 mg Z).
Example 4
Effect of Two Macular Carotenoids and a Placebo Formulations on VP in Normal Subjects
Subjects and Recruitment
[0135] This study was conducted on 36 normal subjects with no AMD. Details of the recruitment are given in Example 1. Of the 36 subjects recruited, 32 completed the trial, with one drop-out from each of the intervention groups and two drop-outs from group 3, the placebo group. All further analysis was confined to those subjects with a complete data set (Group 1, n=11; Group 2, n=11; Group 3, n=10).
Study Design and Formulations
[0136] The normal subjects were divided into 3 groups of (initially) 12 subjects and given the following supplements:
[0000] Group 1: L20; Z 2 mg/day
Group 2: MZ 10; L 10; Z 2 mg/day
Group 3: Placebo 0 mg/day
[0137] The carotenoid formulations were in 0.3 ml vegetable oil and were administered in soft gel capsules.
[0138] Visual performance was assessed as described in detail below, at baseline, 3 months and at 6 months.
Statistical Analysis
[0139] The statistical software package PASW Statistics 18.0 (SPSS Inc., Chicago, Ill., USA) was used for analysis. All quantitative variables investigated exhibited a typical normal distribution. Means±SDs are presented in the text and tables. Statistical comparisons of the three supplementation groups, at baseline, were conducted using one way ANOVA, while paired samples t tests and repeated measures ANOVA (using a general linear model approach) were used to analyze visual performance and MPOD measures in each supplementation group for change across study visits as appropriate. Where relevant, the Greenhouse-Geisser correction for violation of sphericity was used. A 5% level of significance was used throughout the analysis.
Results
[0140] 1. Baseline Analysis Following randomization, one-way analysis of variance revealed no significant differences between groups at baseline, in terms of demographic, macular pigment, visual performance parameters, or other parameters, as illustrated for selected parameters in table 14 below.
[0000]
TABLE 14
Group 1:
Group 2:
Group 3:
Variable
Mean ± SD
Mean ± SD
Placebo
P value
N
12
12
12
Age
56 ± 8
51 ± 13
46 ± 20
0.3
BMI
27 ± 3
25 ± 3
26 ± 5
0.31
BCVA
107 ± 5
109 ± 6
108 ± 6
0.72
MPOD 0.25
0.32 ± 0.13
0.37 ± 0.13
0.35 ± 0.18
0.69
MPOD 0.5
0.25 ± 0.14
0.27 ± 0.12
0.28 ± 0.16
0.88
MPOD 1.0
0.15 ± 0.14
0.20 ± 0.07
0.16 ± 0.11
0.46
MPOD 1.75
0.07 ± 0.10
0.10 ± 0.07
0.04 ± 0.04
0.16
MPOD 3
0.07 ± 0.08
0.08 ± 0.07
0.04 ± 0.05
0.26
SD = standard deviation; BMI = body mass index; BCVA = best corrected visual acuity; MPOD = macular pigment optical density
2. MPOD Response at 3 and 6 Months
MPOD Measurement
[0141] A spatial profile of MPOD was generated across 0.25°, 0.5°, 1°, 1.75° and 3° of retinal eccentricity in relation to a 7° reference location, using the Macular Densitometer™, which employs a heterochromatic flicker photometry (HFP) technique. Subjects were shown an explanatory video of the technique, and afforded a practice session prior to test commencement. HFP flicker frequencies were optimized following determination of individual critical flicker fusion (CFF) frequency measurements, in a customization process that optimizes MP measurements, (Stringham et al, Exp. Eye res. 2008, 87, 445-453). The MPOD measurement comprised the average of six readings (computed as the radiance value at which the subject reported null flicker) at each retinal eccentricity, and was deemed reliable and acceptable only when the standard deviation of null flicker responses was below 0.1
[0000]
TABLE 15
MPOD response and significance at each retinal eccentricity across study visits
T
RM
Group Intervention
Baseline
3 months
T test
6 months
Test
ANOVA
MPOD0.25
MPOD0.25
p*
MPOD0.25
p**
p***
20 mg L; 2 mg Z
0.32 ± 0.12
0.38 ± 0.15
0.080
0.41 ± 0.14
0.444
0.092
10 mg MZ; 10 mg L; 2 mg Z
0.37 ± 0.13
0.49 ± 0.14
0.002
0.50 ± 0.20
0.012
0.002
Placebo
0.35 ± 0.20
0.38 ± 0.20
0.709
0.37 ± 0.18
0.637
0.814
MPOD0.50
MPOD0.50
p
MPOD0.50
P
p
20 mg L; 2 mg Z
0.27 ± 0.13
0.32 ± 0.22
0.456
0.30 ± 0.14
0.459
0.096
10 mg MZ; 10 mg L; 2 mg Z
0.28 ± 0.12
0.38 ± 0.16
0.011
0.37 ± 0.21
0.042
0.010
Placebo
0.28 ± 0.17
0.31 ± 0.16
0.404
0.28 ± 0.16
0.966
0.572
MPOD1.0
MPOD1.0
p
MPOD1.0
P
p
20 mg L; 2 mg Z
0.16 ± 0.14
0.18 ± 0.12
0.455
0.15 ± 0.14
0.767
0.533
10 mg MZ; 10 mg L; 2 mg Z
0.21 ± 0.08
0.28 ± 0.10
0.035
0.27 ± 0.14
0.085
0.047
Placebo
0.16 ± 0.12
0.14 ± 0.11
0.954
0.13 ± 0.10
0.400
0.997
MPOD1.75
MPOD1.75
p
MPOD1.75
P
p
20 mg L; 2 mg Z
0.08 ± 0.10
0.08 ± 0.10
0.859
0.07 ± 0.10
0.867
0.929
10 mg MZ; 10 mg L; 2 mg Z
0.11 ± 0.07
0.19 ± 0.05
0.005
0.18 ± 0.10
0.041
0.036
Placebo
0.03 ± 0.03
0.03 ± 0.05
0.767
0.03 ± 0.05
0.732
0.815
MPOD3.0
MPOD3.0
p
MPOD3.0
P
p
20 mg L; 2 mg Z
0.05 ± 0.02
0.07 ± 0.06
0.588
0.03 ± 0.03
0.185
0.671
10 mg MZ; 10 mg L; 2 mg Z
0.09 ± 0.07
0.11 ± 0.11
0.275
0.10 ± 0.07
0.707
0.915
Placebo
0.02 ± 0.03
0.02 ± 0.03
0.810
0.02 ± 0.05
0.682
0.480
*difference between baseline and 3 months (paired samples t test)
**difference between baseline and 6 months (paired samples t test)
***repeated measures ANOVA across all visits
[0142] It can be seen here that the greatest increase in MP, at all eccentricities measured, can be seen in Group 2, a supplement containing 10 mg MZ; 10 mg L; 2 mg Z.
Visual Performance Assessment
[0143] Visual acuity (VA) was measured at baseline with a computer-generated log MAR test chart (Test Chart 2000 Pro; Thompson Software Solutions, Hatfield, UK) at a viewing distance of 4 m, using the Sloan ETDRS letterset. VA was measured using a single letter scoring visual acuity rating, and recorded as the average of three measurements facilitated by the software letter randomization feature. The eye with better visual acuity was chosen as the study eye; however, when both eyes had the same corrected acuity, the right eye was chosen as the study eye.
[0144] Contrast sensitivity was measured using a functional acuity contrast test (Optec6500 Vision Tester; Stereo Optical Co. Inc, Chicago, Ill.), which incorporates sine wave gratings, presented as Gabor patches, at spatial frequencies of 1.5, 3, 6, 12 and 18 cycles per degree (cpd) to produce a contrast sensitivity function. Testing was performed under mesopic (3 candelas per square meter [cd/m 2 ]) and photopic (85cd/m2) conditions. (By way of explanation, 3 candelas per square meter is considered to represent the upper limit of mesopic conditions: any greater level of illumination is considered to constitute photopic conditions). Contrast sensitivity testing was performed using a Thomson Chart or using the EDTRS (Early Treatment Diabetic Retinopathy Study) letters in log MAR form at five different spatial frequencies (see Lorente—Velazquez et al., 2011 Optom. Vis Sci. 88 (10): 1245-1251).
[0145] Glare disability was assessed using the same test, and testing conditions, but in the presence of an inbuilt circumferential LED glare source (42 lux for mesopic and 84 lux for photopic glare testing). The LED glare source rendered a daylight simulating color temperature of 6500° K, and a spectral emission profile with a single large peak at 453 nm (close to peak MP spectral absorbance). These tests have been described in more detail elsewhere (Loughman et al. Vis Res. 2010; 50:1249-1256; Nolan et al. Vis Res. 2011; 51:459-69). The subject task, and nature of the test were explained in detail prior to test commencement, and subject performance was monitored closely by a trained examiner during the test, and reinstructed if necessary. Pupil diameter was measured for the background mesopic and photopic conditions used, and also in the presence of both glare sources using a Neuroptics VIP™-200 pupillometer (Neuroptics Inc., Irvine, Calif. 92612, USA).
[0146] Photostress recovery time (PRT) of the short wavelength sensitive (SWS) visual system was assessed using a macular automated photostress (MAP) test, an adaptation of the Humphrey visual field analyzer (Model 745i Carl Zeiss Meditec Inc. Dublin, Calif., USA) for the assessment of foveal incremental light threshold (Dhalla et al., Am J. Ophthalmol. 2007; 143(4), 596-600). To isolate SWS cones, mid and long wavelength sensitive cones were desensitized using a three minute sustained exposure to a 100 cd/m 2 , 570 nm bleaching background. A Goldmann V, 440 nm stimulus, presented for 200 milliseconds, was used to test the sensitivity of the SWS system before and after photostress. Following the three minute adaptation and practice session (during which subject performance was assessed for reliability and understanding), subjects were directed to fixate centrally between four circumferential light stimuli, and to respond to the detection of a “blue” stimulus at that location using the response button provided. Foveal sensitivity was determined as the average of three consecutive measurements recorded in decibels (dB), with each dB representing a 0.1 log unit sensitivity variation. Following baseline foveal sensitivity calculation, the subject was exposed to a short wavelength dominated photostress stimulus, which consisted of a 5-s exposure to a 300-W lamp viewed at 1 m through a low-pass glass dichroic filter, thus creating a temporary foveal “blue” after-image to mask fixation and reduce foveal sensitivity. Immediately post-photostress, a continuous and timed cycle of foveal sensitivity measurements were conducted and recorded. The reduction in foveal sensitivity from baseline, along with the recovery characteristics of the SWS system sensitivity, was recorded. Pupil diameter was again recorded for background light conditions, and in the presence of the photostress light source.
[0147] Ocular straylight was measured using an Oculus C-Quant (OCULUS Optikgeräte GmbH, Wetzlar, Germany), an instrument designed to quantify the effect of light scatter on vision. A central bipartite 14° test field was viewed monocularly through the instrument eyepiece. Subjects were instructed to respond, using the appropriate response button, to indicate the position of the most strongly flickering right or left test hemi-field. Subjects were allowed a defined practice session, during which reliable understanding of the task was assessed by the trained examiner. Test results were deemed acceptable only when the standard deviation of measured straylight value (esd) was ≦0.08, and the reliability coefficient (Q) was ≧1. Absolute straylight values were recorded in logarithmic form [log(s)].
[0148] Visual discomfort was assessed during the glare disability and photostress testing procedures. Subjects were asked to rate their discomfort immediately following presentation of the glare and photostress light sources on a scale ranging from 1-10, where “1” indicated “no ocular discomfort”, “5” indicated “moderate ocular discomfort”, and “10” indicated “unbearable ocular discomfort”. Such a scale has previously been used effectively in an exemplar macular pigment/glare study (Stringham et al., Invest Ophthalmol Vis Sci. 2011; 52(10):7406-15). Visual experience was also assessed by questionnaire, using a modified version of the Visual Activities Questionnaire, as used and described in detail elsewhere (Loughman et al. Vis Res. 2010; 50:1249-1256; Sloane et al., The Visual Activities Questionnaire: Developing an instrument for assessing problems in everyday visual tasks. Technical Digest, Noninvasive Assessment of the Visual System, Topical Meeting of the Optical Society of America , January, 1992). Iris color was also graded using a standardized iris classification scheme as defined by Seddon et al. (Invest Ophthalmol Vis Sci 1990 (31), 8:1592-1598).
[0000] 3. BCVA demonstrated no significant effect for any of the intervention groups at 3 months. At 6 months, pair t-test analysis revealed a statistically significant improvement in BCVA compared to baseline for group 2(p=0.008). Repeated measures ANOVA confirmed a significant change across the three study visits for group 2 (p=0.034).
4. Contrast Sensitivity
[0149] Mesopic and photopic contrast sensitivity improved from baseline values across a range of spatial frequencies at three months, and in particular, at six months. At three months, statistically significant improvements were noted at 1.5 cpd (p=0.008) for mesopic conditions, and at 3 cpd (p=0.024) and 12 cpd (p=0.025) for photopic conditions for Group 2. At six months, statistically significant improvements in CS were noted across a substantially broader set of spatial frequencies, most notably under mesopic conditions, for Group 2, Mesopic CS at 6 CPD improved significantly for Group 1 at 6 months (p<0.05). Repeated measures ANOVA confirms the improvements in contrast sensitivity to be statistically significant across all study visits for at least 3 of the 5 spatial frequencies tested under mesopic and photopic conditions. A detailed summary of contrast sensitivity results are provided in Table 16.
[0000]
TABLE 16
Contrast sensitivity change and significance levels at each spatial
frequency tested under mesopic and photopic conditions
Contrast sensitivity
Contrast sensitivity
T Test
RM ANOVA
Group Intervention
at baseline
at six months
p*
p**
Photopic at 1.5 cpd
Photopic at 1.5 cpd
20 mg L; 2 mg Z
44 ± 26
53 ± 20
0.05
0.12
10 mg MZ; 10 mg L; 2 mg Z
49 ± 30
68 ± 28
0.07
0.12
Placebo
52 ± 22
62 ± 29
0.41
0.28
Photopic at 3.0 cpd
Photopic at 3.0 cpd
20 mg L; 2 mg Z
85 ± 37
85 ± 29
0.96
0.68
10 mg MZ; 10 mg L; 2 mg Z
73 ± 25
100 ± 28
0.002
0.002
Placebo
95 ± 36
94 ± 46
0.84
0.81
Photopic at 6.0 cpd
Photopic at 6.0 cpd
20 mg L; 2 mg Z
99 ± 27
100 ± 28
0.71
0.43
10 mg MZ; 10 mg L; 2 mg Z
95 ± 36
114 ± 45
0.23
0.26
Placebo
103 ± 54
116 ± 64
0.83
0.88
Photopic at 12.0 cpd
Photopic at 12.0 cpd
20 mg L; 2 mg Z
30 ± 10
39 ± 17
0.178
0.26
10 mg MZ; 10 mg L; 2 mg Z
32 ± 13
50 ± 30
0.011
0.008
Placebo
57 ± 43
62 ± 42
0.643
0.92
Photopic at 18.0 cpd
Photopic at 18.0 cpd
20 mg L; 2 mg Z
8 ± 5
12 ± 9
0.168
0.38
10 mg MZ; 10 mg L; 2 mg Z
12 ± 6
23 ± 17
0.059
0.042
Placebo
20 ± 17
17 ± 14
0.527
0.73
Mesopic at 1.5 cpd
Mesopic at 1.5 cpd
20 mg L; 2 mg Z
57 ± 30
63 ± 23
0.618
0.83
10 mg MZ; 10 mg L; 2 mg Z
52 ± 18
76 ± 24
0.003
0.000
Placebo
65 ± 27
75 ± 24
0.201
0.24
Mesopic at 3.0 cpd
Mesopic at 3.0 cpd
20 mg L; 2 mg Z
78 ± 45
74 ± 35
0.792
0.91
10 mg MZ; 10 mg L; 2 mg Z
58 ± 17
88 ± 38
0.003
0.001
Placebo
68 ± 39
96 ± 44
0.101
0.11
Mesopic at 6.0 cpd
Mesopic at 6.0 cpd
20 mg L; 2 mg Z
41 ± 13
53 ± 21
0.06
0.004
10 mg MZ; 10 mg L; 2 mg Z
50 ± 19
77 ± 49
0.14
0.058
Placebo
53 ± 46
63 ± 43
0.58
0.82
Mesopic at 12.0 cpd
Mesopic at 12.0 cpd
20 mg L; 2 mg Z
7 ± 4
9 ± 6
0.198
0.16
10 mg MZ; 10 mg L; 2 mg Z
10 ± 6
33 ± 30
0.040
0.01
Placebo
13 ± 14
21 ± 25
0.400
0.50
Mesopic at 18.0 cpd
Mesopic at 18.0 cpd
20 mg L; 2 mg Z
2 ± 0
2 ± 0
NS
0.17
10 mg MZ; 10 mg L; 2 mg Z
2 ± 9
11 ± 14
0.047
0.021
Placebo
4 ± 5
5 ± 3
0.593
0.28
RM ANOVA—Repeated measures ANOVA across all study visits; NS—non significant (statistic not computed as SE of difference = 0)
*difference between baseline and 6 months (paired samples t test)
**repeated measures ANOVA across all visits
Group 1: n = 11; Group 2: n = 11; Group 3: n = 10
5. Glare Disability
[0150] Mesopic and photopic glare disability improved from baseline across a range of spatial frequencies at three months and at six months. At three months, statistically significant improvements were noted at 12 cpd (p=0.048) for mesopic conditions, and at 1.5 cpd (p=0.023) and 3 cpd (p=0.033) for photopic conditions for Group 2. At six months, statistically significant improvements were noted across a substantially broader set of spatial frequencies for Group 2. Repeated measures ANOVA across all study visits reveals no statistically significant change, at any spatial frequency, in mesopic or photopic glare disability for Groups 1 and 3. The statistically significant improvements in glare disability for Group 2, under both mesopic and photopic conditions, for all spatial frequencies tested (other than 18 cpd) were robust to repeated measures ANOVA. A detailed summary of glare disability results are provided in Table 17.
[0000]
TABLE 17
Glare disability change and significance levels at each spatial
frequency tested under mesopic and photopic conditions
Glare Disability
Glare Disability
T test
RM ANOVA
Group Intervention
at baseline
at six months
p*
p**
Photopic at 1.5 cpd
Photopic at 1.5 cpd
Group 1: 20 mg L; 2 mg Z
56 ± 27
67 ± 20
0.056
0.12
Group 2: 10 mg MZ; 10 mg L; 2 mg Z
50 ± 22
67 ± 22
0.059
0.033
Group 3: Placebo
60 ± 25
74 ± 29
0.134
0.24
Photopic at 3.0 cpd
Photopic at 3.0 cpd
Group 1: 20 mg L; 2 mg Z
84 ± 26
95 ± 31
0.175
0.28
Group 2: 10 mg MZ; 10 mg L; 2 mg Z
86 ± 24
121 ± 34
0.003
0.002
Group 3: Placebo
96 ± 30
97 ± 44
0.964
0.92
Photopic at 6.0 cpd
Photopic at 6.0 cpd
Group 1: 20 mg L; 2 mg Z
114 ± 43
96 ± 37
0.181
0.26
Group 2: 10 mg MZ; 10 mg L; 2 mg Z
91 ± 39
130 ± 40
0.032
0.04
Group 3: Placebo
105 ± 51
112 ± 58
0.644
0.80
Photopic at 12.0 cpd
Photopic at 12.0 cpd
Group 1: 20 mg L; 2 mg Z
34 ± 13
32 ± 14
0.785
0.13
Group 2: 10 mg MZ; 10 mg L; 2 mg Z
42 ± 20
70 ± 25
0.004
0.006
Group 3: Placebo
29 ± 21
62 ± 48
0.06
0.13
Photopic at 18.0 cpd
Photopic at 18.0 cpd
Group 1: 20 mg L; 2 mg Z
17 ± 11
23 ± 12
0.35
0.08
Group 2: 10 mg MZ; 10 mg L; 2 mg Z
33 ± 13
65 ± 20
0.17
0.23
Group 3: Placebo
33 ± 15
46 ± 22
0.41
0.75
Mesopic at 1.5 cpd
Mesopic at 1.5 cpd
Group 1: 20 mg L; 2 mg Z
23 ± 8
45 ± 35
0.08
0.05
Group 2: 10 mg MZ; 10 mg L; 2 mg Z
39 ± 26
58 ± 29
0.08
0.04
Group 3: Placebo
32 ± 24
38 ± 23
0.76
0.25
Mesopic at 3.0 cpd
Mesopic at 3.0 cpd
Group 1: 20 mg L; 2 mg Z
36 ± 10
61 ± 43
0.066
0.06
Group 2: 10 mg MZ; 10 mg L; 2 mg Z
40 ± 14
74 ± 40
0.009
0.02
Group 3: Placebo
54 ± 39
59 ± 46
0.820
0.93
Mesopic at 6 cpd
Mesopic at 6 cpd
Group 1: 20 mg L; 2 mg Z
64 ± 41
90 ± 53
0.15
0.17
Group 2: 10 mg MZ; 10 mg L; 2 mg Z
50 ± 19
77 ± 49
0.07
0.049
Group 3: Placebo
53 ± 46
64 ± 43
0.66
0.71
Mesopic at 12 cpd
Mesopic at 12 cpd
Group 1: 20 mg L; 2 mg Z
5 ± 2
10 ± 17
0.303
0.35
Group 2: 10 mg MZ; 10 mg L; 2 mg Z
5 ± 2
12 ± 8
0.016
0.014
Group 3: Placebo
7 ± 5
10 ± 7
0.238
0.15
Mesopic at 18 cpd
Mesopic at 18 cpd
Group 1: 20 mg L; 2 mg Z
2 ± 0
2 ± 0
0.34
0.44
Group 2: 10 mg MZ; 10 mg L; 2 mg Z
2 ± 1
11 ± 13
0.16
0.21
Group 3: Placebo
4 ± 5
5 ± 3
0.14
0.22
cpd—Cycles per degree
*difference between baseline and 6 months (paired samples t test)
**repeated measures ANOVA across all visits
Group 1: n = 11; Group 2: n = 11; Group 3: n = 10
6. Photostress Recovery Time
[0151] Photostress recovery time did not improve significantly for any of the Groups during the study period (p>0.05 for all). Paired t test analysis revealed, however, that the improvement in PRT for Group 2 (PRT 37 seconds [or 21%] shorter on average at six months compared to baseline) approached, but did not reach statistical significance (t=2.067, p=0.069).
[0152] Ocular straylight measures did not change significantly for any Group (p>0.05 for all). Visual experience and ocular discomfort, as determined by questionnaire and discomfort rating, did not change significantly during the study period for any Group.
[0000] 7. Comparison of Changes in MP with Changes in Visual Performance Parameters
[0153] A comparison was made between changes in macular pigment and changes in visual performance parameters between baseline and 6 months. There was no statistically significant relationship between change in macular pigment and any of the visual performance variables (p>0.05 for all). Table 18 gives the results for photopic (daytime) and mesopic (night-time) contrast sensitivity at 1.5 cpd.
[0154] Table 18 Changes in macular pigment (at 0.25° eccentricity) compared with changes in the following visual performance parameters between baseline and 6 months: BCVA, photopic (daytime) contrast sensitivity, mesopic (night-time) contrast sensitivity, photopic contrast sensitivity under glare conditions, mesopic contrast sensitivity under glare conditions.
[0000]
r
p
Change in MP vs change in BCVA
Group 1 (20 L, 2 Z)
−0.075
0.827
Group 2 (10 L, 10 MZ, 2 Z)
0.09
0.794
Group 3 (placebo)
0.119
0.743
Change in MP vs change in photopic CS (1.5 cpd)
Group 1 (20 L, 2 Z)
−0.104
0.76
Group 2 (10 L, 10 MZ, 2 Z)
−0.154
0.651
Group 3 (placebo)
−0.242
0.5
Change in MP vs change in mesopic CS (1.5 cpd)
Group 1 (20 L, 2 Z)
0.394
0.231
Group 2 (10 L, 10 MZ, 2 Z)
−0.082
0.81
Group 3 (placebo)
−0.179
0.621
Change in MP vs change in photopic GD (1.5 cpd)
Group 1 (20 L, 2 Z)
−0.348
0.294
Group 2 (10 L, 10 MZ, 2 Z)
0.263
0.435
Group 3 (placebo)
0.331
0.351
Change in MP vs change in mesopic GD (1.5 cpd)
Group 1 (20 L, 2 Z)
0.394
0.231
Group 2 (10 L, 10 MZ, 2 Z)
−0.082
0.81
Group 3 (placebo)
−0.179
0.621
Abbreviations: MP = macular pigment; BCVA = best corrected visual acuity; L = lutein; Z = zeaxanthin; MZ = meso-zeaxanthin; CS = contrast sensitivity; cpd = cycles per degree; GD = glare disability.
[0155] Surprisingly, these data show that the observed increases in visual performance parameters were independent of the increases in macular pigment.
Discussion
[0156] In terms of MPOD, there was no significant change at any eccentricity, at 3 or at 6 months, in subjects supplemented with a preparation that does not contain MZ or in subjects given placebo. In contrast, subjects supplemented with all three macular carotenoids exhibited a significant increase in MPOD at 4 of the 5 eccentricities tested, at 3 months and at 6 months.
[0157] The current study demonstrates a novel and important effect of MP augmentation on visual performance among healthy subjects without ocular disease. Across a broad range of testing modalities and conditions, visual performance improved significantly among subjects who exhibited a significant rise in MPOD. Specifically, improvements in contrast sensitivity and glare disability (across virtually all spatial frequencies, and under daytime and nighttime conditions), and improvements in visual acuity, were demonstrated in subjects supplement with all three macular carotenoids, but no such observations were seen in the placebo control subjects or in subjects supplemented with L and Z (but not MZ).
[0158] The data support the view that MP may influence visual performance through its optical filtration effects, as the glare disability test protocol included an LED glare source that exhibited a short wavelength peak emission profile matching the known spectral absorbance of MP. The observed improvements in acuity and contrast sensitivity, however, are less consistent with a solely optical explanation. The stimuli used do, however, contain a relatively small short wavelength component. It is possible, therefore, that MP augmentation results in optical image enhancement through a reduction of the deleterious effects of chromatic aberration and light scatter, and thereby improves visual acuity and contrast sensitivity, even for such spectrally broadband stimuli. It is also possible that the macular carotenoids, which are intracellular compounds, also play a neurobiological role, thereby contributing to, and/or facilitating, optimal neurophysiological performance, and hence visual function (the limits of spatial vision represent the combined influence of optical and neural efficiency limits). This view is supported by observation that there was no correlation between increases in visual performance and increases in macular pigment, suggesting that the MP carotenoids may exert effects on visual performance by a neuro-physiological mechanism.
[0159] In conclusion, we have demonstrated a rapid and sustained rise in MPOD following supplementation with all three macular carotenoids, and this was not observed in placebo-controlled subjects or in subjects supplemented with a preparation lacking MZ. Further, supplementation with all three macular carotenoids resulted in significant improvements in contrast sensitivity and glare disability (under photopic and scotopic conditions) and in corrected distance visual acuity, whereas no such changes were seen in placebo controls or in subjects supplemented with a preparation lacking MZ. These findings have potentially important implications for people engaged in activities where optimization of visual importance is important (especially if operating under bright conditions), and warrant further study.
Example 5
[0160] Effect of a Supplement Containing MZ on Visual Performance in Subjects with an Atypical Distribution of Macular Pigment (a Central Dip)
Subjects and Dosage
[0161] Eight subjects with pre-identified central dips in their macular pigment spatial profile as described in example 2 were recruited into this study. All eight subjects consumed a supplement containing 10 mg L, 10 mg MZ, and 10 mg Z daily for 3 months.
Methods
[0162] Macular pigment optical density (MPOD) was measured as in Example 1 at baseline and after 3 months of MZ supplementation. Letter contrast sensitivity (Thomson Chart) was likewise measured using the method described in Example 3 section 4
Results
[0000]
1. MPOD results: As seen from Table 19 and FIG. 10 , the spatial profile of MP was normalised following supplementation with 10 mg L, 10 mg MZ, and 10 mg Z for 3 months. All subjects responded to this intervention. Statistically significant increases were seen at all eccentricities except for 0.5°.
[0000]
TABLE 19
Eccentricity
Baseline
3 months
p
0.25°
0.51 ± 0.25
0.64 ± 0.21
<0.001
0.5°
0.54 ± 0.25
0.57 ± 0.20
0.140
1°
0.37 ± 0.20
0.43 ± 0.21
0.016
1.75°
0.20 ± 0.12
0.26 ± 0.12
0.008
2. Contrast sensitivity: as seen from Table 20 there was an improvement in contrast sensitivity following supplementation with 10 mg L, 10 mg MZ, and 10 mg Z for 3 months.
[0000]
TABLE 20
Contrast
sensitivity
Baseline
3 months
p
1.2
cpd
2.00 ± 0.15
2.07 ± 0.12
0.103
2.4
cpd
1.86 ± 0.16
2.02 ± 0.19
0.003
6
cpd
1.56 ± 0.19
1.71 ± 0.21
<0.001
9.6
cpd
1.34 ± 0.21
1.46 ± 0.18
0.051
15.15
cpd
1.02 ± 0.16
1.11 ± 0.20
0.035
Example 6
[0165] In one embodiment, the composition of the invention takes the form of a mineral-and vitamin-containing dietary supplement, augmented with MZ, L and, optionally Z. The supplement is formulated as a tablet, with the following composition of active ingredients:—
MZ 5 mg
L 5 mg
Z 1 mg
[0166] Vitamin A 800 micrograms
Thiamin 1.1 mg
Riboflavin 1.4 mg
Vitamin B6 2.0 mg
[0167] Vitamin B12 2.5 micrograms
Folic acid 400 micrograms
Niacin 20 mg
Pantothenic Acid 6 mg
[0168] Biotin 50 micrograms
Vitamin C 80 mg
[0169] Vitamin D 20 micrograms
Vitamin E 12 mg
Calcium 120 mg
Magnesium 60 mg
Iron 14 mg
Zinc 10 mg
Copper 1 mg
[0170] Iodine 150 micrograms
Manganese 3 mg
[0171] Chromium 40 micrograms
Selenium 55 micrograms
Molybdenum 50 micrograms
[0172] The following ingredients may be used as a source of the minerals and vitamins.
[0173] Minerals: calcium carbonate, magnesium hydroxide, ferrous fumarate, zinc oxide, copper sulphate, potassium iodide, manganese sulphate, chromic chloride, sodium selenate, sodium molybdate
[0174] Vitamins: Retinyl acetate, Thiamin mono nitrate, Riboflavin, Pyridoxin hydrochloride, Cyano cobalomin, Folic Acid, Niacin, Calciun-D—pantothenate, D-biotin, Sodium Ascorbate#, Cholecalciferol, D-alpha-tocopherol acetate
[0175] The tablets may conveniently additionally comprise one or more of the following fillers: Malto dextrin, Microcellulose, Hydroxy propyl methyl cellulose, Shellac, Talcum, Gum acacia, Glycerol, Titanium dioxide, Polyfructose
[0176] One tablet (e.g. 500 mg) to be taken per day.
Example 7
Provision of MZ in Egg Yolks for Human Consumption
[0177] Several workers have shown that uptake of L and Z from egg yolks is 2-4 times more efficient than from capsules (Handleman et al, 1999 Am. J. Clin. Nutr. 70, 247-251; Goodrow et al., 2006 J. Nutr. 136, 2519-2524; Johnson 2004, J. Nutr. 134, 1887-1893).
[0178] The objective of this study was to feed hens a mixture of L, MZ and Z to determine the total amount of MZ in the yolk. In addition 24 eggs collected at the end of the experiment were consumed by one subject, one egg/day and the blood MZ composition determined.
Methods
[0179] Eight Bovan Goldline hens were obtained at approximately 18 weeks of age.
[0180] When the hens were producing at least 8 eggs per day in total, the hens were isolated and fed only a commercial meal. The experiment was started 1 week later when a premix containing the mixed carotenoids was added to the meal. The premix provided 250 mg MZ/kg feed with proportions of L 50, MZ 30, Z 20.
[0181] The yolk carotenoids were measured in mixtures prepared from all eggs collected at baseline, three and six weeks.
Preparation of Egg-Yolk Suspensions
[0182] Yolks were individually weighed and mixed with phosphate-buffered saline and made up to 50 ml. Two ml of each suspension was mixed in a separate universal tube for each of the three batches separately and stored at −40 C.
Carotenoid Extraction
(i) Egg Yolk Suspensions
[0183] The egg yolk suspension (0.1 ml) was mixed with 0.15 ml aqueous KOH (25 gl 100 ml water), 0.15 ml absolute ethyl alcohol and 0.1 ml echinenone (internal standard, 0.4 mg/500 ml ethyl alcohol) in a glass extraction tube and incubated at 45 C for 45 minutes.
[0184] Solutions were then cooled and mixed vigorously with 1.5 ml hexane (containing BHT500 mg/l) and centrifuged to separate the hexane and aqueous layers. One ml of the upper hexane layer was transferred to an evaporating tube and the residue was re-extracted with 1.5 ml hexane. After centrifuging, 1.5 ml of the upper layer was removed and the extracts combined and evaporated to dryness under nitrogen at 40 C. The residue was made up to 0.15 ml with mobile phase (see Ultracarb HPLC below) and 0.1 ml was injected onto a Ultra Carb Column for HLPC analysis.
(ii) Plasma
[0185] Blood (10 ml) from a human subject was collected in lithium heparin tubes at baseline, day 12 and day 24 after consumption of one egg per day and centrifuged to provide plasma subsequently stored at −40 C. Plasma, 0.25 ml was mixed with 0.2 ml sodium dodecyl sulphate, 0.4 ml ethyl acetate (internal standard). Hexane containing BHT (1.0 ml) was added and the mixture extracted vigorously for 4 minutes, centrifuged for 10 mins and 0.7 ml of the upper hexane layer removed and evaporated to dryness.
[0186] The residue was made up to 0.1 ml with mobile phase (see HPLC procedure below) and 0.05 ml was injected onto the column.
Liquid Chromatography (HPLC) to Measure L, MZ, Z
[0187] Separation and quantitation of the MZ was achieved using a two column procedure.
[0188] Ultracarb procedure: Extracts prepared as described above were reconstituted in a mobile phase comprising acetonitrile:methanol (85: 15 containing 0.1% triethylamine). Using the same solvent mixture at 1.5 ml/min, extracts were chromatographed isocratically using a 3 micro m Ultracarb ODS column (250×4.6 mm, Phenomenex, UK) and detected using a photodiode-array detector (model 2996, Waters Ltd) to quantify L and Z+MZ at 450 nm. Eluent that coincided with the emergence of MZ+Z was collected from the waste line and evaporated to dryness under nitrogen.
[0189] Chiral chromoatography: The Z+MZ extract was then reconstituted in 0.1 ml of hexane:isopropanol (90: 10) and 50 uL was chromatographed on a 10 micro m Chiralpak®AD column (250×4.6 mm; Chiral Technologies Europe, 67404 Illkirch Cedex, France) to determine the proportion of MZ and Z isomers using gradient elution at 0.8 ml/min starting with 90% hexane and 10% isopropyl alcohol and increasing to 95% hexane in a linear gradient over 30 minutes.
Results
MZ in Egg Yolks
[0190] Mean (SD) weights of the yolks at baseline and at the end of weeks 3 and 6 were 12.29 (0.35), 14.23 (0.87) and 15.73 (0.72) g respectively. The MZ contents of the yolks are shown in Table 21. At baseline only L and Z were present;
[0191] Feeding 250 ppm of the carotenoid mixture for 3 weeks produced egg yolks containing 2.78 mg MZ/yolk of which L was circa 76% Z 13% and MZ 11%. There was no further increase at 6 weeks
Plasma
[0192] The MZ content in plasma from one human subject consuming one egg per day are shown in table 22.
[0193] Baseline total MZ concentration was 0.81 micro mol/litre of which L was 53% Z was 47% and MZ 0%. The concentration of L had almost trebled at day 12 but the concentration then fell to only double the baseline value at day 24.
[0194] The increase in MZ+Z at days 12 and 24 was 30% and 23% respectively and was due solely due to increase in MZ.
Conclusions
[0195] Feeding a mixture of carotenoids to chickens for 3 and 6 weeks increased L+MZ+Z in the egg yolks and in plasma in a subject consuming one egg per day.
[0196] The MZ content per yolk was raised from circa 0.8 mg to 2.8 mg. Since it is known that the absorption of L and Z from egg yolk is enhanced, two or three eggs from chickens fed a mixture of L, Z and MZ could provide sufficient MZ to improve visual performance in the subject, although this was not tested.
[0000]
TABLE 21
MZ contents of egg yolks from chicken fed 250
mg/kg mixed carotenoids micro grams per yolk
Weeks
L
Z
MZ
Total
0
563
278
0
841
3
2100
366
315
2781
6
2260
328
272
2860
[0000]
TABLE 22
MZ contents of plasma in one person consuming one
egg per day (units are micro moles per litre).
Day
L
Z
MZ
Total
0
0.55
0.26
0
0.81
12
1.20
0.28
0.06
1.54
24
1.06
0.25
0.07
1.38
Example 8
The Addition of MZ to Dietary Formulations and VP
[0197] A dry powder formula dietary supplement composition can be prepared by mixing 5 mg MZ, 5 mg L and 1 mg Z with the contents of 4 sachets containing circa 50 g each of “The Cambridge Diet” product, obtained from Cambridge Nutritional Foods Limited, Stafford House, Brakey Road, Corby NN17 5LU, United Kingdom (The Cambridge Diet is a registered trade mark).
Example 9
Fish oils, MZ and VP
[0198] The retina contain a high concentration of Omega 3 fatty acids which are especially abundant in fish oils, for example oils from salmon, herring, mackerel, anchovies, sardines; also from krill and green-lipped muscles. Omega 3 fatty acids are found as eicosapentanoic acid C22.6n-3 (EPA) and docosahexanoic acid C22.6n-3 (DHA) and combined make up about 30% of fish body oil. The acceptable daily macro nutrient dose (AMND) of EPA+DHA is about 1.6 g/day for men and 1.1 g/day for women, i.e. about 5 g and 3.5 g fish oil respectively.
[0199] The occurrence of a high concentration of omega 3 fatty acids in the retina suggests that they may play and important role in vision. A combination of macular carotenoids (MC) containing MZ with omega3 fatty acids would thus be beneficial to the retina and improve visual performance. The mixture can be in capsules or as an emulsion in a sachet. The latter has the advantage that fewer doses can be given in a sachet whilst several large capsules (which many elderly people find difficult to swallow) are needed for the AMND. The emulsion can contain from 25-60% fish oils to provide from 0.5-2.0 g omega-3 fatty acids and sufficient MC to give a daily dose of 0.5 mg to 50 mg MC per day.
[0200] A commercial preparation of active macular carotenoids (MC) consisting of mesozeazanthin 10 g lutein 10 g and zeaxanthin 2 g in 78 ml krill oil is mixed with 900 ml salmon oil and made into soft gel capsules each containing 1 g oil formulation. A daily dose of 5 capsules will provide the 1.5 g of Omega 3 fatty acids and a 22 mg dose of macular carotenoids to improve visual performance.
[0201] An alternative embodiment may be formulated as follows:
[0000]
Ingredients
The mixture of and MC, krill
55%
and salmon oils as above
Water
35%
Sucralose (Splenda ™)
4%
Milk powder
5%
Potassium sorbate
0.1%
Alpha tocopherol
0.1%
Flavorings (e.g. citrus)
0.8%
[0202] An emulsion is made under an inert atmosphere using standard techniques and then packed into airtight sachets each containing 5 grams emulsion. The daily dose is 2 sachets per day containing 6 g omega 3 fatty acids and 22 mg MC.
|
Disclosed is a composition comprising MZ for use as a dietary supplement or food additive for oral consumption for improving the visual performance of a human subject.
| 0
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CROSS-REFERENCE TO A RELATED APPLICATION
[0001] This application is a continuation of International Patent Application Number PCT/EP2011/058021, filed on May 18, 2011, which was published in German as WO 2011/144648. The foregoing international application is incorporated by reference herein.
BACKGROUND
[0002] The invention relates to an airbag arrangement for a vehicle occupant restraint system.
[0003] Airbag arrangement arrangements comprising an inflatable airbag and a gas generator arranged at a gas generator carrier for inflating the airbag are know from the prior art. The airbag is covered by means of a housing part (in particular in the form of an airbag cap) at least at a side facing towards the vehicle interior, wherein the airbag cap is connected to the gas generator carrier.
SUMMARY
[0004] The problem to be solved by the invention is to provide an airbag arrangement permitting to realize a stable connection between the housing part and a gas generator carrier and which nevertheless requires little space.
[0005] According to an exemplary embodiment of the invention an airbag arrangement for a vehicle occupant restraint system is provided, comprising
an airbag inflatable for protecting a vehicle occupant; a gas generator for inflating the airbag; a gas generator carrier at which the gas generator is arranged; a housing part which—with regard to the state of the airbag arrangement installed in the vehicle—covers the airbag towards the vehicle interior, wherein the housing part comprises at least one latching element and the gas generator carrier comprises at least one latching opening assigned to the latching element, the housing part can be connected to the gas generator carrier by inserting the latching element into the latching opening along an insertion direction up to a latching position, where the latching element reaches behind a blocking element adjacent the latching opening and connected to the gas generator carrier such that pulling the latching element out of the latching opening is counteracted, the blocking element is configured in such a way that it at least in sections presses against the latching element in a direction running obliquely or transversely to the insertion direction when a tensile force opposite the insertion direction is exerted on the latching element in latching position, and the blocking element comprises a first and a second subsection, wherein the first subsection is connected to the gas generator carrier and via a curvature to the second subsection such that the blocking element is designed at least approximately U- or V-shaped in cross section.
[0014] The blocking element thus in particular is configured in such a way that it presses against the latching element if it is attempted to remove the locked housing part from the gas generator carrier such that the blocking element is blocked by the latching element, and for example, a deformation (e.g. bending) of the blocking element is prevented. In particular, a tensile force exerted on the latching element during an attempt to remove the housing part is deflected at least partially towards the latching element by the blocking element in such a way that it is held by the latching element itself. In other words, a self-locking latching connection of the housing part on the gas generator carrier is realized.
[0015] The blocking element also is designed flexible in such a way that it will be at least in section pushed aside during insertion of the latching element into the latching opening such that the diameter of the latching opening increases and in particular a latching portion of the latching element whose dimensions are larger than the dimensions of the latching opening in the initial state can be inserted through the latching opening. After insertion of the broader latching portion of the latching element, the blocking element returns to its original position such that the latching portion of the latching element engages behind the blocking element.
[0016] The gas generator carrier, in particular, is configured in such a way that it extends along a main extension plane, i.e. it has its largest extension along a plane. It is, of course, conceivable that the gas generator carrier comprises structures protruding away from the main extension plane, i.e. the gas generator carrier may, of course, have a certain extension perpendicular to its main extension plane. For example, the gas generator carrier comprises a side wall extending along its outer circumference.
[0017] The latching opening (or the multiple latching openings) according to an example of the invention is not arranged in a side wall area orientated perpendicular to the main extension plane but in a portion of the gas generator carrier extending parallel to the main extension plane such that the insertion direction, along which the latching element (or the multiple latching elements) of the housing part is to be inserted into the latching opening, at least approximately extends perpendicular to the main extension plane of the gas generator carrier. The possibility to arrange the latching connection not in a side wall of the gas generator carrier but in an area orientated parallel to the main extension plane permits, for example, the elements (latching elements, blocking elements, latching opening) of the latching connection to have relatively low space requirements.
[0018] In particular, if a plurality of latching openings is provided, these can be arranged in a common plane.
[0019] It is, of course, also possible that the latching opening (or at least some latching openings) is arranged in a structure orientated obliquely or perpendicular to the main extension plane of the gas generator (e.g. a wall protruding from a bottom area of the gas generator carrier or a side wall) such that the insertion direction points obliquely or parallel to the main extension plane of the gas generator carrier.
[0020] Further more, the gas generator carrier may comprise structures, for example, an opening, for arranging the gas generator at the gas generator carrier. For example, the gas generator carrier comprises a longitudinal bulging in which a tube gas generator can be arranged. It is, however, also conceivable that the gas generator is configured to receive a pot gas generator and for this, for example, comprises an, especially circular (for example central), opening.
[0021] The airbag arrangement according to the invention can, in particular, be used in a driver airbag module. Accordingly, the invention also relates to a driver airbag module comprising the airbag arrangement described above.
[0022] The housing part, in particular, is designed in the form of an airbag cap which covers the airbag with a dome-like (hollow hemisphere-like) bulge, wherein the bulge faces away from the gas generator carrier and wherein a front side of the airbag cap faces towards the gas generator carrier or bears against it when the airbag cap is locked to the gas generator carrier.
[0023] If multiple latching openings are arranged in the gas generator carrier, they are, for example, arranged along an outer circumference of the gas generator carrier, wherein, for example, at least some of the latching openings have a constant distance from one another. Accordingly, multiple latching elements are provided at the housing part. The latching openings, for example, have a rectangular cross section, wherein, in particular, they are orientated in such a way that the long sides extend along the circumferential direction.
[0024] The latching opening, in particular, is limited by a rim formed by the gas generator carrier and the blocking element. Especially, a surface of the blocking element extending obliquely to the gas generator carrier (i.e. to its main extension plane) limits the latching opening.
[0025] According to an example, which is not part of the invention, the blocking element, for example, extends at least in sections at an angle to the gas generator carrier, i.e. the blocking element is angled with respect to the main extension plane of the gas generator carrier in such a way that extends towards the latching elements in the latching position and not away from the latching element (see FIG. 1B ).
[0026] Exemplarily, the blocking element in such a design, which is not part of the invention, does not comprise a curvature connecting two sections of the blocking element, but rather is connected to the gas generator carrier via a curvature, only. More particularly, the blocking element is bent away from the gas generator carrier in such a way that during an attempt to pull the latching element out of the latching opening, the latching element presses against a portion of the blocking element so that the blocking element experiences a torque around a point in the region of the curvature. Thereby, it is pivoted (bent) towards the latching element until it bears against another portion of the latching element such that the pivot movement of the blocking element is blocked. Therefore, a withdrawal of the latching element from the latching opening is prevented or at least counteracted.
[0027] According to another non-inventive example, the blocking element can be bent away from a side of a gas generator carrier to be turned towards the housing part and can be exclusively turned away in a direction facing away from the housing part. In particular, according to this variant, the blocking element is located mainly or completely on a side of a gas generator carrier that is to be turned away from the housing part, which in the assembled state of the gas bag arrangement faces away from the airbag. For example, the blocking element comprises a front side extending at least approximately parallel to the gas generator carrier, wherein the latching element in its latching position bears against the front side or will be brought into contact with the front side of the blocking element when a tensile force opposite the insertion direction is exerted on the latching element.
[0028] Thereby, the blocking element, as described above, is moved towards the latching element in a direction perpendicular or inclined to the insertion direction until it presses against a section of the latching element different from the portion bearing against the front side or, if it already bears against this section before exerting the tensile force, presses stronger against this section of the latching element. The force induced into the blocking element via the latching element, is thus at least partially held by a section of the latching element. In this case, for example, a rim section of the latching opening can bear against the latching element and can provide a counter-bearing for the latching element. For example, this “counter-bearing” rim section of the latching opening is arranged opposite to a rim section of the latching opening that is formed by the blocking element and that under tensile load on the latching element presses against the latching element.
[0029] According to an exemplary embodiment of the invention, the blocking element comprises a first and a second subsection, wherein the first subsection is connected to the gas generator carrier. The first and the second subsection are connected to one another via a curvature. According to an embodiment of the invention, the blocking element thus has an essentially U- or V-like shaped cross-section. The blocking element thus comprises exactly one curvature, which connects the two subsections of the blocking element to one another. In this case, the curvature of the U forms the curvature by which the first subsection (the arms of the “U”) of the blocking element is connected to the second subsection.
[0030] In particular, the curvature via which the first and the second subsection are connected to one another is located on a side of the gas generator carrier that is to be turned towards the housing part. However, the second subsection, for example, comprises a front side that at least approximately extends parallel to the gas generator carrier (i.e. its main extension plane) against which the latching element in its latching position or at least when a tensile force is exerted on the latching element bears against.
[0031] Exemplarily, the front side of the second section of the blocking element is positioned in such a way that it is aligned with a side of the gas generator carrier that is to be turned towards the housing part, i.e. it approximately is located in a plane together with this side of the gas generator carrier. It is, however, also conceivable that the second section of the blocking element is configured in such a way that the front side, which the latching element in latching position or under tensile force bears against, is not positioned in the plane of the side of the gas generator carrier that is to be turned towards the housing part, but is located, for example, more or less away from the housing part.
[0032] Further more, the connection of the first subsection of the blocking element to the gas generator carrier can comprise a reinforcement (for example, in the form of a thickening of the gas generator carrier or of a reinforcement material), in order to prevent that the blocking element upon exertion of a tensile force on the latching element opposite the insertion direction, i.e. under the exertion of a pressure on the second section of the blocking element against the insertion direction, mainly bends away from the gas generator carrier in the region of the connection to the gas generator carrier. In particular, the connection between the first subsection of the blocking element and the gas generator carrier is so stable that the second subsection, when a pressure is exerted on the second subsection (via the latching element) against the insertion direction, bends away from the first subsection mainly or exclusively in the region of the curvature.
[0033] According to another exemplary embodiment of the invention, the blocking element is integrally formed with the gas generator carrier. In particular, the gas generator carrier is a plastic part to which the blocking element is moulded. For example, the gas generator carrier and the blocking element are fabricated by injection moulding.
[0034] According to another exemplary embodiment of the invention, the latching element comprises a latching portion in the form of a protrusion which in latching position of the latching element is located on a side of the gas generator carrier that faces away from the housing part and that, for example, bears against the blocking element. Exemplarily, the latching element in latching position reaches through the latching opening in the gas generator carrier with a first section, wherein the first section extends essentially perpendicular to the gas generator carrier. At an ending of this first section, which reaching through the latching opening, a second section is arranged forming the protrusion, wherein the protrusion protrudes from the first section of the latching element along the gas generator carrier (with respect to the locked state).
[0035] The protrusion with an upper side, i.e. a side facing opposite the insertion direction, forms a bearing surface which (with respect to the latching position of the latching element) extends at least approximately parallel to the main extension plane of the gas generator carrier. Subsequently, the bearing surface of the protrusion during an attempt to pull the latching element out of the latching opening will be pressed against the blocking element, in particular against its front side, which e.g. also at least approximately extends parallel to the main extension plane of the gas generator carrier.
[0036] For example, the front side (bearing surface) of the blocking element, against which the latching element in latching position bears against or against which it will be pressed when a tensile force is exerted on the latching element, extends inclined to the main extension direction of the blocking element and parallel to the main extension plane of the gas generator carrier, respectively. In other words, the blocking element (or the portion of the blocking element that forms the bearing surface) can run inclined to the gas generator carrier, wherein, however, the bearing surface, which is formed at an ending of the blocking element, extends parallel to the gas generator carrier and thus, in particular, parallel to a bearing surface of the latching element.
[0037] The latching opening according to another exemplary embodiment of the invention comprises an at least approximately rectangular cross section, wherein it is referred to the cross section which extends in the main extension plane of the gas generator carrier. It is, of course, also conceivable that latching openings having another geometry are provided. Furthermore, it is, of course, also possible that multiple latching openings having different geometries and multiple latching elements configured accordingly are used.
BRIEF DESCRIPTION OF THE DRAWINGS
[0038] The invention will be discussed in more detail in the following by means of embodiments with reference to the Figures.
[0039] FIG. 1A shows a perspective view of an example of an airbag arrangement which does not form part of the invention.
[0040] FIG. 1B shows a sectional view of a detail of the airbag arrangement of FIG. 1A .
[0041] FIG. 2A shows a sectional view of a part of the airbag arrangement according to an embodiment of the invention before the assembly of the housing part and the gas generator carrier.
[0042] FIG. 2B shows the gas generator arrangement of FIG. 2A in perspective view.
[0043] FIG. 3A shows a sectional view of the gas generator arrangement of FIG. 2A in the locked state.
[0044] FIG. 3B shows a detail of FIG. 3A .
[0045] FIG. 4A shows a top view of a gas generator carrier of an airbag arrangement according to the invention
[0046] FIG. 4B shows the gas generator carrier of FIG. 4A in perspective view.
DETAILED DESCRIPTION
[0047] According to FIG. 1A , an airbag arrangement 1 comprises a housing part in the form of an airbag cap 2 configured to cover an airbag (not shown). The airbag arrangement further more comprises a gas generator carrier 3 configured for receiving a gas generator (not shown). The airbag cap 2 will be connected to a gas generator carrier 3 after arranging the gas generator and the airbag.
[0048] For connecting the airbag cap 2 to the gas generator carrier 3 the airbag cap 2 comprises a plurality of latching elements 21 which are inserted into corresponding latching openings 31 of the gas generator carrier 3 . The latching elements 21 , in turn, comprise a latching portion 211 formed as a protrusion, the latching portion protruding from a vertical section 25 of the latching element 21 extending essentially along the insertion direction (i.e. perpendicular to the gas generator 3 ) and reaching through the latching opening 31 in latching position. After complete insertion of the latching elements 21 in the respective latching opening 31 , in each case the protrusion 211 engages behind a blocking element 4 which is integrally formed with the gas generator carrier 3 and which forms a section of the rim of the latching opening 31 .
[0049] The latching elements 21 are also integrally formed with the airbag cap 2 , wherein the latching elements in particular are provided at an inner circumferential partition wall of the airbag cap. The inner partition wall extends in a distance from an outer circumference of the airbag cap and can also be configured to mechanically stabilize the airbag cap.
[0050] The blocking element 4 is integrally connected to the gas generator carrier 3 via a curvature 41 , wherein because of the curvature 41 it is bent away from the gas generator carrier 3 in such a way that it extends increasingly inclined to the main extension plane of the gas generator carrier 3 and in the latching position of the latching element shown in FIG. 1B bears against a bearing surface 2111 of protrusion 211 of the latching element 21 with a front side 411 when it is attempted to pull the latching element 21 out of the latching opening 31 against the insertion direction.
[0051] The blocking element 4 furthermore is elastically connected to the gas generator 3 via the curvature 41 in such a way that it bends away from the opposite rim of the latching opening 31 during the insertion of the latching element 21 in the latching opening 31 and thus enlarges the diameter of the latching opening 31 such that the protrusion 211 of the latching element 21 can be fed through the latching opening 31 . After having fed through the protrusion 211 the blocking element 4 snaps back towards the latching element 21 (e.g. in its initial position) such that it e.g. bears against the vertical section 25 , e.g. extending parallel to the insertion direction, of the latching element 21 or against another section of the airbag cap 2 . In particular, the front side 411 and the bearing surface 2111 of the protrusion 211 of the latching element 21 are located at least approximately parallel and opposite to one another. This, however, is not necessary; the front side 411 can also be arranged at an angle relative to the bearing surface of protrusion 211 .
[0052] Thus, the curvature 41 on the one hand permits to bend away the blocking element during insertion of the latching element 21 in the latching opening 31 and on the other hand the blocking element 4 is orientated via the curvature 41 in such a way that, when a tensile force is exerted on the latching element 21 against the insertion direction, it moves in a direction perpendicular to the insertion direction towards the latching element 21 (in particular its vertical section) or another section of the airbag cap 2 until it presses against the latching element 21 or the section of the airbag cap 2 so that further (pivot) movement of the blocking element is prevented. In other words, the blocking element 4 is bent away around a pivot point in the region of the curvature 41 against the insertion direction when a tensile force is exerted on the latching element 21 until it rests on the vertical section of the latching element.
[0053] In particular, because the latching element 21 is supported by a rim portion 32 of the latching opening 31 of the gas generator carrier opposite the blocking element 4 a bending of the blocking element 4 during withdrawal of the latching element 21 is efficiently blocked. In other words, the blocking element 4 is self-locking since an attempt to pull out the latching element 21 from the latching position leads to an increasing blocking of the blocking element.
[0054] FIGS. 2A , 2 B and 3 A, 3 B relate to a refined airbag arrangement according to an embodiment of the invention, wherein FIGS. 2A and 2B relate to the unlocked state, whereas FIGS. 3A and 3B illustrate the airbag cap 2 being locked to the gas generator carrier 3 . FIGS. 2A , 3 A and 3 B are sectional views of the airbag arrangement, wherein FIG. 2B is a perspective view of the airbag arrangement.
[0055] The covering cap of the embodiment according to the invention corresponds to the carrying cap of FIGS. 1A and 1B . In contrast to FIGS. 1A and 1B , however, the blocking element 4 is designed differently: The blocking element 4 in this case comprises a first subsection 42 and a second subsection 43 , wherein the first subsection 42 (e.g. via a curvature 421 ) is integrally connected to the gas generator carrier 3 and via a curvature 41 to the second subsection 43 . In particular, the blocking element 4 also in this embodiment is moulded at the gas generator carrier 3 by means of injection moulding.
[0056] In other words, the blocking element 4 at least approximately is designed U-shaped in cross section, wherein the first and the second subsection 42 , 43 represent the two arms of the U and the curvature 41 a connection between the two arms. The blocking element 4 is orientated in such a way that the curvature 41 is located on a side (upper side) 33 of the gas generator carrier 3 which is to be turned towards the airbag cap 2 , i.e. on a side that in the locked state of the airbag cap 2 and the gas generator carrier 3 faces towards the airbag cap 2 . The blocking element 4 is formed flap-like, i.e. it comprises a longitudinal extension (parallel to the gas generator carrier) orientated perpendicular to the U-shaped base area.
[0057] Subsequently, according to the embodiment shown in FIGS. 2A , 2 B and 3 A, 3 B the blocking element 4 protrudes as a bulged portion from an essentially planar side of the gas generator carrier 3 facing towards the airbag cap 2 (the housing part) towards the airbag cap 2 .
[0058] The latching elements 21 of the airbag cap 2 , as already mentioned, are designed analogously to the latching elements 21 of FIGS. 1A and 1B , i.e. they comprise a vertical section 25 which in latching position reaches through the latching opening 31 of the gas generator carrier 3 , wherein a protrusion 211 having a bearing surface 2111 and engaging behind the blocking element 4 protrudes from section 25 . Because the second subsection 43 is connected to the first subsection 42 via the curvature 41 , the second subsection 43 has a certain flexibility such that when the latching element 21 is inserted into the latching opening 31 in insertion direction A the protrusion 211 presses against a surface of the second subsection 43 facing away from the first subsection 42 . Thus, the second subsection 43 is moved towards the first subsection 42 such that the dimensions (the width of the essentially rectangular) latching opening 31 enlarge and the protrusion 211 of the latching element 21 can be fed through the latching opening 31 . For example, the distance b between the curvature 41 and the front edge of the second subsection 43 , which limits the rim portion of the latching opening 31 , is at least 1.5 times the width a of the second section 43 (measured perpendicular to its longitudinal extension, i.e. perpendicular to the insertion direction A).
[0059] If the latching element 21 reaches its latching position, the second subsection 43 snaps back such that a front side 4221 of the second subsection 43 —viewed against the insertion direction A—is located above the bearing surface 2111 of protrusion 211 of the latching element 21 . The front side 4221 of the second subsection 43 forms a bearing surface that is in contact or gets in contact when a tensile force is exerted on the latching element with the bearing surface 2111 of protrusion 211 of the latching element.
[0060] Further more, the second subsection 43 is orientated in such a way that, when the latching element 21 is in its latching position, it extends slightly inclined relative to the insertion direction A so that its ending connected to the first subsection 42 via the curvature 41 has a larger distance to the locked latching element 21 that its ending (forming the front side 4221 ) that faces away from the curvature 41 . Therefore, the second subsection 43 experiences a deflection (in particular around a pivot point positioned in the region of the curvature 41 ) towards the vertical section of the latching element 21 or another section of the airbag cap 2 (see FIG. 3B ), when a tensile force in a direction B opposite the insertion direction A is exerted on the latching element 21 . The deflection of the second subsection 43 is indicated by arrow “C” in FIG. 3B .
[0061] The vertical section of the latching element 21 thus blocks a further bending of the second subsection 43 which is assisted by the fact that the vertical section of the latching element is supported by a rim section of the latching opening 31 opposite the second subsection 43 of the blocking element 4 . It is also possible that the second subsection 43 of the blocking element 4 in the latching position of the latching element 21 already presses against the vertical section of the latching element 21 reaching through the latching opening 31 such that during an attempt to pull the latching element 21 out of the latching opening 31 a further pivot movement of the second subsection 43 towards the latching element 21 is not possible anymore. The blocking element, i.e. the second subsection 43 , nevertheless, experiences a force component towards the vertical section of latching element 21 such that it will increasingly press against the section of the latching element 21 reaching through the latching opening 31 .
[0062] The at least essentially rectangular front side 4221 of the second section 43 of the blocking element 4 in the initial position, i.e. before locking the airbag cap to the gas generator carrier, extends essentially parallel to the gas generator carrier although the second section itself, as mentioned above, is orientated inclined to the gas generator carrier. According to an example, the front side 4221 even at least approximately is located in a plane together with a section of a lower side of the gas generator carrier 3 facing away from the upper side 33 and adjacent the blocking element 4 . In such an example, thus, the end of the second, inclined subsection 43 can be aligned with the (lower) side of the gas generator carrier 3 facing away from the airbag cap 2 or the ending is located in the main extension plane of the gas generator carrier 3 on the (lower) side of the gas generator carrier 3 facing away from the airbag cap 2 .
[0063] For example, the front side 4221 comprises a surface (bearing surface) of about 280 mm 2 against which the bearing surface of the protrusion 211 of the latching element 21 presses. The bearing surface is of great importance for the stability of the latching connection. Accordingly, the stability can be increased by arranging a plurality of latching elements.
[0064] The gas generator carrier 3 of the embodiment of FIGS. 2A , 2 B and 3 A, 3 B comprises a plurality of latching openings 31 that are arranged along an outer circumference, which is essentially circularly shaped, wherein the distance between adjacent latching openings 31 is at least partially constant.
[0065] Further more, the gas generator carrier 3 comprises a recess 5 to which a bulge 6 is joined. The recess 5 and the bulge 6 realize a receptacle for a tube-like gas generator (not shown) at the gas generator carrier 3 . The receptacle for the tube gas generator formed by the recess 5 and the bulge 6 is in particular also shown in FIGS. 4A and 4B which illustrate the gas generator carrier 3 of the embodiment of FIGS. 2A , 2 B and 3 A, 3 B, only.
[0066] It is noted that elements of the described embodiments can, of course, also be used in combination. For example, blocking elements according to the embodiments of FIGS. 1A and 1B as well as blocking elements according to the embodiments of FIGS. 2A , 2 B and 3 A, 3 B can be arranged at the gas generator carrier.
[0067] The priority application, German Patent Application Number 10 2010 029 087.4, filed May 18, 2010 is incorporated by reference herein.
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An airbag arrangement for a vehicle occupant restraint system is provided. The airbag arrangement comprising airbag inflatable for protecting a vehicle occupant, a gas generator for inflating the airbag, a gas generator carrier at which the gas generator is arranged, a housing part which—with regard to the state of the airbag arrangement installed in the vehicle—covers the airbag towards the vehicle interior. The housing part comprises at least one latching element and the gas generator carrier comprises at least one latching opening assigned to the latching element. The housing part can be connected to the gas generator carrier by inserting the latching element into the latching opening along an insertion direction up to a latching position. The latching element reaches behind a blocking element adjacent the latching opening and connected to the gas generator carrier such that pulling the latching element out of the latching opening is counteracted.
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RELATED APPLICATION DATA
[0001] This application is a continuation of U.S. patent application Ser. No. 10/448,544, filed May 29, 2003 (published as US 2003-0202681 A1), which is a continuation of U.S. patent application Ser. No. 09/473,396, filed Dec. 28, 1999 (now U.S. Pat. No. 6,577,746). Each of these patent documents are each hereby incorporated by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to data processing, and more particularly relates to use of watermark technology for object substitution.
BACKGROUND AND SUMMARY OF THE INVENTION
[0003] Object linking and embedding (“OLE,” sometimes also known as dynamic data exchange, or “DDE”) is a well-known data processing construct by which a first digital object (e.g., a graph) can be embedded within a second digital object (e.g., a word processing document). In some embodiments, the embedding is static. That is, once the embedding takes place, subsequent changes to the first digital object (e.g., the graph) are not reflected in the second, composite digital object (e.g., the document). In other embodiments, the embedding is dynamic (and thus more commonly termed linking rather than embedding). In such arrangements, if the graph is changed, the document is automatically updated to incorporate the latest version of the graph.
[0004] The technology underlying OLE is sophisticated, but is well understood by artisans in the field. Reference may be made to the many patents (e.g., U.S. Pat. Nos. 5,581,760 and 5,581,686) and reference books (e.g., Brockschmidt, Inside OLE 2, Microsoft Press, Redmond, Wash., 1994) on the subject for further details.
[0005] In accordance with the present invention, OLE-like principles are implemented using watermark data in digital objects in order to effect object linking or embedding.
[0006] In one illustrative embodiment, a photocopier scans an original paper document to produce image data. This image data is analyzed for the presence of watermark data that identifies the graphic(s) on the document. With this watermark identifier, the photocopier can query a remote image database for pristine image data corresponding to the graphic(s) on the document. This pristine data can be relayed from the remote database to the photocopier and substituted into the scanned image data. Output printed from the photocopier is thus based, at least in part, on pristine image data, rather than on image data that has been subjected to various corruption mechanisms (e.g., degradation of the original paper document, artifacts due to scanning, etc.).
[0007] The foregoing and other features and advantages of the present invention will be more readily apparent from the following detailed description, which proceeds with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 shows an apparatus according to one embodiment of the present invention.
DETAILED DESCRIPTION
[0009] Referring to FIG. 1 , an illustrative embodiment of the present invention is a photocopier 10 . The photocopier includes a platen 12 , a scanner assembly 14 , a raw data memory 16 , a watermark decoder 18 , a processor 20 , a network connection 22 , a pristine image buffer 24 , a compositing memory 26 , and a reproduction engine 28 .
[0010] A paper document, such as document 30 , is placed on platen 12 , and scanner assembly 14 is activated to generate scan data corresponding to the document. The scanner assembly is conventional and may include a linear array of CCD or CMOS sensor elements that optically scans along an axis of the platen to generate 2D image data. Alternatively, the scanner can comprise a 2D array of sensor elements onto which an image of the document is projected through one or more lenses. In the illustrated embodiment, the document 30 includes a picture 31 that is encoded with a plural-bit digital watermark. Document 30 may be referred to as a compound document since it incorporates plural components (e.g., text and picture).
[0011] The scan data from the scanner assembly 14 is stored in the raw data memory 16 , where it is analyzed for the presence of watermark data by the watermark decoder 18 .
[0012] There are many different techniques by which imagery can be digitally watermarked and decoded. One is the Digimarc watermark system detailed, e.g., in U.S. Pat. No. 5,862,260, and in pending application Ser. No. 09/452,023, filed Nov. 30, 1999 (now U.S. Pat. No. 6,408,082), the disclosures of which are incorporated herein by reference. A great variety of other systems are known. All that is required is that the watermark permit the conveyance of plural-bit auxiliary data without objectionable image degradation.
[0013] Upon detection of the watermark in picture 31 , the processor 20 is programmed to initiate communication with a remote server 32 (e.g., over the internet) through the network connection 22 . The programmed processor sends to the server a query message identifying the detected watermark (which may be, e.g., an identifier of 16-64 bits). A database 34 at the server 32 searches its records 37 for a digital object indexed by that watermark ID 39 and, if located, causes a pristine version of the object 38 (in this case a pristine version of the picture 31 ) to be sent to the photocopier.
[0014] In the embodiment illustrated, the database has the pristine version of the object stored within the database record for that watermark ID, and relays same directly back to the photocopier. In other embodiments, the object itself is not stored in the database. Instead, the database stores (in a record associated with the watermark ID) the address of a remote data repository at which the pristine object is stored. In this case the object server 32 can transmit an instruction to the remote repository (e.g., again over the internet), requesting the remote repository to provide the pristine object. The object can be sent directly from the remote data repository to the photocopier, or may be relayed through the object server 32 . In any case, the pristine object may be provided in TIFF, JPEG, GIF, or other format. (In some embodiment, the request signal from the photocopier specifies the format desired, or may specify plural formats that the photocopier can accept, and the pristine object is then output by the server 32 or remote repository in such a format. In other embodiments, the request signal from the photocopier does not include any format data.)
[0015] In some embodiments, the object server 32 can be of the sort more particularly detailed in copending application Ser. Nos. 60/164,619 (filed Nov. 10, 1999), and 09/343,104 (filed Jun. 29, 1999), the disclosures of which are incorporated herein by reference.
[0016] In addition to detecting the ID of any watermark in the scanned image data, the photocopier's watermark detector also discerns the placement of the watermarked picture within the document image, and its state (e.g., size, rotation, etc.), and produces corresponding state information. In some embodiments, this state information is passed to the object server 32 , permitting the pristine object 38 to be sized/rotated/etc. (e.g., by the object server) to match the object detected in the document image. In other embodiments, a generic version of the pristine object is passed back to the photocopier, and the processor 20 attends to sizing, rotating, etc., of the pristine picture 38 as necessary to match that of the original picture 31 .
[0017] In some embodiments the picture 31 in the paper document has been cropped. (The watermark can nonetheless be detected from the cropped image.) When the pristine picture 38 is received from the remote location, it can be pattern-matched to the picture 31 detected in the original document to determine the cropping boundaries (if any), and corresponding cropping of the pristine picture can be effected.
[0018] Once the foregoing scaling/rotation/cropping, etc., adjustments (if any) have been made on the pristine picture 38 stored in buffer 24 , the processed pristine picture is combined with the original document scan data in compositing memory 26 , yielding a composite document image that includes the pristine picture data 38 in lieu of the scanned picture 31 . (The substitution of the pristine picture for the original picture data can be accomplished by various known image processing techniques, including masking, overwriting, etc.) The composite document image is then passed to the reproduction engine 28 to produce a hard-copy output (i.e., an enhanced compound document 30 ′) in the conventional manner. (The reprographic engine 28 can take many different forms including, e.g., xerography, ink-jet printing, etc.)
[0019] The pristine picture 38 received from the server 32 can, itself, be watermarked or not. If watermarked, the watermark will usually convey the same payload information as the watermark in the original picture 31 , although this need not always be the case. In other embodiments, the pristine picture 38 received from the remote server 32 has no watermark. In such case the pristine picture can be substituted into the compound document 30 in its unwatermarked state. Alternatively, the apparatus 10 can embed a watermark into the picture prior to (or as part of) the substitution operation.
[0020] If the substituted picture is watermarked, this permits later watermark-based enhancement or updating. For example, if the enhanced compound document 30 ′ including the pristine picture 38 is printed by the photocopier, and the resulting photocopy is thereafter photocopied, the latter photocopying operation can again substitute pristine picture data for the scanned picture data produced by the second photocopier's scanner. Moreover, in applications where it is appropriate for a picture to be updated with the latest version whenever printed, the watermarking of the picture 38 permits substitution of a latest version whenever the document is scanned for printing.
[0021] In other situations, it is desirable for the picture 38 included in the enhanced compound document 30 ′ to be unwatermarked. This is the case, for example, in certain archival applications where it is important that the document 30 ′ not be changed after archiving. By assuring that the picture 38 is not watermarked, inadvertent changing of the picture in subsequent photocopying can be avoided. (In cases where the pristine image 38 is provided from server 32 in a watermarked state, the photocopier may remove or disable the watermark in response to corresponding instructions from a user through a user interface or the like.)
[0022] From the foregoing, it will be recognized that the illustrative embodiment can produce “photocopies” that are better than the “originals.” This is accomplished by watermark-based substitution of pristine digital objects to replace less pristine counterparts.
[0023] Having described and illustrated the principles of our invention with reference to an illustrative embodiment, it will be recognized the invention is not so limited.
[0024] For example, while the invention is particularly illustrated with reference to a photocopier, the same principles are equally applicable in other systems, including personal computers (e.g., in conjunction with image editing software, such as Adobe Photoshop). In such case the input image data needn't come from a scanner but may come, e.g., from a digital file, from a network location, etc.
[0025] Likewise, while the invention is particularly illustrated with reference to picture (i.e., graphic) data, the same principles are equally applicable in connection with other data types, such as video, sound, text, etc. Moreover, the reference to “documents” is illustrative only; the invention can similarly be employed with any compound object that includes a watermarked component—whether in digital or analog form.
[0026] While the detailed embodiment is described as using separate raw data memory 16 , pristine image buffer 24 , and compositing memory 26 , more typically some or all of these functions are served by a single memory, which may be a computer system's main RAM memory.
[0027] Likewise, while the detailed embodiment employs a processor 20 programmed in accordance with software instructions (e.g., stored in a memory or on a storage medium), in other embodiments some or all of the described functionality can be achieved using dedicated hardware (e.g., ASICs), or programmable hardware (e.g., PLAs).
[0028] Still further, while the invention is illustrated with reference to an arrangement in which a document includes a single watermarked photograph, it will be recognized that plural such watermarked components may be present in a compound document, and the system may be arranged to obtain pristine versions of each, and edit/composite same as necessary as to recreate an enhanced version of the original document.
[0029] Moreover, while the illustrative embodiment contemplates that a watermarked photograph may be a component of the original document, in other embodiments the watermarked object may comprise the entirety of the original document.
[0030] While reference has been made to substitution of pristine image components, in some embodiments it may be desirable to substitute components that are not “pristine.” Indeed, in some embodiments an object may be substituted that is visually dissimilar to the original object. Consider artwork for a Christmas card. The artwork may include a watermarked “generic” corporate logo. When encountered by a computer according to the present invention, the generic logo may be replaced with a logo corresponding to the corporate owner of the computer. In such case, the substitute imagery may be stored within the computer itself, obviating the need for any network connection. The registry database maintained by the computer's operating system may include keys defined by watermark IDs.
[0031] When a watermark ID is encountered, the registry database can be consulted to identify a corresponding graphic that can be substituted into the object being processed. If none is found, the watermark ID can be passed to the remote server 32 .
[0032] While, for expository convenience, the illustrative embodiment was described as always substituting pristine data when available, more typically this is a function that would be enabled or disabled by an operator of the device, e.g., by an appropriate switch, button, or user interface control. In some embodiments, the device may be arranged to query the user when substitution of a pristine component is possible, in some cases presenting the user with a depiction of the image component proposed to be substituted.
[0033] The illustrative embodiment may be said to employ watermark-based object embedding, since the hard-copy output is static (i.e., cannot change) after printing. In other embodiments, the enhanced compound document 30 ′ is not printed, but stored. Each time the compound document is utilized (e.g., opened for editing, or printed), any watermarked component(s) therein can be updated to include the latest-available version(s) of the watermarked component(s). In such case, the document may be said to employ watermark-based object linking.
[0034] In view of the many embodiments to which the principles of our invention may be applied, it should be apparent that the detailed embodiment is illustrative only and should not be taken as limiting the scope of our invention. Rather, we claim as our invention all such modifications as may fall within the scope and spirit of the following claims, and equivalents thereto.
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Digital watermarking is provided in a printed photograph. The digital watermarking includes an identifier. The printed photograph is scanned and the digital watermark is decoded to obtain the identifier. The identifier is used to obtain a substitute image for use when generating a copy of the printed photograph. A user interface can be provided to allow a user to select options prior to printing the copy.
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BACKGROUND OF THE INVENTION
[0001] The subject matter of the present invention relates to a method and apparatus for downhole pipe or casing repair including a corrosion monitoring tool for evaluating the extent of corrosion on an internal surface of a pipe, a surface treatment apparatus, such as a sand blaster, for cleaning the internal surface of the pipe and removing the corrosion, and a plating apparatus for plating a new metallic layer on the internal surface of the pipe.
[0002] Corrosion in an oil or gas well is a problem. Tubing disposed downhole in a wellbore can become corroded with rust and, as a result, it is often necessary to determine the extent of that corrosion on an internal surface of the tubing disposed downhole. Corrosion monitoring tools can determine the extent of that corrosion, however, when the corrosion monitoring tool is disposed downhole, there exists no additional apparatus disposed downhole with the corrosion monitoring tool for concurrently repairing the internal surface of the corroded tubing. Therefore, although it would be desirable to determine the extent of the corrosion on the internal surface of the pipe, there exists no additional apparatus for concurrently repairing the corroded pipe downhole without pulling the pipe out of the wellbore, replacing the pipe, and increasing the rig-time and the resultant costs to a customer.
[0003] Therefore, a need exists to provide a downhole pipe or casing repair apparatus adapted to be disposed in a wellbore which would include a surface treatment apparatus and a plating apparatus in addition to the corrosion monitoring tool, the downhole pipe or casing repair apparatus using the corrosion monitoring tool to monitor the extent of the corrosion on an internal surface of a pipe disposed downhole and, when the corrosion is detected, repairing the internal surface of the pipe by using the surface treatment apparatus to remove the corrosion from the internal surface of the pipe and using the plating apparatus to plate a new metallic layer on the internal surface of the pipe disposed downhole.
SUMMARY OF THE INVENTION
[0004] Accordingly, one aspect of the present invention includes a downhole pipe repair apparatus, comprising: a surface treatment apparatus adapted for cleaning an interior surface of the pipe; and a plating apparatus adapted for plating a new surface on the interior surface of the pipe after the surface treatment apparatus cleans the interior surface of the pipe.
[0005] Another aspect of the present invention includes a downhole pipe repair apparatus, comprising: a surface treatment apparatus adapted for cleaning an interior surface of the pipe; a plating apparatus adapted for plating a new surface on the interior surface of the pipe after the surface treatment apparatus cleans the interior surface of the pipe; and a corrosion monitoring tool adapted for examining the interior surface of the pipe after the plating apparatus plates the new surface on the interior surface of the pipe.
[0006] Another aspect of the present invention includes a method for downhole pipe repair, the method comprising: cleaning an interior of the pipe, and plating a new surface on the interior of the pipe after the cleaning step.
[0007] Another aspect of the present invention includes a method for downhole pipe repair, the method comprising: examining the interior of the pipe, cleaning the interior of the pipe after the examining step, and plating a new surface on the interior of the pipe after the cleaning step.
[0008] Another aspect of the present invention includes a method for downhole pipe repair, the method comprising: examining the interior of the pipe, cleaning the interior of the pipe after the examining step, plating a new surface on the interior of the pipe after the cleaning step, and re-examining the interior of the pipe after the plating step.
[0009] Further scope of applicability of the present invention will become apparent from the detailed description presented hereinafter. It should be understood, however, that the detailed description and the specific examples, while representing a preferred embodiment of the present invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become obvious to one skilled in the art from a reading of the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] A full understanding of the present invention will be obtained from the detailed description of the preferred embodiment presented hereinbelow, and the accompanying drawings, which are given by way of illustration only and are not intended to be limitative of the present invention, and wherein:
[0011] FIG. 1 illustrates a preferred embodiment of the downhole pipe or casing repair apparatus of the present invention;
[0012] FIG. 2 illustrates a more detailed construction of the downhole pipe or casing repair apparatus of FIG. 1 of the present invention;
[0013] FIG. 3 illustrates a detailed construction of the surface treatment apparatus portion of the downhole pipe or casing repair apparatus of FIG. 2 ,
[0014] FIG. 4 illustrates an alternate embodiment of the corrosion monitoring tool of FIG. 1 , FIG. 2 illustrating one embodiment of the corrosion monitoring tool of FIG. 1 , and FIG. 4 illustrating another embodiment of the corrosion monitoring tool of FIG. 1 , and
[0015] FIGS. 5A and 5B illustrate the principle behind the operation of the alternate embodiment of the corrosion monitoring tool of FIG. 4 .
DESCRIPTION OF THE INVENTION
[0016] Referring to FIG. 1 , a downhole pipe or casing repair apparatus 10 , adapted to be disposed inside a tubing or pipe or casing 16 in a wellbore 12 , is illustrated. In FIG. 1 , the downhole pipe or casing repair apparatus 10 includes a corrosion monitoring tool 14 adapted for examining the internal wall of the tubing 16 to determine the extent of any corrosion or rust which may exist on the inside of the tubing 16 , a surface treatment apparatus 18 adapted for cleaning the inside of the tubing 16 when corrosion or rust is determined to exist on the inside of the tubing 16 , a plating apparatus 20 adapted for plating a new metallic layer on the inside of the tubing 16 when the surface treatment apparatus 18 cleans the inside of the tubing 16 , a packer sealing apparatus 22 adapted for sealing off the surface treatment apparatus 18 from the corrosion monitoring tool 14 when the surface treatment apparatus 18 is cleaning the inside of the tubing 16 , and a packer sealing apparatus 23 adapted for sealing off the plating apparatus 20 from the surface treatment apparatus 18 when the plating apparatus 20 is plating the new metallic layer on the inside of the tubing 16 .
[0017] Referring to FIG. 2 , a detailed construction of the downhole pipe or casing repair apparatus 10 of FIG. 1 is illustrated. In FIG. 2 , the downhole pipe or casing repair apparatus 10 includes the corrosion monitoring tool 14 which is owned and operated by Schlumberger Technology Corporation of Houston, Tex. Examples of such corrosion monitoring tools 14 , which are owned and operated by Schlumberger Technology Corporation, include the CPET tool, the METT tool, and the CET tool. The corrosion monitoring tool 14 includes a plurality of fingers 14 a extending from a central conductor 14 b , the fingers 14 a being adapted for contacting the inside 16 a of the tubing 16 and flexing when the corrosion monitoring tool 14 is pushed downwardly or pulled upwardly inside the tubing 16 . During the flexing of the fingers 14 a , an electrical signal is generated in each finger 14 a which is proportional to and representative of the extent of the corrosion which exists on the inside 16 a of the pipe or tubing or casing 16 . The electrical signal from each finger 14 a propagates uphole and is recorded on a log which displays the extent of the corrosion existing on the inside 16 a of the tubing 16 . The downhole pipe or casing repair apparatus 10 further includes a surface treatment apparatus 18 which further includes a cleaning apparatus 18 a adapted for cleaning the inside 16 a of the pipe or tubing or casing 16 and a container 18 b adapted for collecting any corrosive elements which are removed from the inside 16 a of the pipe or tubing or casing 16 when the cleaning apparatus 18 a cleans the inside 16 a of the tubing or casing 16 . A packer sealing apparatus 22 is disposed between the corrosion monitoring tool 14 and the surface treatment apparatus 18 , the packer sealing apparatus 22 sealing off the surface treatment apparatus 18 from the corrosion monitoring tool 14 inside the pipe or tubing or casing 16 when the surface treatment apparatus 18 is cleaning the inside 16 a of the pipe or tubing or casing 16 . The downhole pipe or casing repair apparatus 10 further includes a plating apparatus 20 , the plating apparatus 20 further including an anode 20 a , a cathode 20 b which is the pipe or tubing or casing 16 , and an electrolyte 20 c disposed between the anode 20 a and the cathode 20 b . Note the corroded areas 24 which exist on the inside 16 a of the pipe or tubing or casing 16 . A spacer/centralizer 20 d will centralize the anode 20 a inside the pipe or tubing or casing 16 . The anode 20 a is adapted for depositing a metallic layer on the cathode 20 b via an electrolytic reaction when a voltage “V” is applied across the anode 20 a and cathode 20 b . Assume that the plus side of voltage V is applied to the anode 20 a via a central conductor 21 and the negative side of the voltage V is applied to the tubing or casing ‘cathode’ 20 b . The metallic layer can be either a Nickel (Ni), Chromium (Cr), Iron (Fe), or Copper (Cu) layer. A packer sealing apparatus 23 is disposed between the plating apparatus 20 and the surface treatment apparatus 18 , the packer sealing apparatus 23 sealing off the plating apparatus 20 from the surface treatment apparatus 18 inside the pipe or tubing or casing 16 when the plating apparatus 20 is plating a new metallic layer on the inside 16 a of the pipe or tubing or casing 16 .
[0018] Referring to FIG. 3 , a detailed construction of the cleaning apparatus 18 a of FIG. 2 is illustrated. In FIG. 3 , although the cleaning apparatus 18 a can be either a mechanical cleaning apparatus or an ultrasonic cleaning apparatus, the cleaning apparatus 18 a of FIG. 3 includes a central bore 18 a 1 in which a fluid or sand propagates downwardly in FIG. 3 along a longitudinal axis of the cleaning apparatus 18 a , and a transverse bore 18 a 2 in which the fluid or sand will propagate from the central bore 18 a 1 in a transverse direction with respect to the longitudinal axis of the cleaning apparatus, as shown in FIG. 3 . The cleaning apparatus 18 a of FIG. 3 can be the “Jet Blaster” tool that is owned and operated by Schlumberger Technology Corporation of Houston, Tex. In operation, the Jet Blaster cleaning apparatus 18 a of FIG. 3 will propagate a fluid or sand at a high velocity through the central bore 1 gate and through the transverse bore 18 a 2 , the fluid or sand being blasted against the inside 16 a of the pipe or tubing or casing 16 at the high velocity thereby removing the corroded areas 24 from the inside 16 a of the pipe or tubing or casing 16 . The corrosive elements of the corroded areas 24 will fall into the container 18 b when the corrosive elements are removed from the inside 16 a of the pipe or tubing or casing 16 by the Jet Blaster cleaning apparatus 18 a of FIG. 3 . Referring to FIGS. 4, 5A and 5 B, an alternate embodiment of the corrosion monitoring tool 14 of FIG. 1 is illustrated. In FIG. 4 , the alternate embodiment of the corrosion monitoring tool 14 of FIG. 1 is an Ultrasonic Imaging Tool that uses a single rotating transducer 26 , housed in a sub at the bottom of the tool, to give full coverage of the tubing or casing 16 . In FIG. 4 , the transducer 26 is used to resonate the tubing or casing 16 . The fundamental mode of resonance is analyzed in the received waveform to obtain information regarding the existence of corrosion on the inside 16 a of the pipe or tubing or casing 16 . The Ultra Sonic Imaging Tool of FIG. 4 is owned and operated by Schlumberger Technology Corporation of Houston, Tex. The principle of operation of the Ultrasonic Imaging Tool of FIG. 4 is discussed below with reference to FIGS. 5A and 5B . In FIG. 5A , a sonic monopole transmitter 28 produces positive compressional waves in the tubing or casing 16 on both sides of the transmitter via volumetric expansion and constraction of the transmitter 28 . Compressional waves are generated in the pipe or tubing or casing 16 , the compressional waves propagating longitudinally along the axis of the pipe or tubing or casing 16 . One or more corroded areas 24 on the inside of the pipe or tubing or casing 16 will affect the propagation of the compressional waves which are propagating along the pipe or tubing or casing 16 . A receiver 30 will record the compressional waves which are received from the pipe or tubing or casing 16 , that record produced by the receiver 30 reflecting the extent of the corroded areas 24 which exist on the inside of the pipe or tubing or casing 16 . In FIG. 5B , a sonic dipole transmitter 32 produces a positive shear wave on one side of the pipe or tubing or casing 16 and a negative shear wave on the other side of the pipe or tubing or casing 16 . No net volume change is produced. A positive shear wave propagates longitudinally on one side of the pipe or tubing or casing 16 and a negative shear wave propagates longitudinally on the other side of the pipe or tubing or casing 16 . One or more corroded areas 24 on the inside of the pipe or tubing or casing 16 will affect the propagation of the shear waves which are propagating along the pipe or tubing or casing 16 . A receiver 34 will record the shear waves which are received from the pipe or tubing or casing 16 , that record produced by the receiver 34 reflecting the extent of the corroded areas 24 which exist on the inside of the pipe or tubing or casing 16 . The principle of operation described above with reference to FIGS. 5A and 5B is also discussed in U.S. Pat. No. 5,036,945 to Hoyle et al, the disclosure of which is incorporated by reference into this specification.
[0019] A functional description of the operation of the downhole pipe or casing repair apparatus 10 of the present invention will be set forth in the following paragraphs with reference to FIGS. 1 through 5 B of the drawings.
[0020] Assume that the downhole pipe or casing repair apparatus 10 of FIGS. 1 and 2 , which includes the corrosion monitoring tool 14 , the packer sealing apparatus 22 , the surface treatment apparatus 18 , the packer sealing apparatus 23 , and the plating apparatus 20 , is lowered downwardly into the pipe or tubing or casing 16 , as indicated by downwardly directed arrow 17 in FIG. 2 . In FIG. 2 , in response to the downward movement of the downhole pipe or casing repair apparatus 10 , the fingers 14 a of the corrosion monitoring tool 14 will flex whenever corroded areas 24 are encountered on the inside 16 a of the tubing 16 thereby generating an electrical signal which propagates uphole along the central conductor 21 and records the existence of corroded areas 24 on the inside 16 a of the pipe or tubing or casing 16 . The packer sealing apparatus 22 will seal off the corrosion monitoring tool 14 of FIG. 1 from the surface treatment apparatus 18 and the packer sealing apparatus 23 will seal off the surface treatment apparatus 18 from the plating apparatus 20 , since an electrolyte solution 20 c will be disposed above the packer sealing apparatus 23 inside the pipe or tubing or casing 16 of FIG. 2 . In FIG. 2 , in response to the downward movement of the downhole pipe or casing repair apparatus 10 , when the corrosion monitoring tool 14 is recording the existence of the corroded areas 24 on the inside of the pipe or tubing or casing 16 , and when the packer sealing apparatus 22 and 23 are both firmly sealed against the inside 16 a of the tubing or casing 16 , the cleaning apparatus 18 a of the surface treatment apparatus 18 is busy cleaning the inside 16 a of the pipe or tubing or casing 16 by removing the corroded areas 24 from the inside 16 a of the pipe or tubing or casing 16 . When the corroded areas 24 are removed from the inside 16 a of the tubing or casing 16 by the cleaning apparatus 18 a , the removed corroded areas 24 are deposited into the container 18 b of the surface treatment apparatus 18 . In FIG. 3 , the cleaning apparatus 18 a cleans the inside 16 a of the pipe or tubing or casing 16 by initially rapidly propagating a fluid or sand down the central bore 18 a 1 of the cleaning apparatus 18 a , in FIG. 3 , at a high velocity and then rapidly propagating the fluid or sand transversely through the transverse bore 18 a 2 of the cleaning apparatus 18 a at a high velocity, the rapidly propagating fluid or sand which is transversely propagating in the transverse bore 18 a 2 striking the inside 16 a of the pipe or tubing or casing 16 while the downhole pipe or casing repair apparatus 10 is still moving downwardly inside the pipe or tubing or casing 16 . As a result, the rapidly propagating fluid or sand, exiting the transverse bore 18 a 2 of FIG. 3 , will function as a jet blaster since the fluid or sand will blast against the inside 16 a of the pipe or tubing or casing 16 while the downhole pipe or casing repair apparatus 10 is moving downwardly inside the pipe or tubing or casing 16 of FIG. 1 or 2 . The corroded areas 24 are removed from the inside 16 a of the pipe or tubing or casing 16 , the removed corroded areas 24 being deposited into the container 18 b of the surface treatment apparatus 18 . In addition to or simultaneously with the blasting of the fluid or sand from the transverse bore 18 a 2 of the cleaning apparatus 18 a of FIG. 3 against the inside of the tubing or casing 16 , the inside 16 a of the tubing or casing 16 can be acid washed using an acid solution comprised of approximately 15% of HCL in order to remove any rust from the inside 16 a of the tubing or casing 16 prior to a plating operation using the plating apparatus 20 of FIGS. 1 and 2 . In FIG. 2 , in response to the downward movement of the downhole pipe or casing repair apparatus 10 , when the corrosion monitoring tool 14 is recording the existence of the corroded areas 24 on the inside of the tubing or casing 16 , and when the packer sealing apparatus 22 and 23 are both firmly sealed against the inside 16 a of the tubing or casing 16 , and when the cleaning apparatus 18 a of the surface treatment apparatus 18 is cleaning the inside 16 a of the pipe or tubing or casing 16 , the plating apparatus 20 is busy plating a new metallic surface on the inside 16 a of the tubing or casing 16 . In FIG. 2 , a voltage V is applied across the anode 20 a and the cathode 20 b when an electrolyte solution 20 c is disposed inside the pipe or tubing or casing 16 above the packer sealing apparatus 23 . As a result, due to an electrolytic reaction which is taking place between the anode 20 a and the cathode 20 b in FIG. 2 , a new metallic layer is being deposited on the inside 16 a of the tubing or casing 16 of FIG. 2 , the new metallic layer being deposited over the cleaned areas on the inside 16 a of the tubing or casing 16 where the corroded areas 24 previously existed. The new metallic layer can be either Chromium, Iron, Nickel, or Copper.
[0021] In FIG. 2 , the downhole pipe or casing repair apparatus 10 of FIG. 2 is now moved upwardly inside the pipe or tubing or casing 16 for the purpose of confrmning the repaired pipe or tubing or casing, as indicated by the upwardly directed arrow 19 in FIG. 2 . During the movement upwardly inside the pipe or tubing or casing 16 , the corrosion monitoring tool 14 of FIGS. 1 and 2 will now create a new record of the existence of any remaining corroded areas 24 , if any, on the inside 16 a of the tubing or casing 16 . The fingers 14 a of the corrosion monitoring tool 14 of FIG. 2 will flex when a corroded area 24 is encountered on the inside 16 a of the pipe or tubing or casing 16 . However, in view of the above referenced cleaning operation, wherein the inside 16 a of the pipe or tubing or casing 16 was cleaned by the surface treatment apparatus 18 and the inside 16 a was plated by the plating apparatus 20 , the new record of the inside 16 a of the pipe or tubing or casing 16 that was created by the corrosion monitoring tool 14 will now record the absence of any corroded areas 24 on the inside 16 a of the pipe or tubing or casing 16 .
[0022] Instead of using the electrolytic plating apparatus 20 shown in FIG. 2 , a chemical plating method and apparatus could be used. Electroless or chemical plating is a chemical deposition process autocatalytically occurring on the metal surface without applying electric current in contrast to the conventional electroplating. The deposited metal ions are reduced on the metal surface by reducing agents instead of current. The reducing agents give up electrons to the deposited ions directly forming a metal layer which is coated on the substrate surface. Due to the chemical reaction, the thickness of the coated metal layer is very uniform and accurate as compared with electroplating, especially in connection with a complicated shape of metal parts. Electroless Ni and its alloy (Ni—P) were proven superior in corrosion resistance, especially in a highly corrosive oil and gas production environment, which may contain H2S, CO2 and brine at high pressure and high temperature.
[0023] In addition, instead of using the corrosion monitoring tool 14 shown in FIG. 2 , the corrosion monitoring tool shown in FIGS. 4 and 5 could be used in order to accomplish the function of the downhole pipe or casing repair apparatus 10 of the present invention.
[0024] The invention being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims.
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A downhole pipe or casing repair method and apparatus includes a corrosion monitoring tool adapted for examining an interior of a pipe or tubing or casing to create a record of the condition of said interior of said pipe, a surface treatment apparatus for cleaning said interior of said pipe, a plating apparatus for plating a new surface over the interior of said pipe after the surface treatment apparatus cleans the interior of said pipe, a packer sealing apparatus for sealing the surface treatment apparatus from the corrosion monitoring tool, and another packer sealing apparatus for sealing the plating apparatus from the surface treatment apparatus. The corrosion monitoring tool will examine the interior of the pipe, the surface treatment apparatus will clean the interior of the pipe, the plating apparatus will plate a new surface over the newly cleaned interior of the pipe, and the corrosion monitoring tool will re-examine the interior of the pipe after the plating step is completed. This abstract is provided for the sole purpose of aiding a patent searcher; it is provided with the understanding that this abstract shall not be used to interpret or limit the scope or meaning of the claims.
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BACKGROUND OF THE INVENTION
The present invention relates to a system for controlling an ignition device for vehicles, and more particularly to a system for controlling movement of a key operated movable member of an engine ignition device such that the key operated movable member will not return once the key operated movable member has moved beyond a predetermined position until the vehicle assumes a predetermined condition, even though such return movement is permitted if a manual release member is operated after the vehicle has attained the predetermined condition.
The present invention is applied to a motor vehicle equipped with an engine ignition device operable by a key operated member and a parking mechanism. The parking mechanism is operated when a manual shift lever is placed at a "P" (Parking) position in a motor vehicle with an automatic transmission or when a manual parking brake lever is pulled in a motor vehicle with a manual transmission. The vehicle therefore assumes a predetermined condition where it is forced to stay at a halt and thus it will not move.
Usually, the engine ignition device includes an ignition switch incorporated in a locking device for a vehicle steering mechanism and is operable by a key operated rotatable lock cylinder disposed in a stationary cylinder housing. When a proper key is inserted in a key slot formed in the lock cylinder, the lock cylinder is rotatable from a "LOCK" position to an "ON" position beyond an "ACC" position, and then to a "START" position. The "ACC" position, "ON" position and "START" position correspond to respective operating positions, namely "ACC", "ON" and "START", of the ignition switch. The locking device carries in a housing a locking bolt, such that when it is suitably mounted on a motor vehicle steering column, the bolt may extend into the steering column to lock a steering shaft extending through the steering column. In order to prevent inadvertent rotation of the key operated lock cylinder to the "LOCK" position, the locking device usually comprises a mechanism for automatically blocking the key operated lock cylinder against return movement to the "LOCK" position once the key operated lock cylinder has moved beyond the predetermined position. The blocking mechanism includes a blocking pawl which is movable to a blocking position by means of a rotary cam rotatable with the key operated lock cylinder and retained in the blocking position once the key operated lock cylinder has moved beyond the predetermined position from the "LOCK" position. A manual button is disposed in the vicinity of the hole which can be depressed when the key operated lock cylinder returns to an "OFF" position to move the blocking pawl from its blocking position to a released position. Thus, the key operated lock cylinder can be returned to the "LOCK" position if the manual button is depressed and the key can be removed from the key operated lock cylinder when and only when the key operated lock cylinder has returned to the "LOCK" position.
Drivers' behavior differs from one person to another. For instance a driver may leave the vehicle with the shift lever of the automatic transmission placed at "R" (Reverse) range position rather than returning it to the "P" (Parking) position when the vehicle is parked on a slope. In this case, if he or another person tries to start the engine by inserting the key into the lock cylinder and rotating it to the "START" position, the engine will not start running until the shift lever is returned to the "P" or "N" (Neutral) position.
An object of the present invention is to eliminate this cumbersome operation which would otherwise be required upon re-starting the engine subsequently.
More particularly, an object of the present invention is to provide a system for controlling an ignition device such that a driver of a motor vehicle is always motivated to force the vehicle to stay at a halt before removing a key from a lock cylinder so as to eliminate the above-mentioned cumbersome operation which would otherwise be required upon re-starting the engine subsequently.
SUMMARY OF THE INVENTION
According to the present invention, there is provided in a motor vehicle with a system for controlling an ignition device. This system comprises a key operated movable member; means for automatically blocking the key operated moveable member against return movement once the key operated moveable member has moved beyond a predetermined position, the blocking means including a manual release member; and means for restraining the manual release member from an actuation thereof in releasing the blocking means until the motor vehicle assumes a predetermined condition where it is forced to stay at a halt subsequently after said key operated moveable member has moved beyond said predetermined position.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective diagrammatic view showing a mechanical part of a first embodiment according to the present invention;
FIG. 2 is a fragmentary view partly section through the line II--II of FIG. 1;
FIG. 3 is a control part of the first embodiment according to the present invention;
FIGS. 4(A), 4(B), 4(C), 4(D), 4(E), 4(I), 4(J) and 4(K) are diagrammatic views showing the position of parts with respect to various positions assumed by the rotary cam rotatable with the key operated cylinder;
FIGS. 5(F), 5(G), 5(H), 5(L) and 5(M) are similar diagrammatic views;
FIG. 6 is a time chart;
FIG. 7 is a similar view to FIG. 1 showing a second embodiment;
FIG. 8 is a similar view to FIG. 5(F) showing a third embodiment;
FIGS. 9 and 10 are similar views to FIGS. 1 and 2, respectively and show a fourth embodiment;
FIG. 11 is a similar view to FIG. 1 showing a fifth embodiment;
FIG. 12 is a similar view to FIG. 11 showing different position;
FIG. 13 is a fragmentary section of the embodiment shown in FIG. 11;
FIG. 14 is a diagrammatic view showing the configuration of the rotary cam;
FIG. 15 is a control circuit; and
FIG. 16 is an improved control circuit.
DETAILED DESCRIPTION OF THE INVENTION
Referring now more particularly to the drawings and especially to FIG. 1, a casing 10 shown in phantom line is formed with a bore accommodating therein a stationary cylinder housing 12 and an ignition switch 14. The cylinder housing 12 is secured to the casing 10. A key operated inner cylinder 16 has a key slot 18 and is rotatable in the outer cylinder housing 12 when a proper key (not shown) is inserted into the key slot 18.
A face plate 20 has formed thereon markings such as "LOCK", "OFF", "ACC", "ON", and "START", at positions corresponding to respective operating positions of the ignition switch 14, and is fixed relative to the casing 10.
A blocking mechanism generally indicated by a reference numeral 22 comprises a L-shaped blocking member 24 accommodated in the bore of the casing 10 and extending generally in parallel to the axis about which the key operated cylinder rotates. It is formed with a blocking pawl 26 and axially movable from a rest position as illustrated in FIG. 1 to the left as viewed in FIG. 1 to a blocking position by the control of a rotary cam 28 when the key operated inner cylinder 16 is rotated beyond the "OFF" position (clockwise as viewed in FIG. 1) from the "LOCK" position as illustrated. A manual release button 25 is fixedly connected to the left end, as viewed in FIG. 1, of the blocking member 24.
The rotary cam 28 is attached to the right end, as viewed in FIG. 1, of the key operated inner cylinder 16 to be rotatable therewith. A spindle 30 extends from the right end of the cam 28, as viewed in FIG. 1, to the ignition switch 14 for operable rotational engagement therewith.
A restraining mechanism generally designated by a reference numeral 32 comprises a restraining block 34 carried by the housing 10 for movement in a peripheral direction with respect to the cylindrical housing 12. As best seen in FIG. 2, the restraining block 34 is formed with a dovetail groove 36 receiving therein a projection 38 formed on the inner wall of the casing 10. The block 34 is formed with an inclined guide face 40 slidably engaged with an inclined cam face 42 formed on a reciprocal cam 44. This slidable engagement of the block 34 with the reciprocal cam 44 is maintained by the bias of a spring 46 bearing between the block 34 and the inner wall of the casing 10. The reciprocal cam 44 has one end fixed to an end of a plunger 48 of a solenoid actuator 50 accommodated in the casing 10 and fixedly secured to the inner wall thereof as best seen in FIG. 10. Extending from the opposite end of the reciprocal cam 44 is a guide arm 52 having its end portion engaged with the rotary cam 28. The reciprocal cam 44 is movable between a first position as illustrated in FIGS. 1 and 2 where a detent ball 54 loaded by a detent spring 56 is received in a first detent groove 58 formed in the cam 44 and a second position where the detent ball 54 is received in a second detent groove 60 formed in the cam 44. In the illustrated first position, the restraining block 34 assumes a rest position as illustrated in FIG. 1 and it is out of abutting engagement with the right end of the blocking member 24 as viewed in FIG. 1 allowing axial movement of the blocking mechanism 24. If the reciprocal cam 44 is moved from the first position to the second position, the restraining block 34 is moved against the spring 46 to a restraining position where once the blocking member 24 has assumed the blocking position, the restraining block 34 comes into abutting engagement with the right end of the blocking member 24 as viewed in FIG. 1 and restraining the movement of the blocking member 24 out of the blocking position thereof.
In the illustrated position in FIG. 2, the plunger 48 is in its retracted position. If the key operated cylinder 16 and thus the rotary cam 28 moves from the "LOCK" position beyond the "ON" position, the guide arm 52 is pulled to the left as viewed in FIG. 2 until the reciprocal cam 44 assumes the second position thereof. During this movement, the plunger 48 of the solenoid actuator 50 is pulled from the retracted position thereof to a extracted position thereof. The solenoid actuator 33 is of the type wherein when energized it retracts the plunger 48 to the retracted position thereof but when deenergized it allows the plunger 48 to be pulled out from the retracted position thereof to the extracted position thereof.
Referring to FIGS. 4(A), 4(B), 4(C), 4(D) and 4(E), the rotary cam 28 is further described. FIG. 4(A) is an envelope open diagrammatic view of the cam 28 as viewed from the top in FIG. 1. In this and each of the similar FIGS. 4(B) to 4(E), radially extending guide walls of the rotary cam 28 are designated by shadowed area, and the blocking member 22 and guide arm 52 are illustrated by broken line with their ends designated by dots, for ease of recognition. FIGS. 4(A), (B), (C), (D) and (E) illustrate positions of parts when the key operated cylinder 16 is rotated from the "LOCK" position as shown in FIG. 4(A), "OFF" position as shown in FIG. 4(B), "ACC" position as shown in FIG. 4(C), "ON" position as shown in FIG. 4(D) and to the position "START" as shown in FIG. 4(E). FIG. 4(I) is a view as viewed from the bottom of FIG. 4(A), FIG. 4(J) is a view as viewed from the bottom of FIG. 4(C), and FIG. 4(K) is a view as viewed from the bottom of FIG. 4(D).
In the "LOCK" position as shown in FIGS. 4(A) and 4(I), the blocking pawl 26 has its end engaged with a relatively tall radially extending guide wall 70 and received in a groove 72 formed between the relatively tall guide wall 70 and a relatively low guide wall 74 lying opposite to the guide wall 74. The guide arm 52 has its end engaged with the relatively tall guide wall 70 but will not engage with the relatively low guide wall 74. Two cutouts 76 and 78 are formed through the guide wall 70 to allow passage of the blocking pawl 26 and guide arm 52 through the guide wall 70 during assembly. The relatively tall guide wall 70 is connected with a second relatively tall guide wall 80 which is as tall as the guide wall 70. The axially inward radial surface of the guide wall 70 is connected via an inclined surface with the axially inward radial surface of the guide wall 80. The dimensions of the blocking pawl 26 and the guide arm 52 are chosen such that the blocking pawl 26 is in slidable engagement not only with the axially inward radial surfaces of the guide walls 70 and 80 but also with an axially inward radial surface of the guide wall 74, while the guide arm 52 is out of engagement with the axially inward radial surface of the guide wall 74.
Referring to FIG. 3, a control circuit 86 for selectively energizing the solenoid of the solenoid actuator 50 is described. This control circuit 86 is supplied with three input signals. Among them, a so-called "OFF" position indicative signal, which assumes a high level (Hi) when the key operated cylinder 16 assumes the "OFF" position, is supplied from the ignition switch 14 to terminals A A and C DB of one-shot multivibrators 88 and 90, respectively. Next, a so-called "P" position indicative signal, which assumes a high level (Hi) when the shift lever assumes the "P" (Parking) position, is supplied to terminals C DA and A B of the one-shot multivibrators 88 and 90, respectively. Last, a key insertion indicative signal is derived from a key switch 92 which is closed upon insertion of the proper key into the key operated cylinder 16. When the key switch 92 is closed, a relay 94 is activated to close a pair of relay contacts 96, thus causing a voltage V D to be applied to an automatic voltage regulator (AVR) 98. The AVR 98 serves as a source of constant voltage V CC applied to terminals B A and B B of the one-shot multivibrators 88 and 90, respectively. Output terminals G A and G B of the one-shot multivibrators 88 and 90 are supplied to inputs of a logical OR gate 100 whose output is applied to a base of a transistor 102. When the transistor 102 is rendered ON, an electric current is allowed to pass through the solenoid 50 to energize same owing to the provision of a source of electric power V B .
Referring to FIGS. 4(A) to 4(E), 4(I) to 4(K), FIGS. 5(F) to 5(H), 5(L) and 5(M), and FIG. 6, an operation of this embodiment is described.
The key can be inserted into or removed from the key operated cylinder 16 when key operated cylinder 16 and the rotary cam 28 rotatable therewith is in the "LOCK" position as illustrated in FIG. 4(A). In this position, the blocking pawl 26 and the guide arm 52 are in alignment with the cutouts 76 and 78, respectively. When the key is inserted into the key slot 18, the key switch 92 is closed detecting this insertion of the key, energizing the relay 94 to close the relay contacts 96, thus causing the AVR 98 to apply voltage V CC to the various terminals of the control circuit 86.
When the key operated cylinder 16 is rotated from the "LOCK" position to the "OFF" position, the rotary cam 28 moves to the position as illustrated by FIG. 4(B) and the cutouts 76 and 78 move away from the blocking pawl 26 and the guide arm 52, respectively.
Further rotation of the key operated cylinder 16 to the "ACC" position as illustrated by FIGS. 4(C) and 4(J), the guide wall 80 moves the blocking pawl 26 to the left as viewed in FIGS. 4(B) and 4(C) to the blocking position where the blocking pawl 24 is engaged with the axially inward radial surface of the guide wall 80.
Further rotation of the key operated cylinder 16 to the "ON" position as illustrated in FIGS. 4(D) and 4(K) causes the guide wall 80 to move the guide arm 52 to the right as viewed in FIG. 4(C) to move the cam 44 to the second position thereof, thus pushing the restraining block 34 against the spring 46 to the restraining position thereof where the restraining block 34 is in abutting engagement with the end of the blocking member 24 from which the blocking pawl 26 extends.
Further rotation of the key operated cylinder 16 from the "ON" position to the "START" position as illustrated in FIG. 4(E) causes the guide wall 80 to move in sliding engagement with the blocking pawl 26 and the guide arm 52. The blocking member 24, integral with the blocking pawl 26, is kept at the blocking position by the restraining block 34 in the restraining position and the reciprocal cam 44, integral with the guide arm 52, is retained in the second position by means of the ball retainer 54 (see FIG. 2).
Subsequently, when the key operated cylinder 16 is returned from the "ON" position to the "OFF" position as illustrated in FIG. 5(F), the guide arm 52 moves over the relatively low radial guide wall 74, but the blocking pawl 26 comes into abutting engagement with the boundary end of the guide wall 74. Thus, further return movement toward the "LOCK" position is blocked by this abutting engagement of the blocking pawl 26 with the end of the guide wall 74. In this position illustrated in FIG. 5(F), the restraining block 34 restrains movement of blocking member 24 in a direction to disengage the blocking pawl 26 from the end of the guide wall 74 so that the manual control member 25 will not move the blocking member 24 in such direction even if pressed by a driver.
However, if the shift lever of the automatic transmission is shifted to the "P" (Parking) position, the "P" position indicative signal assumes the high (Hi) level. Since the "OFF" position indicative signal has already assumed the high (Hi) level corresponding to the return movement of the key operated cylinder 16 to the "OFF" position, the signal at the output terminal Q B becomes high (Hi) level for a predetermined time and thus the output of the OR gate 100 turns to the high (Hi) level to render the transistor 102 on for the predetermined time. The trailing half of the time chart shown in FIG. 6 shows the above described behavior of the signals. As a result, immediately after the shift lever is placed to the "P" position, the solenoid actuator 50 is energized for the predetermined time.
If the shift lever has been shifted to the "P" position before the key operated cylinder 16 returns to the "OFF" position, the signal at the output terminal Q A becomes high (Hi) level immediately after the "OFF" position indicative signal turns to the high (Hi) level since the "P" position indicative signal has already assumed the high (Hi) level. The leading half of the time chart shown in FIG. 6 illustrates this behavior of signals. Thus, the solenoid actuator 50 is energized immediately after the return movement of the key operated cylinder 16 to the "OFF" position when the shift lever has been already shifted to the "P" position.
This energization of the solenoid actuator 50 causes movement of the reciprocal cam 44 from the position illustrated in FIG. 5(F) to the position illustrated in FIG. 5(G) or 5(L), permitting the spring 46 to move the restraining block 34 from the restraining position illustrated in FIG. 5(F) to the position illustrated in FIG. 5(G). Small arrows indicated by the character a show the direction of the above-mentioned movements of the parts.
Now, it is possible to press the manual control member 25 to move the blocking member 24 and pawl 26 out of blocking position illustrated in FIG. 5(G) to the position illustrated in FIG. 5(H). Small arrows indicated by reference character b show direction of movement of the blocking member 24 in response to pressing on the manual control member 25. Return movement of the key operated cylinder 16 from the "ON" position as illustrated in FIG. 5(H) to the "LOCK" position is now permitted and the key can be removed from the key operated cylinder when and only when it is in the "LOCK" position.
In the previously described embodiment, the "P" position indicative signal which turns to the high (Hi) level when the shift lever is moved to the "P" (Parking) position has been used as a signal indicative of a predetermined condition of the vehicle where the vehicle is forced to stay at a halt. Alternatively, a "P" position indicative signal which turns to the high level when the manual parking brake has been set to the parking position may be used.
In the control circuit 86, the AVR 98 is used because CMOS integrated circuits are employed. Such AVR may be eliminated if TTL type IC is employed in the control circuit 86. The "OFF" position indicative signal is used as one of input signals to the control circuit 86 using a circuit including the switch 92 specially designed for this purpose. Without the provision of such switch, the "OFF" position indicative signal may be obtained as an output of a logical NAND which has inputs fed with signals indicative of the "ACC" position and "ON" position of the ignition switch 14.
FIG. 7 shows a second embodiment of the present invention. This embodiment is substantially the same as the previously described first embodiment except that an emergency button 110 is connected via a rod 112 to a guide arm 52 integral with a reciprocal cam 44. In case of emergency, pressing the emergency button 112 after a key operated cylinder 16 has returned to the position as illustrated in FIG. 5(F) will cause a restraining block 34 to move out of its restraining position, thus rendering manual control member 25 operable.
FIG. 8 shows a third embodiment of the present invention. This embodiment is substantially the same as the previously described first embodiment except that a restraining block 44 is formed with an inclined surface 116, adapted to be engaged by the end of a blocking member 24 when it is in its restraining position. According to this embodiment, even if the restraining block 44A remains in its restraining position, return movement of a key operated cylinder 16 from the position as illustrated in FIG. 5(F) to the "LOCK" position is permitted by pressing a manual release button 25 to cause the end of the blocking member 24 to abut against the inclined surface 116 of the restraining block 44A, moving the restraining block 44A out of the restraining position after the shift lever has been placed to the "P" position, energizing the solenoid actuator 50 to pull its plunger toward the retracted position thereof.
FIGS. 9 and 10 show a fourth embodiment of the present invention. This embodiment aims at facilitating rotation of a key operated cylinder 16 from the "OFF" position as illustrated in FIG. 4(B) to the "ON" position as illustrated in FIG. 4(D). During this rotation, a guide arm 52, cam 44, plunger 48 have to be pulled. In order to accomplish the above-mentioned aim, a solenoid actuator 50A is received in a bore of a retainer housing 120 with an end wall 122 closing one end of the bore, as distinguished from the first embodiment where the solenoid actuator is secured to the housing 10. In order to resiliently hold the solenoid actuator 50A within the retainer housing 120 a spring 124 has one end securely fixed to the end wall and an opposite end securely fixed to inner end of the solenoid actuator 50A. The spring 124 is chosen such that it will not expand by the reaction created when a retainer ball 58 biases a cam 44 during movement of the cam 44 together with a plunger 40 of the solenoid actuator 50A. Let us consider the unitary movement of the guide arm 52, cam 44 and plunger 48 in a direction toward the extracted position of the plunger during rotation of a key operated cylinder 16 from the "OFF" to the "ON" position and then to the "START" position, see FIGS. 4(B) to 4(E). Since, according to this embodiment, the solenoid actuator 50A can move in such a direction as to extend the plunger 48 due to the action of the spring 124, the manual effort in rotating the key operated cylinder can be lowered.
Referring to FIGS. 11 to 13, a seventh embodiment of the present invention is described. For ease of description, the same reference numerals used in the previously described first embodiment are used to designate substantially the same or similar parts with the character "B" added.
This embodiment is different from the first embodiment in that a solenoid actuator 50B is of the so-called two-position type so that it can selectively retain a plunger 48B and an integral reciprocal cam 44B in a first position as illustrated in FIG. 11 or a second position as illustrated in FIG. 12. A blocking mechanism 22B is different from the blocking mechanism 22 used in the first embodiment in that a blocking member 24B has a crank end portion 130 to which a manual release button 25B is attached. As illustrated in FIG. 11, a restraining block 34B is formed with a recess 132 which receives the crank end portion 130 to allow movement of the blocking member 24B out of a blocking position as illustrated in FIG. 11 upon depressing the manual release button 25B. As best seen in FIG. 13, the blocking member 24B is formed with a first detent groove 134 which receives a detent ball 136 loaded by a spring 138 when the blocking member 24B in the released position and a second detent groove 140 which is adapted to receive the detent ball 136 when the blocking member 24B has moved to the blocking position.
FIG. 14 diagrammatically shows the relationship between the position of a blocking pawl 26B with respect to positions assumed by the key operated cylinder 16B when the key operated cylinder 16B is rotated from the "LOCK" position to the "START" position. It will be readily understood that the blocking mechanism assumes its blocking position once the key operated cylinder 16B has rotated beyond the "ON" position.
Referring now to FIG. 15, a control circuit 150 for the solenoid actuator 50B is explained. This circuit 150 is supplied with the outputs of each of a key insertion indicative switch 152, an ignition switch 154 and a "P" (Parking) position indicative switch 156. The control circuit 150 includes lines 158, 160, 162 and 164, a transistor Tr, and a relay 166.
The function of the key insertion indicative switch 152 is to indicate whether the key is inserted into the key operated cylinder 16B or not. This switch may be expressed for illustration purpose by a set of switch contacts 152a is connected between the line 158 and a battery line 168 connected to a vehicle battery V B . This set of contacts 152a is closed when the key is inserted into the key operated cylinder 16B to connect the line 158 with the line 168. An automatic voltage regulator (AVR) 170 is provided in the line 158. The AVR 170 generates an electric voltage V DD having a 5 volt.
The function of the ignition switch 154 is to detect whether the key operated cylinder 16B is in the "ACC" position or not. Another function is to detect whether the key operated cylinder 16B is in the "ON" position or not. This ignition switch may be expressed by an "ACC" position detecting contacts 154a and an "ON" position detecting contacts 154b. These contacts 154a and 154b are connected to the line 168 in parallel. The "ACC" position detecting contacts 154a are closed when the key operated cylinder 16B is in the "ACC" position or "ON" position to connect the line 160 with the line 168. The "ON" position detecting contacts 154b are closed when the key operated cylinder 16B is in the "ON" position or "START" position to connect the line 162 with the line 168.
The control circuit 150 includes four logical NOR gates 172, 174, 176 and 178. It is to be noted that the function of the NOR gate 178 is to selectively render the transistor Tr ON, and the output of this NOR gate 178 is fed back to one input of the NOR gate 176.
The function of the "P" (Parking) position indicative switch 156 is to detect whether the shift lever is placed at the "P" (Parking) position or not. For this purpose, a select position sensor for sensing the select position by the shift lever, for example, an inhibitor switch, is used. This "P" position indicative switch 156 may be expressed by "P" position detecting contacts 156a connected to a grounded line 180 and they are opened when the shift lever is in the "P" (Parking) position to interrupt connection of the line 164 with the grounded line 180. This line 164 is connected to one input of the NOR gate 174. The other input of this NOR gate 174 is grounded.
The output of the NOR gate 178 is connected with the base of the transistor Tr. The emitter is grounded and collector is connected with one end of a coil 182 of the relay 166. This coil 62 has a function to close a set of normally open contacts 184. Via the normally open relay contacts 184, the solenoid actuator 50B is connected with a line 186 connected with the batter V B via the line 168. A zener diode 188 is connected between the collector and emitter of the transistor Tr.
The operation of this control circuit 150 is explained.
When the vehicle is running, since the key is inserted into the key operated cylinder 16B, the key insertion detecting contacts 152a are closed, the "ACC" position detecting contacts 154a and "ON" position detecting contacts 154b are both closed, and the "P" position detecting contacts 33a are opened because the shift lever is placed out of the "P" position. Under this condition, both of the inputs of the NOR gate 174 are 0 levels. The output of the NOR gate 174 is always 1 level except when the shift lever is in the "P" (Parking) position.
The output of the NOR gate 172 is 0 level because both inputs are 1 levels. Since both of the inputs to the NOR gate 178 are 1 levels and thus the output of the NOR gate 178 is 0 level. Thus, the transistor Tr is rendered nonconductive. Thus, the solenoid actuator 50B is not energized and the plunger 48B is kept at its projected position as illustrated in FIG. 12.
After the vehicle has come to a halt, the shift lever is moved to the "P" (Parking) position. Then, the "P" position detecting contacts 156a are opened. Thus, the input of the NOR gate 174 which is connected with the line 164 turns from 0 level to 1 level. As a result, the output of the NOR gate 174 changes from 1 level to 0 level.
Subsequently, the key operated cylinder 16B is rotated from the "ON" position to the "OFF" position disposed between the "ACC" position and "LOCK" position, the "ON" position detecting contacts 154b are opened and the "ACC" position detecting contacts 154a are opened, too. The line 160 is disconnected from the battery line 168, the input to the NOR gate 172 connected with the line 160 becomes 0 level. Since the other input of the NOR gate 172 is 0 level, the output of the NOR gate 172 becomes 1 level.
Since the input to the NOR gate 176 from the output of the NOR gate 172 is 1 level, the output of the NOR gate 176 becomes 0 level irrespective of the signal level at the other input. This causes a capacitor 200 to discharge current, and thus the input to the NOR gate 178 from the capacitor 200 becomes 0 level from 1 level. The other input to the NOR gate 178 has become 0 level from 1 level because of disconnection of the line 162 from the battery line 168. Thus, the output of the NOR gate changes from 0 level to 1 level. This causes the transistor to become conductive to energize the relay coil 182, closing the relay contacts 184, thus allowing electric current to pass through the solenoid actuator 50B to energize the same. This energization of the solenoid actuator 50B causes the plunger 48B to move from the protruded position as illustrated in FIG. 12 to the retracted position as illustrated in FIG. 11. If in this state, the manual release button 25B is pressed, the key operated cylinder 16B can return to the "LOCK" position and the key can be removed from the key operated cylinder 16B.
When the key is inserted into the key operated cylinder 16B, the charging of the capacitor 200 starts, and thus the input to the NOR gate 178 from the capacitor 200 becomes 1 level. When the key operated lock cylinder 16B is rotated toward the "START" position, the "ACC" position detecting contacts 154a are closed, to cause the input to the NOR gate 172 via the line 160 to become 1 level from 0 level. However, since the "ACC" position detecting contacts 154a are opened again before reaching the "ON" position, the input to the NOR gate 172 via the line 35 returns to 0 level and thus the output of the NOR gate 172 becomes 0 level, causing the output of the NOR gate 176 to become 0 level. This causes discharge of electric current from the capacitor 200, causing the output of the NOR gate 178 to assume the 1 level for a predetermined time, rendering the transistor Tr conductive. As a result, the solenoid actuator 50B moves the plunger 48B to the projected position as illustrated in FIG. 12. Thus, the manual release button become inoperable immediately after the key cylinder 16B has rotated beyond the "ACC" position.
FIG. 16 shows another control circuit 150A which is improved over the control circuit 150 in the provision of a flip-flop 210 between a NOR gate 172 and a NOR gate 176. The D terminal of the flip-flop 210 is connected with a line 158, the R terminal is connected with a line 160, the CK terminal is connected with the output of the NOR gate 172, and the Q terminal is connected with one input 176a of the NOR gate 176.
According to this control circuit, even if the shift lever is moved between the "P" position and any of the other positions when the key operated cylinder 16B is in the "OFF" position, the flip-flop 210 is not reset so that the output at the Q terminal stays in 1 level. Thus, discharge of capacitor 200 will not take place, keeping the output of the NOR gate 178 at 0 level, so that the transistor Tr will not be rendered conductive. Therefore, even if the shift lever is moved from the "P" position, the key cylinder 16B can be returned to the "LOCK" position.
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A system for controlling an ignition device for a a motor vehicle comprises a key operated movable member, a blocking mechanism for automatically blocking the key operated movable member against return movement once the key operated movable member has moved beyond a predetermined position, and means responsive to a predetermined condition of the vehicle for restraining a manual release member of the blocking mechanism from actuation for releasing the blocking mechanism.
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BACKGROUND OF THE INVENTION
The invention relates to a dismantlable scaffold and in particular to a facade scaffold in.
In a known scaffold of this lind (DE196 33 091 A1), latching catches are provided at the end fittings of the individual floor panels and ensure latching of the end fittings on placement of a floor panel on the associated rail section, so that a lifting of the end fittings from the associated rail section is only possible after pivoting of the latching catch into a release position. A design of this kind admittedly ensures that a floor panel is securely held against lifting on the rail section, even without a transverse strut which contacts against its end fittings from above; it is, however, disadvantageous that for this purpose a movable element in the form of a latching catch must be present which has to be actuated by suitable measures by the operator for the lifting and which can be damaged with rough operation on a building site and thereby made partly or wholly inactive.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide a scaffold of the initially named kind in which, on the one hand, the floor panels can be installed on the rail sections and removed from them without problem without the use of movable elements on the rail section and end fitting, and, on the other hand, in the installed position undesired lifting, for example by winding or other lifting forces acting from below, is however avoided, without the end fittings having to be secured by transverse struts of the scaffold lying above them.
The concept underlying the invention is thus to be seen in the fact that simply by a sequence of suitable shifts of a floor panel in the horizontal and vertical direction, a simple installation and removal of the floor panels is, on the one hand, possible with respect to the associated rail sections, and, on the other hand, the floor panels are secured against lifting up-wardly by wind or other forces in the installed state. The lifting of the floor panel required to cancel the security against shifting preferably takes place at one side and indeed in particular at the front.
The security against lifting and/or the security against shifting are preferably formed by abutments.
The depth of insertion of each floor panel is advantageously restricted with the insertion restriction when using a plurality of floor panels arranged behind one another preferably being ensured for the last floor panel by the vertical supports and for the floor panels lying in front of it by the respective rearwardly disposed floor panel.
The security against lifting is expediently realized with a linearly operating bayonet connection between the end fitting and the associated rail section.
An abutment serving for the positioning is also provided in the pull-out direction, at least for the frontmost floor panel, so that on pulling out the floor panel, the position in which the lifting security is cancelled is found without particular attention on behalf of the operator. This abutment is preferably formed by the forwardly disposed vertical supports.
An embodiment of the invention brings the shifting security abutments out of engagement while the lifting security abutments are still active.
Even though it is fundamentally possible for the different abutments to be provided on the same side of the rail section, it is, however, preferred when these abutments are arranged so that the shifting security abutments can be comfortably executed between the rail sections as plates which preferably consist of sheet metal.
Even though a single floor panel can basically be provided between two vertical supports and designed in accordance with the invention, it is, nevertheless, advantageous, to preferably provide two or more floor panels of like design behind one another, because in this way an easier manipulation is possible at greater heights because of the lower weight of the individual floor panel.
Insofar as a plurality of floor panels are provided behind one another, the shifting security abutments of the rear floor panels can be expediently designed differently from those of the front floor panel.
Thus, whereas the shifting security abutments of the front floor panel are so positioned relative to one another that a lifting of the front floor panel is still not possible when they come into engagement, the abutment plates of the rail sections which lie further to the rear are so arranged that on entry into engagement with the positioning abutments of the end fittings, the security against lifting has already been cancelled. This design is possible and expedient because, as long as the front floor panel has not yet been removed, the floor panels lying further to the rear are secured by the same measures as the front floor panel against shifting towards the insertion side into a position which makes lifting possible.
A particularly advantageous further embodiment signals to the operator on inserting the floor panels particularly forcefully, whether these are already latched in place or not. So long as the shifting security abutments are located on the shifting security abutment plates between the rail sections, the floor panel tilts during handling to the front and to the rear so that the operator gets a feeling for the fact that the relevant panel is not yet in its desired position. Only when the shifting security abutment of the end fitting of the abutment plate drops rearwardly into the lowered position does the tilting cease and signal to the user that the floor panel is now located in its final desired position. With a plurality of floor panels arranged behind one another, it is sufficient if only the frontmost shifting security abutment plate is correspondingly designed.
Another embodiment of the invention ensures that the floor panels can also extend up to the region adjacent the vertical supports, so that broad walking surface is present. The design of the invention proves to be particularly expedient here, because it results in a certain overhang of the floor panels beyond the support surfaces on the rail sections, which, when walked on, exert a tilting moment on the floor panels about their longitudinal axis in the sense that they attempt to lift from the rail sections. This is, however, effectively avoided by the security against lifting provided in accordance with the invention so that the over-hang of the floor panels to the front and rear beyond the rail sections does not represent any deterioration of the security in use.
A further embodiment of the invention provide that the opening in the region of the end cutouts, which is present with two floor panels contacting one another, is secured downwardly by the positioning plate, which has the advantage that articles falling through this opening are stopped by the abutment plate.
Another embodiment of the invention makes it possible for the security against lifting to be cancelled by pivoting the floor panel downwardly about one of the rail sections, whereby the relevant floor panel can be lifted off without shifting in the direction of the rail section but rather by simple downward pivoting. In the inverse sense the placement of a floor panel on the rail section is also possible. The pivoting downwardly or upwardly of the floor panels can be made possible by elastic pressing apart of two adjacent vertical support pairs.
A further feature of the invention provides a situation in which a maximum support surface is made available between the end fittings and the associated rail sections.
The present inventor facilitates the placement of a floor panel obliquely from below onto a transverse strut in that the shifting security abutment forms a stop with the rail section, which is to be correspondingly dimensioned, and prevents a shifting of the end fitting beyond the transverse strut and thus prevents a dropping down of the relevant end of the floor panel.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic perspective view of a facade scaffold being assembled in which the invention can be used,
FIG. 2 is a partly sectioned schematic plan view of a scaffold in accordance with the invention in the region of the arrangement of floor panels on a transverse strut provided between two vertical supports,
FIG. 3 is a schematic sectional view in accordance with the line III—III in FIG. 2,
FIG. 4 is a schematic sectional view in accordance with the line IV—IV in FIG. 2,
FIG. 5 is a partial plan view analogous to FIG. 2 during the removal or installation of a floor panel,
FIG. 6 is a schematic side view in accordance with the line VI—VI in FIG. 5,
FIG. 7 is a schematic side view in accordance with the line VII—VII in FIG. 5,
FIG. 8 is a partial plan view analogous to FIGS. 2 and 5, with the front floor panel completely removed and in the stage of removal of a rear floor panel,
FIG. 9 is a schematic sectioned view in accordance with the line IX—IX in FIG. 8,
FIG. 10 is a schematic sectioned view in accordance with the line X—X in FIG. 8, and
FIG. 11 is a sectional view analogous to FIG. 3, but with one of the two illustrated floor panels being pivoted downwardly about the associated rail section.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The same reference numerals designate corresponding components in all Figures.
In accordance with FIG. 1 a facade scaffold is being assembled at a building construction 37 , On the ground 27 four vertical supports 11 are supported via vertically adjustable spindle arrangements 28 in an arrangement with a rectangular base area, the longer side of which extends parallel to the front of the building construction 37 , and are completed by transverse beams 30 provided above head height, longitudinal supports 29 and also diagonal struts 38 to a supporting base framework 41 , which is continued in a suitable manner at the bottom right in FIG. 1, which is not shown in detail. The base framework 41 has no transverse struts in its lower region, i.e. beneath head height, so that a passage can be provided there, for example for pedestrians.
Whereas the rear vertical supports 11 continue upwardly, the front vertical supports 11 are offset to the rear above the transverse beams 30 , so that the spacing between the front and rear vertical supports 11 is more than halved. The vertical supports 11 arranged behind one another, which consist of plugged-together individual elements 11 ′, form, together with horizontal transverse struts 12 extending between them at a vertical spacing, end frames 32 , which, as one can recognize from the top left in FIG. 1, are asymmetrically designed and can be plugged together. In this manner numerous end frames 32 are so plugged together, optionally with the intermediary of individual elements 11 ′ not connected by transverse struts 12 , so that in each case one transverse strut 12 is present per vertical support pair at the vertical spacing of the stories A, B, C, D, E and F that are provided. A total of seven end frame arrangements consisting of end frames 32 assembled vertically above one another, each having a number of transverse struts 12 lying at the same height, are provided along the building construction 37 at uniform intervals.
The narrow sides of rectangular floor panels 13 each provided with end fittings 15 are releasably placed, in the manner which will be described in detail with reference to FIGS. 2 to 11 , on two transverse struts 12 arranged alongside one another in front of the building construction 37 .
The facade scaffold has, furthermore, two forwardly projecting auxiliary scaffolds 33 and 34 respectively.
The front vertical supports 11 at the comers of the base frame 41 can be used at the top for the mounting of suitable further support elements. For the security of persons working on the floor panels 13 , railings 39 , 40 are secured to the vertical supports 11 at a suitable height at the side and also at the end faces.
Curb strips 36 are releasably secured at the bottom, in particular at the side of the floor panels 13 remote from the building construction 37 , and also if required at the side adjacent the building construction 37 and at the end faces, preferably to the transverse struts 12 . The curb strips 36 are intended to prevent tools lying on the floor panels being pushed sideways beyond the floor panels 13 when walked upon and being able to fall down from the facade scaffold.
In accordance with FIG. 1 the stories A, B, C, D are already finished, whereas the stories E, F are being assembled.
In accordance with FIGS. 2 to 4 the transverse struts 12 consist of two rail sections 14 , 14 ′ which are mounted spaced apart and parallel to one another on two individual elements 11 ′ located behind one another of vertical supports 11 by welding or by a releasable type of attachment, which have a substantially C-shaped or inverse C-shaped cross-section, and consist of a vertical strip part 14 a , 14 ′ a respectively, a lower, horizontal, short, reinforcing flange 14 b , 14 ′ b respectively, and an upper horizontal flange 17 , which can have a greater width than the reinforcing flange 14 b , 14 ′ b . In principle the two rail sections 14 , 14 ′ can be connected at the bottom by elongate plates 43 , indicated in broken lines in FIG. 3, to form a constructional unit.
The flanges 14 b , 14 ′ b and 17 of the two rail sections 14 , 14 ′ extend in opposite directions.
In accordance with FIG. 2 the rail sections 14 , 14 ′ are welded at their ends at a spacing K to a vertical support 11 in each case. The mounting could also, for example, be releasable via attachment roses provided on the vertical supports 11 .
Between the vertical planar strip parts 14 a , 14 ′ a of the two rail sections 14 , 14 ′ there extend, in accordance with FIGS. 3, 4 , approximately at half height, at a horizontal spacing, a shifting security abutment plate 18 and a positioning plate 18 ′, which, in accordance with FIG. 4, can extend substantially horizontally, or can rise slightly from the insertion side 21 towards the building side 22 . The plates 18 , 18 ′ are fixedly connected at both ends to the rail sections 14 , 14 ′, for example by welding. Apart from the function of the plates 18 , 18 ′ described further below, the transverse struts 12 comprising the rail sections 14 , 14 ′ are reinforced in this manner.
In the upper horizontal flanges 17 of the rail sections 14 , 14 ′, which extend in opposite directions, cutouts 20 are provided behind one another, with one cutout 20 being located in each case relatively close to the insertion side 21 , and one further cutout 20 being located in each case close to the building side 22 .
On the narrow ends of the floor panels 13 , there are secured end fittings 15 , 15 ′, which are of substantially hook-like design in accordance with FIG. 3, and have at the side adjacent the floor panel 13 a vertical strip part 15 a , 15 ′ a respectively, fixedly connected to the latter, a substantially horizontally extending and substantially planar cover part 15 b , 15 ′ b and an outer strip part 15 c , 15 ′ c , such that the end fittings 15 , 15 ′ have a substantially inverted U-shaped cross-section.
In order to be able to more simply distinguish the components disposed above one another as illustrated in FIG. 1, the rail sections 14 , 14 ′ are provided with hatching extending from the top left to the bottom right, and the end fittings 15 , 15 ′ are provided with hatching extending from the top right to the bottom left.
In accordance with the invention, there are provided, at the lower edge of the strip parts 15 a , 15 ′ a , horizontal lifting security projections 16 extending in the direction towards the associated rail section 14 , 14 ′ beneath the horizontal flanges 17 , and downwardly projecting shifting security abutments 19 at the strip parts 15 c , 15 ′ c lying between the rail sections 14 , 14 ′, which cooperate with rear abutment edges 23 , 23 ′ of the shifting security abutment plate 18 and the positioning plate 18 ′ respectively.
The vertical spacing G between the lifting security projections 16 and the horizontal flange 17 is greater in the installed state of the floor panel 13 , in accordance with the invention, than the vertical degree of overlap between the plates 18 , 18 ′ and the shifting security abutments 19 .
The surface 24 of the abutment plate 18 serves as a sliding surface for a shifting security abutment 19 lifted onto it.
The abutment plate 18 and the abutments 19 are positioned relative to one another in the horizontal direction such that with abutment of the projection 19 at the rear edge 23 of the abutment plate 18 , the lifting security projection 16 of the end fittings 15 , 15 ′ is still located beneath the horizontal flange 17 , and in any event is still clearly behind the cutout 20 , so that on lifting up the end fittings 15 , 15 ′ in this state, the projections 19 are admittedly lifted onto the surface 24 , but the lifting security projection 16 cannot yet pass upwardly through the cutout 20 . This is only possible when the downwardly projecting abutments 19 have been shifted so far on the surface 24 in the direction towards the insertion side 21 that the end fittings 15 , 15 ′ come into abutment against the front vertical support 11 in the region of the front cutouts 25 . The length of the abutment plate 18 and of the shifting security abutments 19 in the direction of insertion is such that the shifting security abutments 19 lifted onto the surface 24 of the abutment plate 18 slidingly contact the surface 24 until the associated end fitting 15 , 15 ′ respectively abuts against the front vertical support 11 on being pulled out toward the front.
In accordance with FIGS. 2 to 4 two identically formed floor panels 13 are mounted behind one another on a respective rail section 14 , 14 ′. The rear floor panel 13 abuts in this arrangement in the region of a cutout 26 provided at the rear at the end fittings 15 , 15 ′ against the rear vertical support 11 . In the center, the two floor panels 13 have at most a small spacing 31 or preferably abut against one another.
As one clearly recognizes from FIGS. 2 and 4, the horizontal spacing H of the shifting security projections 19 of the rear floor panel 13 and of the rear edge 23 ′ of the rear positioning plate 18 ′ is substantially greater than the spacing 35 , which is as small as possible, between the shifting security abutment 19 of the front end fitting 15 and the rear edge 23 of the abutment plate 18 , which should only lie in the region of the tolerances that are necessary.
In FIG. 2 bores 44 are also indicated in the end region of the rail sections 14 , 14 ′, which serve for the insertion of non-illustrated holding pins of the curb strips 36 (FIG. 1 ). In the region of the rear vertical supports 11 , the bores 44 are generally unnecessary, because curb strips 36 are not prescribed at the building construction side. In accordance with the invention, the non-illustrated vertical pins of the curb strips 36 , which are inserted into the front bores 44 , in particular represent an additional security against shifting of the floor panels 13 to the front. The bores 44 are thus to be correspondingly arranged.
In FIG. 4 it is, furthermore, indicated, at the left, how plug-in spigots 11 ″ provided on the individual elements 11 ′ can be plugged telescopically into an adjoining individual element 11 ′, in order to form a vertical support 11 assembled from numerous individual elements 11 ′. Further features and details of the invention result from the following functional description, with additional reference to FIGS. 5 to 11 .
In accordance with FIGS. 2 to 4 two end fittings 15 , 15 and 15 ′, 15 ′ respectively of two floor panels 13 are in each case arranged behind one another on the two rail sections 14 , 14 ′, and indeed in such a way that a distance 31 which is as small as possible remains between the floor panels 13 and must be so small that no components or tools can fall downwardly through it. The size of the spacing 31 is determined by the tolerances which are necessary in the assembly of such a scaffold.
At the building side 22 the end fittings 15 , 15 ′ located there abut in the region of the cutout 26 against the rear vertical support 11 , whereby the depth of insertion of the two floor panels 13 arranged behind one another is determined. The shifting security abutment 19 of the end fittings 15 , 15 ′ disposed towards the insertion side 21 in each case engages behind the rear edge 23 of the shifting security plate 18 , and indeed while leaving the minor spacing 35 which should be as small as possible and is determined by the usual tolerances with such scaffolds. In this manner two floor panels 13 lying behind one another are in each case also secured against sliding towards the insertion side 21 .
Should now wind forces, for example acting from the bottom on the floor panels 13 , attempt to lift these from the rail sections 14 , 14 ′, then this is prevented by the lifting security projections 16 , which engage beneath the horizontal flange 17 . The same applies if any form of tilting moments occur about the longitudinal axis of the floor panels 13 , for example by treading on the front or rear marginal region of the floor panels 13 which project beyond the region of support on the rail sections 14 , 14 ′.
If the floor panels 13 are to be lifted from the rail sections 14 , 14 ′, then the curb strips 36 are first removed from the securing bores 44 . Thereafter, one of the front floor panels 13 is first lifted in accordance with FIGS. 5 and 7 sufficiently far that the downwardly projecting shifting security abutment 19 is lifted to the level of the surface 24 of the shifting security abutment plate 18 , and the floor panel 13 is then shifted in the direction of the arrow P towards the insertion side 21 , with the abutment 19 being able to slide on the surface 24 . Through the lifting of the shifting security abutment 19 to the level of the surface 24 , the sliding prevention lock formed by the shifting security abutment plate 18 and the shifting security abutment 19 is cancelled. The relevant floor panel 13 can then be shifted in the direction of the arrow P sufficiently far until the edge of the front cutout 25 abuts against the rear side of the front vertical support 11 , in which position the projection 16 is vertically aligned with the cutout 20 in the horizontal flange 17 , whereupon the end fittings 15 and 15 ′ respectively can be lifted upwardly without problem from the associated rail section 14 . In order to release the front floor panel 13 , a wholly conscious movement of the floor panel 13 first vertically upwardly and then forwardly is necessary, such as cannot be randomly produced, for example by wind forces, so that as a result of the measure of the invention, an extensive security of the front floor panels 13 against chance lifting is given, and, on the other hand, a problem-free conscious removal is also possible.
After the one of the two front floor panels 13 has been removed in accordance with FIGS. 8 to 10 , the rear floor panel 13 , which is now no longer restricted at the front by another floor panel 13 , can likewise be shifted forwardly in the direction of the insertion side 21 , until the shifting security abutment 19 provided at its end fitting 15 , 15 ′ abuts against the rear edge 23 ′ of the rear positioning plate 18 ′ (FIG. 10 ). Now, in contrast to the relationships for the front floor panels 13 , the lifting security projections 16 and the cutouts 20 in the horizontal flanges 17 are vertically aligned with one another, so that in accordance with FIG. 9 the end fitting 15 can be lifted from the associated rail section 14 . At the rear floor panels 13 , the shifting security abutments 19 and the positioning plate 18 ′ thus simply serve as an indicator through which the operator is made aware by the abutment of the two components 18 ′, 19 against one another that the floor panel 13 is now ready for the lifting from the rail section 14 .
After the shifting security abutment 19 has been lifted beyond the level of the surface 24 ′ of the positioning plate 18 ′, the rear floor panel 13 can now be pulled out forwardly in the direction of the arrow R, with the shifting security abutment 19 being able to slide on the surface 24 ′ if necessary.
The mounting of the floor panels on the rail sections 14 , 14 ′ takes place in the reverse sequence as follows:
First of all the rear floor panel 13 is mounted from the insertion side 21 in such a manner that the shifting security abutment 19 is placed onto the rear positioning plate 18 ′, and the floor panel 15 is shifted with the end fittings 15 , 15 ′ towards the building side 22 , with the shifting security abutment 19 sliding rearwardly on the surface 24 ′ of the positioning plate 18 ′ until it finally reaches behind the end edge 23 ′, whereupon the end fitting drops downwardly until it contacts the horizontal flange 17 over its full length. During this the lifting security projection 16 moves through the cutout 20 below the level of the horizontal flange 17 , whereupon the floor panel 13 with the end fitting 15 is shifted rearwardly into the position evident in FIGS. 5 to 7 , until the end fitting 15 comes into contact against the rear vertical support 11 in the region of the cutout 26 . The rear floor panel 13 is now located in its desired position.
In order to facilitate the sliding of the shifting security abutment 19 on the positioning plate 18 ′, this can either itself be formed as a rearwardly rising ramp or can have such a run-up ramp 18 ″ at its end adjacent the insertion side 21 . In this manner the shifting security abutment 19 can enter into sliding engagement with the surface of the ramp 18 ″ solely by pushing the floor panel 13 rearwardly, without the floor panel 13 having to be lifted on being pushed into place, so that the end fitting 15 is lifted on further shifting of the floor panel towards the building side 22 , until finally the shifting security abutment 19 reaches behind the end edge 23 ′ of the positioning plate 18 ′, and the end fitting 15 drops downwardly in the above-described manner, whereupon the cover parts 15 b , 15 ′ b lie on the flange 17 , as can, for example, be recognized in FIG. 3 . Thereafter, the shifting of the end fittings 15 , 15 ′ into the desired position evident from FIGS. 2 to 7 then takes place again.
Now the front floor panel 13 is also mounted as follows:
The front floor panel 13 is first placed onto the associated rail section 14 in such a way that the end fitting 15 abuts from the rear against the front vertical supports 11 in the region of the front cutouts 25 . In this position the lifting security projection 16 and the cutouts 20 and the horizontal flanges 17 are vertically aligned with one another so that the end fitting 15 can move sufficiently far downwardly for the shifting security abutments 19 to come into contact on the surface of the shifting security abutment plates 18 . As a result of the dimensioning in accordance with the invention the lifting security projection 16 now come to lie lower than the horizontal flanges 17 , so that on shifting the floor panel 13 in the direction of the arrow S in FIG. 7, the lifting security projections 16 already engage beneath the horizontal flanges 17 before the shifting security abutment 19 sliding on the surface 24 finally reaches behind the rear edge 23 of the shifting security abutment plate 18 , whereupon the floor panel 13 with the end fittings 15 , 15 ′ drops downwardly into its desired position shown in FIGS. 2 to 4 , where the cover parts 15 b , 15 ′ b of the end fittings 15 lie throughout on the horizontal flanges 17 .
The shifting security abutments 19 should be arranged in the region of the center of the end fittings 15 , 15 ′, so that when the shifting security abutments 19 lie on the shifting security abutment plates 18 , 18 ′, the floor panel 13 adopts an unstable position in which it tilts about its longitudinal axis during handling, which is an indication for the operator that the floor panel 13 is not yet located in its end position. A stable, no longer tilting position is first achieved when the shifting security abutments 19 have slid off from the shifting security plates 18 at the rear.
In accordance with FIG. 11 the rail sections 14 , 14 ′ and also the end fittings 15 , 15 ′, with their various projections and cutouts, should be so dimensioned that a tilting of each floor panel 13 downwardly is also possible out of the position secured against lifting, and indeed in such a way that, for example, on pivoting of the floor panel 13 downwardly about the rail section 14 ′, a lifting in the direction of the arrow T in FIG. 11 is possible without previous horizontal shifting of the floor panel 13 . In the reverse sequence each floor panel 13 can thus also be mounted in an oblique position on the rail sections 14 , 14 ′; however, a lifting out in the above-indicated sense must first take place at the opposite side. As soon as the end of the floor panel 13 has been lifted there from its associated rail section 14 , 14 ′, the end frame 32 located there with the vertical supports 11 and transverse struts 12 can be resiliently pushed away from the floor panel 13 somewhat, whereupon a tilting of the floor panel 13 downwardly in accordance with FIG. 11 is possible. On the mounting of a floor panel 13 in the tilted state in accordance with FIG. 11, the other end must subsequently be lifted above the level of the rail section there, with the end frame 32 resiliently pushed away, and subsequently mounted on the rail section in the above-described sense.
It is thus particularly advantageous that on tilting of a floor panel 13 downwardly in accordance with FIG. 11, none of the parts moved relative to one another come into engagement with one another in such a manner that they could be damaged or destroyed.
As a result of the design in accordance with the invention, each front floor panel 13 can be removed and installed independently of the remaining floor panels 13 . In order to remove one of the rear floor panels 13 , it is only necessary to first push the floor panel 13 lying in front of it forwardly, and indeed until the frontmost one abuts against the front vertical support 11 .
The insertion of the floor panels 13 is in particular facilitated by the design of the invention and made safer, because the operator receives a feeling both for the non-latched and also for the latched position of each floor panel 13 .
Since the safety curb holding bores 44 are located, in accordance with the invention, relatively close to the front and rear edges of the floor panels 13 , i.e. of the end fittings 15 , 15 ′, a further indication for a problem-free positioning of the mounted floor panels 13 can be seen in the fact that the safety curb retaining bores 44 are exposed for the reception of the holding pins of the curb strips 36 . By inserting the vertical spigots of the curb strips into the bores 44 , the floor panels 13 are additionally secured against shifting to the front.
The shifting security abutments 19 have the further advantage that when a floor panel 13 lies with its lower side obliquely (FIG. 11) on a rail section 14 , 14 ′, and is then shifted in its longitudinal direction up to vertical alignment of the upper end fitting 15 , 15 ′ with the associated rail section 14 , 14 ′, the downwardly projecting shifting security abutment 19 first engages behind the associated rail section 14 , 14 ′, and thus the longitudinal shifting is terminated at the instant where the end fitting 15 , 15 ′ is located in the relative position required for a holding engagement with the associated rail section 14 , 14 ′.
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The invention relates to a dismountable scaffolding with vertical struts and horizontal struts. A base plate extends between said struts and is provided with hook-shaped end fittings on each front face. Said base plate can be placed on a rail section in such a way that vertical locking or unlocking can be selectably achieved by sliding the end fitting in the direction of the rail section. Horizontal antislip locking is achieved and cancelled by raising the end fitting, thereby preventing said fitting from sliding into an inactive vertical locking position when it is in an active vertical position.
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This application is a continuation of application Ser. No. 840,941, filed Oct. 11, 1977, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to solid propellant control systems, and more particularly to a dual pressure solid propellant control system.
2. Description of the Prior Art
For the deployment of packages from an aerospace vehicle during the boost phase of a mission profile it is desired to provide attitude and velocity control of the package platform in response to flight control commands for the proper deployment attitude of the platform and the necessary spacing between packages, respectively. A prior solid propellant control system has a comparatively low specific impulse thrust output at temperatures of approximately 2200° F. The materials of the components such as the valves and hot gas manifold are of high temperature metallic alloys such as Haynes 25, a cobalt alloy. The valves are operated as open centered valves so that one-half the valves are open and one-half the valves are closed at all times with each pair of opposing valves operating in conjunction with each other to provide a constant gas flow. This system is inefficient since the same hot gas flow rate provides both the velocity increment required for package spacing and the attitude control for platform orientation. Additionally, change in the platform center of gravity as packages are deployed results in decreased thrust, another inefficiency of the system.
SUMMARY OF THE INVENTION
Accordingly, the present invention provides a dual pressure solid propellant control system of a relatively high specific impulse whose thrust output can be modulated over a wide range of thrust levels. A solid propellant gas generator with a high burn rate exponent propellant provides a hot gas flow via a manifold to a plurality of valve clusters having at least one nozzle each. The valves and the manifold are made from high temperature materials capable of resisting temperatures of approximately 3000° F. The valves function in a proportional manner, and are independently commanded to provide an effective variable exit area for the hot gases. A pressure feedback loop compares the pressure of the gas generator with a commanded reference pressure to regulate the pulse-width modulation of the valves.
Therefore, it is an object of the present invention to provide a solid propellant velocity and attitude control system for an aerospace vehicle package deployment platform.
Another object of the present invention is to provide a solid propellant control system which operates over a range of thrust levels.
Still another object of the present invention is to provide a solid propellant control system which maintains effective thrust levels constant in the flight direction when the aerospace platform center of gravity changes.
Other objects, advantages and novel features of the present invention will be apparent from the following detailed description when read in conjunction with the claims and attached drawing.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a perspective view of a dual pressure solid propellant control system configuration according to the present invention.
FIG. 2 is a functional schematic view of the dual pressure solid-propellant control system.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The function of a control system is to provide attitude and velocity control for an aerospace platform, such as a payload stage of a rocket, in response to flight control commands. There are in general two major operating modes: (1) coarse mode involving velocity increments for deployment spacing between a plurality of payload packages, and (2) vernier mode for nulling out the small remaining velocity errors and for precise attitude control and deployment.
Referring to FIGS. 1 and 2 the control system is mounted on an aerospace platform 10 and has one or more gas generators 12 connected in parallel via a hot gas manifold 14 to a plurality of valve clusters 16. Each valve cluster 16 has at least one nozzle, such as a high thrust nozzle 18 and/or a low thrust nozzle 20. Each nozzle 18, 20 can be independently opened or closed by a command signal from a flight control package 22. The valve clusters 16 are located symmetrically around the platform 10 to simplify the control logic necessary for computing nozzle commands.
The command signal is a flight control command signal as modified by a pressure feedback system to compensate for the effects of valve tolerances, propellant burn rate and other variables in maintaining a constant pressure. The pressure feedback system has a pressure transducer 24 mounted on the gas generator 12, which is initiated upon command by an igniter 26, to produce a signal indicative of the system hot gas pressure. The transducer signal is compared at 27 in the flight control package 22 with a reference pressure, P ref , determined by the mode of operation of the control system, and the error output modifies the guidance command signal in block 29 to produce the command signal to the nozzles 18, 20. Additional pressure control is provided by a venturi 28 at the inlet of each valve cluster 16 which establishes the minimum system hot gas pressure. The pressure limits of the control system are determined by weight--higher pressure tends to increase weight--and by propellant ballistic characteristics--too low a pressure affects valve dynamics and combustion stability during the vernier mode.
The dual pressure solid propellant control system achieves increased performance due to a higher gas temperature of approximately 3000° F. due to the use of high specific impulse, low burn rate and high pressure exponent propellants such as a free standing class 7 HMX (cyclotetramethylenetetranitramine)-oxidized composite propellant with a binder system based on hydroxy terminated polybutadiene (HTPB) polymer and cured with isophorone diisocyanate (IPDI) curative including a small amount of carbon black as an opacifier which is able to burn stably over a wide pressure range; and due to hot gas valves which function in a proportional manner such as on/off valves operated in a pulse duration mode (PDM). The result in combination with the pressure feedback loop produces a control system able to obtain any desired thrust output within a designed range.
In the vernier mode all thrust nozzles 18, 20 are driven so that each appropriate pair of nozzles operate in the open center fashion, i.e., at any given time one-half the high thrust nozzles 18 and one-half the low thrust nozzles 20 are flowing gas, presenting the highest programmed flow area (combined nozzle throat area) to the gas generator 12. The gas generator thus operates at the minimum expected pressure and thrust which is more efficient for attitude control. In this thrust condition the appropriate nozzles 18, 20 can be operated to terminate all accelerations, to null out any small velocity errors or to continue thrusting at a low level.
The coarse mode is used to accelerate the platform 10 in a particular direction, thus the gas flow output will be from the high thrust nozzles 18. In this mode one-half the high thrust nozzles 18 and all the low thrust nozzles 20 are closed. One-half the high thrust nozzles 18 operating in the thrusting direction are then each commanded to a percentage of the maximum area as determined by the system design. For example, the reduction of the effective gas generator nozzle throat area to 70% increases the gas generator pressure and consequently the gas output. The gas generator pressure and flow will then stabilize at a new higher level depending upon the propellant ballistic characteristics, reducing flight time during spacing maneuvers.
Another advantage of the dual pressure solid propellant control system resulting from independent control of each nozzle 18, 20 is the ability to compensate for center-of-gravity (c.g.) offsets without decreasing the total thrust in the flight direction during acceleration. This is accomplished by increasing the thrust of the nozzles nearest the c.g. offset location and decreasing the thrust of the nozzles farthest from the c.g. offset location by simultaneous and equal increases and reductions of effective nozzle areas so that the total throat area sensed by the gas generator is constant, resulting in constant system pressure and all thrust in the acceleration direction. Prior art constant area control systems require some thrust against the acceleration direction to compensate for c.g. offsets, resulting in reduced total thrust in the acceleration direction.
For example, if the c.g. moves radially toward one nozzle 18 in coarse mode, that nozzle would be PDM'd to 70+Y% and the diametrically opposite nozzle would be PDM'd to 70-Y% until stability is obtained, the other nozzles 18 remaining at 70%. Before the c.g. offset the total throat area was nx70%, and after c.g. offset it is still (n-2)x70%+(70+Y)%+(70-Y)%=nx70%.
To accommodate the hot gas flow at 3000° F. the valve clusters 16 and hot gas manifolds 14 are made from high temperature materials such as refractory alloys of columbium, tantalum and molybdenum. The high oxidation rates of columbium and tantalum when exposed to the oxidizing potential of the hot gases are inhibited by a then (3 mil) silicide coating. Molybdenum and tungsten alloys, used where greater strength is required, are left uncoated as their oxidation rates are acceptable.
Insulation around the hot components protects the platform 10 and associated electronics from the thermal energy emitted.
Each high pressure nozzle 18 is controlled by a two-stage normally closed pneumatic valve having a pilot valve and a piston actuated main stage. The pilot valve powers the main stage piston upon command. Each low thrust nozzle 20 is controlled by a single stage valve similar to the high thrust pilot valve, but modified for a slightly higher flow.
Thus, by using more efficient propellants at a higher temperature with individually controlled nozzles to provide a variable throat area, together with a pressure feedback system to compensate for component tolerances, the present invention provides a dual pressure solid propellant control system which saves energy by switching from a high pressure mode to a low pressure mode depending on the particular impulse requirements. The saving in energy results in an increased range of several hundred miles over prior art solid propellant control systems. Although only two pressure modes have been described, the pressure is variable within the pressure range, 160-550 psi for the described embodiment, depending upon P ref and the commanded rate, which results in a mass flow output ratio, or thrust ratio, of approximately 1.5 or higher, i.e., system output, either mass flow or thrust, at high pressure divided by system output at low pressure.
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A dual pressure solid propellant control system capable of operating at temperatures of approximately 3000° F. and at multiple pressures. A solid propellant gas generator is connected to a plurality of valve clusters by a manifold, the valves and manifold being of a high temperature material and each valve being independently operable. A pressure feedback loop maintains the system pressure at a commanded value by effectively increasing or decreasing the gas exit area by varying the pulse duration modulation of the valves.
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BACKGROUND OF THE INVENTION
The term “MDI” refers to a large number of technically important, but also structurally different, isocyanates. They include both monomers, in which two aromatic structural elements are bonded with one another via a methylene bridge (monomeric MDI), and also higher oligomers, in which more than two aromatic structural elements are bonded with one another in succession via a plurality of methylene bridges (polymeric MDI).
From the user's point of view, it is of great interest to obtain, where possible, the 4,4′- and the 2,4-isomer or mixtures of those two isomers.
The ratio of monomeric to polymeric MDI, and also the proportions of the 4,4′- and 2,4′-isomers in monomeric MDI, can be varied within wide limits by varying the synthesis conditions for the preparation of the precursor.
The separation of the crude MDI obtained in MDI synthesis is for the most part carried out by distillation, wherein there can be separated off, depending on the technical outlay, either almost isomerically pure fractions with contents of 4,4′-MDI, for example, of greater than 97.5 wt. %, or isomeric mixtures with contents of 4,4′- and 2,4′-MDI of in each case about 50 wt. %.
Very recently there has additionally been an increasing need for the 2,4′-isomer. This is due substantially to the different reactivities of the NCO groups in the 2- and 4-positions of 2,4′-MDI (similar to the differences in reactivity of the NCO groups in the 2- and 4-positions of 2,4-toluoylene diisocyanate (TDI)).
These differences in reactivity permit or facilitate the synthesis of low-monomer NCO prepolymers (NCO prepolymers are intermediates which can be isolated during the preparation of finished end polymers—they carry unchanged NCO groups at their chain ends. These are obtained by reacting a polyol with a molar excess of an isocyanate (based on the NCO-reactive or NCO groups) at from room temperature to about 100° C.).
In the case of asymmetric isocyanates (=isocyanates having at least two NCO groups of different reactivities), preferably only one NCO group reacts with the polyol, while the other remains unchanged. The prepolymerization is accordingly considerably simpler to control than is the case with most NCO prepolymers of the prior art, in which there are used isocyanates whose NCO groups do not have different reactivities. In comparison therewith, these also always contain larger amounts of free, monomeric diisocyanate.
The preparation of low-monomer to virtually monomer-free NCO prepolymers is highly desirable in the case of 2,4-TDI because it has a high vapor pressure and polymers containing unreacted 2,4-TDI constitute a high health risk. The NCO prepolymers based on aliphatic diisocyanates, such as, for example, hexamethylene diisocyanate (HDI) or isophorone diisocyanate (IPDI), are to be regarded as even more critical in this respect.
This aspect is also to be taken into consideration in the case of MDI, but it comes to bear to only a reduced extent because of its lower vapor pressure as compared with TDI.
TDI or low-monomer TDI prepolymers are still the current state of the art; the use of pure 2,4′-MDI-containing prepolymers is relatively new on the market.
The preparation of low-monomer NCO prepolymers can be carried out in several ways:
1. By removal of the free monomeric diisocyanate by technically complex thin-layer or short-path evaporation. This possibility can be used regardless of whether diisocyanates having NCO groups of the same or different reactivities are used. Entrainers, for example, can also be used therefor. 2. By the use of diisocyanates having NCO groups of different reactivities or NCO groups of the same reactivity and specially selected stoichiometric ratios, for example molar ratios of NCO to NCO-reactive groups of below 2:1, and/or optionally with special catalysis. 3. Combinations of the two processes, for example in such a manner that the content of free monomeric diisocyanate according to process 2 is first limited to a specific degree and is then minimised further by process 1.
Such combinations can be expedient when the viscosity of the prepolymers is to be minimised. The disadvantage of process 2 is, in principle, that reactions with stoichiometric ratios, in particular below 2:1, lead to increased pre-extension, and there is accordingly an inherent marked increase in the viscosity of the reaction product.
International Pat. Pub. No. WO 01/40340 A2, the entire contents of which are hereby incorporated herein by reference, gives examples of such combinations of process steps, wherein in a first stage the diisocyanate is reacted, using a selectivity-increasing catalyst, to give a NCO prepolymer, which is then freed of excess monomer by thin-layer evaporation.
For particularly critical applications, such as, for example, in the foodstuffs sector, particularly high demands are made of a residual monomer content (key word work hygiene). This is true to a large degree for TDI, but in some cases also for MDI (see above). An indication therefor are numerous publications or patents which are also concerned with low-monomer MDI prepolymers, for example International Pat. Pub. Nos. WO 03/006521, WO 03/033562, WO 03/055929, WO 03/051951, WO 93/09158 and European Pat. Pub. No. EP 0 693 511 A1, the entire contents of each of which are hereby incorporated herein by reference.
For the above-mentioned reasons, the need for the 2,4′-MDI isomer has increased recently, as mentioned. However, owing to the process, this in principle also results in an increased amount of 2,2′-MDI, which has to date been regarded as unusable. For example, it is stated in International Pat. Pub. No. WO 2007/087987, the entire contents of which are hereby incorporated herein by reference: “In the case of monomeric MDI, the 4,4′- and 2,4′-isomers are predominant, owing to the synthesis. The 2,2′-isomer, which is less frequent and is largely of no commercial value, is also formed to a lesser degree”.
This is partly because pure 2,2′-MDI is not available industrially and 2,2′-containing formulations often have the disadvantage that this monomer reacts markedly more slowly and therefore less completely. This can lead, for example, to undesirable migration during the bonding of foodstuffs packaging or to the blowing off of foams.
2,2′-MDI, or the formulations containing it, is therefore regarded as waste and must be disposed of in an expensive manner.
Alternative disposal or use of 2,2′-MDI mentioned in the prior art includes the possibility of using 2,2′-MDI for controlling the reaction velocity of isocyanate mixtures containing it. The following possibilities, inter alia, are described in the prior art for controlling the reaction velocity of MDI mixtures:
1. Mixtures with TDI or TDI prepolymers with the associated disadvantage of increased toxicity. Owing to the higher vapor pressure of the TDI monomer, even permitted residual contents of 0.5% lead to disturbing odors and impairments. 2. Extenders in the form of plasticizers, or hydrocarbons in general. There are used, for example, phthalates such as DINP or alternative plasticizers such as 2-cyclohexane-dicarboxylic acid diisononyl ester, acetyltributyl citrate or solvents such as ethylene/propylene carbonate, dibasic esters (DBE), solvent naphtha and benzines. Disadvantages here are primarily a reduction in quality and the risk of migration of the non-chemically-bonded additives and the accompanying changes in properties over time. 3. High contents of 2,4-MDI (>85%), see WO 2007/087987 with the accompanying high outlay in terms of isomer separation and the associated cost disadvantages.
BRIEF SUMMARY OF THE INVENTION
The present invention relates, in general, to isocyanate mixtures based on 2,2′-diphenylmethane diisocyanate (2,2′-MDI), to a process for their preparation and to their use in the preparation of polyisocyanate polyaddition products.
Various embodiments of the present invention provide for the use of 2,2′-MDI, which is obtained industrially and which was hitherto not very desirable. The use of 2,2′-MDI in accordance with the present invention is not to be associated with any impairment of the processing conditions or of the (mechanical) properties of the resulting products. Various embodiments of products prepared in accordance with the present invention can constitute an improvement over the prior art.
Various embodiments of the present invention provide an isocyanate mixture having a NCO content of from 2 to 22 wt. %, which is characterized in that it comprises
(a) NCO prepolymers having a NCO content of from 1.5 to 18 wt. % and (b) monomeric 2,2′-diisocyanatodiphenylmethane (MDI) in an amount of from 1 to 40 wt. %, based on the isocyanate mixture.
The isocyanate mixtures preferably have a NCO content of from 4 to 17 wt. % and the NCO prepolymers preferably have a NCO content of from 2.5 to 15 wt. %. The isocyanate mixture preferably comprises from 2 to 25 wt. %, particularly preferably from 2 to 18 wt. % and most particularly preferably from 3 to 15 wt. %, monomeric 2,2′-MDI.
NCO prepolymers are prepolymers that form in the reaction of organic polyisocyanates with NCO-reactive compounds used in a deficient amount. There are preferably used as the isocyanate 4,4′-diphenylmethane diisocyanate (4,4′-MDI), 2,4′-MDI, 2,2′-MDI, polymeric MDI and mixtures thereof, modified MDI (modification is mostly effected by the incorporation of uretdione, isocyanurate or allophanate groups), toluoylene diisocyanate (TDI), hexamethylene diisocyanate (HDI), isophorone diisocyanate (IPDI), H12-MDI (hydrogenated MDI) and blends of the above-mentioned compounds. There are preferably used as the NCO-reactive compounds polyols (polyether polyols, polyester polyols, polycarbonate polyols, polyalcohols) and polyether polyamines.
For the preparation of the isocyanate prepolymers there can preferably be used compounds having on average at least 1.5, preferably from two to four, hydrogen atoms that are reactive with isocyanate groups, preferably hydroxyl- and/or amine-terminated compounds, such as polyether polyols, polyester polyols, polyalcohols, polyamines or mixtures of these compounds with one another, there preferably being used compounds having a functionality of from 2 to 4, in particular 2, and having a molecular weight of from 200 to 10,000 g/mol, preferably from 500 to 5000 g/mol, particularly preferably from 1000 to 4000 g/mol and most particularly preferably of approximately 2000 g/mol. Particular preference is given to polyether diols having a molecular weight of from 1000 to 4000 g/mol.
The polyols can optionally contain compounds selected from the group consisting of 1,2-ethanediol, 1,2-propanediol, 1,3-propanediol, 1,4-butanediol, glycerol, trimethylolpropane and mixtures thereof.
The isocyanate mixture can additionally contain conventional rheology improvers (for example ethylene carbonate, propylene carbonate, dibasic esters, citric acid esters), stabilisers (for example Broenstedt and Lewis acids, such as, for example, hydrochloric acid, phosphoric acid, benzoyl chloride, organo-mineral acids such as dibutyl phosphate, also adipic acid, malic acid, succinic acid, racemic acid or citric acid), UV stabilisers (for example 2,6-dibutyl-4-methylphenol), catalysts (for example trialkylamines, diazabicyclooctane, tin dioctoate, dibutyltin dilaurate, N-alkylmorpholine, lead, zinc, tin, calcium, magnesium octoate, the corresponding naphthenates and p-nitrophenolate and/or also mercury phenylneodecanoate), hydrolytic stabilisers (for example sterically hindered carbodiimides), emulsifiers, fillers (for example chalk), colourings which can optionally be incorporated into the polyurethane/polyurea that is later to be formed (which colourings accordingly have Zerewitinoff-active hydrogen atoms) and/or colouring pigments.
Further auxiliary substances and additives include emulsifiers, foam stabilisers, cell regulators and fillers. An overview is given in G. Oertel, Polyurethane Handbook, 2 nd Edition, Carl Hanser Verlag, Munich, 1994, Chap. 3.4.
Additional embodiments of the present invention include processes for the preparation of the isocyanate mixtures according to the invention, which processes are characterized in that
A) an organic polyisocyanate is reacted with a NCO-reactive compound in a deficient amount, B) there is added to the NCO prepolymer formed under A) a mixture of from 20 to 70 wt. % 2,2′-diisocyanatodiphenylmethane (MDI), from 30 to 80 wt. % 2,4′-diisocyanatodiphenylmethane (MDI) and from 0 to 10 wt. % 4,4′-diisocyanatodiphenylmethane (MDI).
Additional embodiments of the present invention include processes for the preparation of the isocyanate mixture according to the invention, which processes are characterized in that
A) a blend comprising a mixture of from 20 to 70 wt. % 2,2′-MDI, from 30 to 80 wt. % 2,4′-MDI and from 0 to 10 wt. % 4,4′-MDI and optionally further polyisocyanates from the group consisting of 4,4′-diphenylmethane diisocyanate (4,4′-MDI), 2,4′-MDT, 2,2′-MDI, polymeric MDI and mixtures thereof, modified MDI, toluoylene diisocyanate (TDI), hexamethylene diisocyanate (HDI), isophorone diisocyanate (IPDI), H12-MDI (hydrogenated MDI) and blends thereof is reacted with B) a NCO-reactive component.
Additional embodiments of the present invention include polyisocyanate polyaddition products obtainable from the reaction of
i) isocyanate mixtures according to the invention and ii) NCO-reactive compounds, in the presence of iii) optionally catalysts, iv) optionally fillers, v) optionally auxiliary substances and/or additives.
There are preferably used as the NCO-reactive compounds chain extenders and/or crosslinkers having a molecular weight of from 62 to 600 and a functionality of from 2 to 4, and optionally polyols from the group consisting of polyether polyols, polyester polyols, polyether ester polyols, polycarbonate polyols, polyalcohols, polyamines and polyether polyamines. It is also possible to use as the NCO-reactive compound water/atmospheric moisture on its own or in conjunction with other NCO-reactive compounds.
The invention further provides processes for the preparation of polyisocyanate polyaddition products, wherein an isocyanate mixture according to the invention is reacted with a NCO-reactive compound, optionally in the presence of catalysts, fillers, auxiliary substances and/or additives.
The various process embodiments are preferably carried out in the presence of conventional rheology improvers, stabilisers, UV stabilisers, catalysts, hydrolytic stabilisers, emulsifiers, fillers, optionally incorporable colourings (which accordingly have Zerewitinoff-active hydrogen atoms) and/or colouring pigments. With regard to the representatives of these classes of compound, the same applies as described above in connection with the process for the preparation of the isocyanate mixtures according to the invention.
It is advantageous in the case of the synthesis route via prepolymers as constituents of the isocyanate mixtures according to the invention that some of the heat of reaction already occurs in the synthesis of the prepolymers, and the heat of reaction in the actual polymer synthesis is accordingly lower. This has an advantageous effect on the rate of build-up of the molecular weight and permits longer casting times, that is to say it constitutes an advantage in terms of processing. A disadvantage is the increasing reactivity as the NCO content falls.
It is surprising that, with the targeted use or by the targeted addition of 2,2′-MDI or of mixtures having high contents of 2,2′-MDI, the reaction velocity can be controlled as desired and the above-mentioned disadvantages of the prior art, such as toxicity and limitations in terms of quality, are thereby avoided. It is particularly advantageous that, with long reactivities, advantageous mould-release times can surprisingly be achieved. The improved hydrolytic stability, in particular as compared with TDI prepolymers, was also surprising.
In particular, the isocyanate mixture is easier to process owing to the reduction in the reaction velocity. In addition, reaction with compounds whose reactivity is too high as compared with isocyanate mixtures of the prior art (for example aminic chain extenders and/or crosslinkers, such as, for example, polyamines) is also possible.
The use of the isocyanate mixtures according to the invention has the advantage of longer processing times.
DETAILED DESCRIPTION OF THE INVENTION
As used herein, the singular terms “a” and “the” are synonymous and used interchangeably with “one or more” and “at least one,” unless the language and/or context clearly indicates otherwise. Accordingly, for example, reference to “an NCO-reactive compound” herein or in the appended claims can refer to a single NCO-reactive compound or more than one NCO-reactive compound. Additionally, all numerical values, unless otherwise specifically noted, are understood to be modified by the word “about.”
The process can be carried out, for example, by reacting the isocyanate mixture in the presence of water, in particular of atmospheric moisture. The “use” of atmospheric moisture corresponds to the use of the isocyanate mixture according to the invention in the form of a 1K system (because, apart from the isocyanate mixture, no further reactants need to be added). The atmospheric moisture reacts sufficiently slowly with the NCO groups to form amine groups, while the hardening is acceptable at the same time. In most cases, such systems are applied in situ.
Alternatively, the process can also be carried out by reacting the isocyanate mixture with at least one polyol component and/or at least one amine component, in particular with a chain extender or crosslinker. This corresponds to reaction in the form of a 2K system. It is also possible to carry out crosslinking with water under pressure, the product so obtained subsequently being used in situ.
Polyurea spray elastomers are also obtainable from the isocyanate mixtures according to the invention.
In general, the component that is reactive towards isocyanates consists of at least 50 wt. %, preferably at least 80 wt. %, of one or more of the described polyether diols. There can be used as amines the compounds described in detail hereinbelow as component bi). The mean functionality of the resulting prepolymer a) is in most cases less than 2.6, preferably less than 2.2. As the main component of the amines b) there is used bi) at least one polyoxyalkyleneamine, preferably a mixture of at least two polyoxyalkyleneamines, so-called polyether amines, that is to say amine-terminated di- or higher-functional polyalkylene oxides, generally polyoxyethylene or polyoxypropylene oxides, having molecular weights of from 200 to 5000 g/mol, in particular from 2000 to 5000 g/mol. It is also possible to use amine-terminated PTHF. The amine groups of the polyether amines are especially primary amine groups. As mentioned, it is also possible to use only one polyether amine. The polyether amines bi) are in particular diamines or triamines. Such compounds are marketed, for example, by Huntsman under the name Jeffamine® or by BASF as polyether amines. Polyamines are mostly prepared by catalytic amination of the corresponding polyalcohols. The polyoxyalkyleneamines bi) are predominantly used to synthesise the soft phase in the polyurea spray elastomers. At least some of the amines bi) used can be replaced by polyetherols. As already mentioned, amine components that contain both polyether amines and polyetherols are referred to as hybrid or mixed polyurea-polyurethane systems. The proportion of amine—as compared with hydroxyl-terminated polyether in the amine component in this invention is preferably more than 50 wt. %, particularly preferably it consists substantially of amine-terminated polyethers. Component b) can further contain as chain extenders bii) low molecular weight, generally aromatic and diaminic amines other than bi). These compounds mostly have a molecular weight in the range from 150 to 500 g/mol, The amine groups of the chain extenders bii) can be primary or secondary. The chain extender mostly used in polyurea spray elastomers is diethylenetoluenediamine (DETDA). As the component that is less reactive as compared with aliphatic amines, DETDA determines the curing behaviour of the system. Accordingly, the gel time can be controlled by alternative chain extenders having reduced reactivity towards isocyanates. In order to obtain light-stable polyurea spray elastomers, it is also possible to use aliphatic chain extenders. It is additionally possible to use the alternative aminic chain extenders already mentioned, such as 4,4′-methylenebis-(2,6-diethyl)-aniline (MDEA), 4,4′-methylenebis-(2,6-diisopropyl)-aniline (MDIPA), 4,4′-methylene-bis-(3-chloro-2,6-diethyl)-aniline (MCDEA), dimethylthiotolucnediamine (DMTDA, Ethacure® 300) or reaction-retarding chain extenders having secondary amine functions, such as N,N′-di(sec-butyl) -amino-biphenylmethane (DBMDA, Unilink® 4200) or N,N′-di-sec-butyl-p-phenylenediamine (Unilink® 4100). Further formulation constituents, which are not absolutely necessary, are, for example diluents, mostly reactive diluents, which, when used, are generally added to the isocyanate component. Examples of reactive diluents of the isocyanate component are alkylene carbonates. However, the addition of reactive diluents can lead to an impairment of the mechanical properties and ageing resistance of the polyurea spray elastomer. The addition of additives to the amine component is limited by a processable viscosity. Such additives are pigments, adhesion promoters, UV stabilisers, antioxidants or other fillers. Component b) can further contain in particular abrasion improvers. There are used as abrasion improvers preferably silicone-modified alcohols, in particular glycols. The system is generally applied by spraying, wherein the components are mixed under high pressure and at elevated temperature in the mixing head of the spray gun before they are discharged therefrom, and are thus made to react. The volumetric ratio in which the polyisocyanate and the amine component are sprayed is preferably 1:1 but can also be from 30:70 to 70:30 vol %, but preferably up to 1.1:1. The sprayed surface can be pretreated with a primer, in particular if it is wet, in order to improve adhesion. The adhesion improver can also be added to the B-component or preferably to the R-component, likewise in particular for adhesion to a wet substrate. Examples of primers are siloxanes and functionalised siloxanes. Particular mention may be made of epoxy-amino-or vinyl-alkoxy-silanes. Further examples of commercially available primers are titanates, such as neopentyl(diallyl)oxytri(m-amino)phenyl titanate, or zirconates, such as neopentyl(diallyl)oxytri(methylenediamino)ethyl zirconate. Further possible primers are 1K or 2K polyurethane systems (1-component or 2-component systems, see hereinbelow), polyvinylamines, polyacrylates or epoxy resins. Before application, the primers can be dispersed, emulsified or dissolved in water or other solvents. The ratio of isocyanate groups to groups that are reactive towards isocyanate groups, in particular, as stated, amine groups, in the preparation of the polyurea spray elastomers is in most cases from 0.90 to 1.20, in particular from 1.05 to 1.15. It has been found that, by increasing the 2,2′-MDI content in the isocyanate prepolymer used, the reduced reactivity of a given polyurea formulation manifests itself in an increase in the gel time by several seconds.
Typical fields of application of polyurea spray elastomers are coatings, in particular for repairing concrete and protecting against water (coverings for roofs and car park decks, bridge and tunnel repairs), so-called “secondary containment” (coatings for receivers of tanks for chemicals, waste water or oil, or loading areas for hazardous goods), corrosion protection (loading areas of freight ships, lorries, pick-ups and railway wagons) or so-called “primary containment” (sewer manholes, clarification plants). Polyurea spray elastomers are reaction products of an at least difunctional isocyanate with an at least difunctional primary or secondary amine. As amines there are conventionally used high molecular weight polyether amines and low molecular weight aminic chain extenders. The amine component, which is frequently referred to in the art as the R component, is conventionally a mixture of primary aliphatic polyether amines and generally aromatic aminic chain extenders. The principal constituent of the amine component of a polyurea formulation is a mixture of polyether amines, that is to say of amine-terminated di- or higher-functional polyethylene or polypropylene oxides having molecular weights from 200 to 5000 g/mol. The aliphatic amines react more quickly than the aromatic components of the chain extenders and serve predominantly to synthesise the soft phase of the polyurea spray elastomers. The chain extender conventionally used in the polyurea formulation is diethylenetoluenediamine (DETDA). As the component that is less reactive compared with aliphatic amines, DETDA determines the curing behaviour of the system. In order to synthesise light-stable polyureas, aliphatic chain extenders are also used. The mostly aromatic chain extenders are incorporated predominantly into the hard phase of the polyurea spray elastomers. As mentioned, polyurea spray elastomers are mostly used as coatings. To that end, their liquid starting components, conventionally referred to as a system or formulation, are mixed under high pressure and sprayed onto the surface to be coated, where they cure. The reaction time is conventionally only a few seconds. In order to achieve optimal processing and product properties, it is desirable to keep the viscosity of the liquid starting components as low as possible or to make the viscosities of the isocyanate component and the amine component largely equal. Only thus is it possible to ensure adequate miscibility of the extremely reactive components. Mixing errors result in a reduced surface quality. Low-viscosity systems are more readily processable, that is to say they can be processed at lower pressures and temperatures. Furthermore, the reaction should not proceed too quickly in order to ensure optimum distribution of the reactive starting components before they cure completely on the surface to be coated.
For the preparation of cast elastomers, the isocyanate mixtures according to the invention are reacted with chain extenders.
In a particularly preferred embodiment of the preparation of PUR cast elastomers by the process according to the invention, the isocyanate mixtures are first degassed at room temperature or at elevated temperature by application of a reduced pressure and then mixed—mostly at elevated temperature—with a chain extender. In the process, the isocyanate mixture is preferably heated to a temperature of from 40° C. to 110° C. and degassed in vacuo, with stirring. The chain extender and/or crosslinker is then added, this optionally being heated to temperatures of typically at least 5° C. above its melting point. The reaction mixture is poured out in the open and/or introduced into open or closed moulds.
Preferred chain extenders are aromatic aminic chain extenders such as, for example, diethyltoluenediamine (DETDA), 3,3′-dichloro-4,4′-diamino-diphenylmethane (MBOCA), 3,5-diamino-4-chloro-isobutyl benzoate, 4-methyl-2,6-bis(methylthio)-1,3-diaminobenzene (Ethacure 300), trimethylene glycol di-p-aminobenzoate (Polarcure 740M) and 4,4′-diamino-2,2′-dichloro-5,5′-diethyldiphenylmethane (MCDEA). MBOCA and 3,5-diamino-4-chloroisobutyl benzoate are particularly preferred. Aliphatic aminic chain extenders can likewise be used or used concomitantly. The use of amines is possible because the isocyanate mixtures according to the invention have markedly lower reactivity as compared with known prepolymers. This permits reaction also with highly reactive amines. This is not possible with the known prepolymers or isocyanate mixtures based on MDI, which are therefore normally reacted with diols, such as diethylene glycol or 1,4-butanediol.
In the preparation of polyisocyanate polyaddition products there can be used as NCO-reactive compounds preferably polyols having OH numbers in a range from 10 to 400, preferably from 27 to 150, particularly preferably from 27 to 120 mg KOH/g and a mean functionality of from 1.8 to 2.4. There can be used as polyols polyether, polyester, polycarbonate and polyether ester polyols.
Polyether polyols are prepared from a starter molecule and epoxides, preferably ethylene and/or propylene oxide, either by means of alkaline catalysis or by means of double-metal-cyanide catalysis or optionally, in the case of a stepwise reaction, by means of alkaline catalysis and double-metal-cyanide catalysis, and have terminal hydroxyl groups. There come into consideration as starters the compounds known to the person skilled in the art having hydroxyl and/or amino groups, as well as water. The functionality of the starters is at least 2 and not more than 4. Of course, mixtures of a plurality of starters can also be used. Mixtures of a plurality of polyether polyols can also be used as polyether polyols.
Polyester polyols are prepared in a manner known per se by polycondensation from aliphatic and/or aromatic polycarboxylic acids having from 4 to 16 carbon atoms, optionally from their anhydrides and optionally from their low molecular weight esters, including cyclic esters, there being used as reaction component predominantly low molecular weight polyols having from 2 to 12 carbon atoms. The functionality of the chain-extension components for polyester polyols is preferably 2, but it can also be greater than 2 in an individual case, components having functionalities greater than 2 being used only in small amounts, so that the calculated number-average functionality of the polyester polyols is in the range from 2 to 2.5, preferably from 2 to 2.1. Alternatively, polyester polyols can also be prepared by ring-opening polymerisation as, for example, in the case of ε-caprolactone.
Polyether ester polyols are prepared by the concomitant use of polyether polyols in the polyester polyol synthesis.
Polycarbonate polyols are obtained according to the prior art by means of polycondensation from carbonic acid derivatives, for example dimethyl or diphenyl carbonate or phosgene, and polyols.
The preparation of the polyisocyanate polyaddition products can also be carried out in the presence of further inorganic and/or organic fillers and/or auxiliary substances, in particular pigments, rubber granules, recycled granules, fibres, quartz stones, wood fibres and/or sand.
The polyisocyanate polyaddition products according to the invention are used as a coating, binder, floor covering, adhesion promoter, adhesive, filling compound, wall covering.
The polyisocyanate polyaddition products according to the invention are used in the production of rolls, wheels, rollers, resins, mouldings, sieves, scrapers and bumpers.
The polyisocyanate polyaddition products according to the invention are used in the automotive industry, in the recreational sector, in the sports sector, in machine and plant construction, in the electrical and electronics industry, in railway construction and in mining.
A particularly valuable use of the isocyanate mixtures according to the invention is the preparation of 1K and 2K coating compositions. The isocyanate mixtures are thereby mixed in amounts of from 6 to 25% with rubber granules, such as, for example, SBR, EPDM, recycled granules of grain size 0.5 to 50 mm and/or fibres having a length of from 0.1 to 50 mm and/or mineral additives of grain size 1 to 20 mm and processed to give a resilient layer for sports floors. It is also possible for the isocyanate mixture to be mixed in amounts of from 10 to 25% with rubber granules, such as, for example, SBR, EPDM, recycled granules of grain size 0.5 to 50 mm and/or fibres, as well as mixtures of the above-mentioned components, and processed to give sports areas, recreation areas and children's play areas. Blending in amounts of from 11 to 15% with quartz sand as well as with decorative quartz stones and processing to give skate parks or (foot)paths is also conventional. An isocyanate mixture can be mixed in amounts of from 10 to 40% with wood fibre materials and processed to give paths for nature parks. When mixed in amounts of from 8 to 20% with rubber granules, it can be used to produce so-called cylinders from which rubber mats for sport, recreation, children's play areas and insulating mats can be produced. From 15 to 25% of isocyanate mixture in a blend with rubber granules can be used to produce decorative sheets for the garden and recreation sector. The isocyanate mixture can also be used in a 2K system in the above-mentioned fields, the isocyanate mixture in amounts of from 25 to 50% functioning as curing agent, It is also possible for the isocyanate mixture to be used in amounts of from 7 to 18% with rubber granules in so-called 1K and 2K envelope coatings. The resulting coated rubber granules are preferably used as an infill material in artificial lawns.
The isocyanate mixtures according to the invention can also be used as 1K and 2K adhesives for the adhesive bonding of artificial lawns, textile and wooden floors, insulating mats, rubber mats and decorative sheets. It is also possible to use 1K and 2K spray coatings based on the isocyanate mixtures on resilient substrates (for example rubber granule mats) or rigid substrates (e.g. asphalt or concrete), which optionally contain from 5 to 80% structural fillers (such as SBR, EPDM, TPE-S granules or PU chips). 1K and 2K adhesion promoters or primers based on the isocyanate mixtures can likewise be used on substrates such as, for example, asphalt, cement-bonded substrates, wood or wood strip, of sports, recreational or children's play flooring. A further possible use is in a 2K system as a flow coating on resilient or rigid substrates, wherein the application can be carried out in one or more layers and optionally with infill granules (in particular EPDM granules of grain size 0.5 to 5 mm). The mixtures according to the invention can also be used as 2K filler compounds for closing the pores of substrates.
The 1K systems according to the invention are moisture-curing systems, The curing process can be carried out in situ without the addition of water (curing takes place by means of atmospheric moisture) or in an industrial manufacturing process with the targeted addition of water and optionally under pressure.
The invention will now be described in further detail with reference to the following non-limiting examples.
EXAMPLES
Hereinbelow, all percentages are wt. % unless indicated otherwise.
Preparation of the Isocyanate Mixtures:
An isocyanate mixture was placed in a reaction vessel and heated to 40 to 60° C., with stirring. Polyol compounds were added, with stirring, and stirring was continued until the theoretical NCO content to be expected according to the chosen stoichiometry had approximately been reached. The catalyst was then optionally added. After the optional addition of acid as stabilizer, the reaction mixture was cooled.
Table 1 below shows the isocyanate mixtures of Examples 1 to 5 prepared according to these instructions, and also some properties of the 1K polyurethanes cured by means of atmospheric moisture.
TABLE 1
Example 4
Example 5
Example 1
Example 2
Example 3
(comparison)
(comparison)
4,4′-MDI
18.50%
17.63%
19.40%
17.5%
26.9%
2,4′-MDI
17.90%
16.77%
15.90%
7.5%
11.5%
2,2′-MDI
5.20%
4.80%
3.97%
Polymeric MDI
4.0
TDI (80/20)
9.8
Arco PPG 2000,
58.40%
55.40%
55.34%
65.175
57.595
polypropylene
glycol having a
mean MW of 2000
and a functionality
of 2
2,2-Dimorpholine
0.02
diethyl ether (amine
catalyst)
Benzoyl chloride,
0.005
0.005
as stabiliser
Jeffsol PC,
5.4%
5.4%
propylene carbonate
NCO content
10.63
10.27
10.3
10.3
10.3
[wt. %]
Viscosity at 21° C.
4392
2380
2450
2899
5428
[mPas]
Curing time (21° C.,
16 h 30 min.
16 h
15 h 30 min.
24 h (dry to
12 h
46% rel. humidity,
(dry to touch)
(dry to
(dry to
touch)
(dry to touch)
0.6 mm layer
touch)
touch)
thickness)
Beginning of
9 h 30 min.
9 h
8 h 40 min.
9 h
6.5 h
reaction with
atmospheric
humidity
Hydrolytic stability
very good
very good
very good
very poor
very good
(80° C.)
Tensile strength
20.35
21.64
24.01
10.36
17.33
[MPa] (according to
DIN 53504)
Ultimate elongation
522
549
435
477
365
[%] (according to
DIN 53504)
In comparison with Example 5, Examples 1 to 3 according to the invention are distinguished by the fact that the reaction starts considerably later (about 40% improvement). It is particularly advantageous that curing is increased by only about 30% and is accordingly still within a technically expedient range. In Example 4, although the late starting reaction is comparable with that in Examples 1 to 3, the shorter curing time is advantageous. A further important advantage of Examples 1 to 3, in addition to the fact that they are TDI-free, is their markedly improved hydrolytic stability and their higher tensile strength, while the elongation is higher at the same time.
Preparation of the NCO Prepolymers:
Preparation of NCO Prepolymer A:
18.89 parts by weight of 2,4′-MDI were placed in a vessel at 50° C. 81.11 parts by weight of a polyester (prepared from adipic acid and ethylene glycol; OH number 56), preheated to 50° C., were than added, with stirring, After a reaction time of 7 hours at 80° C., the reaction was complete. A product having the following data was obtained:
NCO content:
2.98
wt. %
Viscosity (70° C.):
4800
mPas
Preparation of NCO Prepolymer B:
26.67 parts by weight of 2,4′-MDI were placed in a vessel at 50° C. 73.33 parts by weight of a polyether (Terathane® 1000 from INVISTA; OH number 112), preheated to 50° C., were then added. After a reaction time of 2 hours at 80° C., the reaction was complete. A product having the following data was obtained:
NCO content:
2.75
wt. %
Viscosity (70° C.):
5400
mPas
Isocyanate C:
Isocyanate mixture consisting of 36.9% 2,2′-MDI, 59.2% 2,4′-MDI and 3.9% 4,4′-MDI
Preparation of the Isocyanate Mixtures:
The above-mentioned NCO prepolymers were mixed with isocyanate C in the amounts according to Table 2 and stirred for one hour at 80° C. for the purpose of homogenization. Mixtures having the data indicated in Table 2 were obtained.
TABLE 2
NCO content
Viscosity
Isocyanate C
NCO prepolymer A
NCO prepolymer B
of the mixture
of the mixture
Mixture
[wt. %]
[wt. %]
[wt. %]
[wt. %]
mPas (70° C.)
M1
3.63
96.37
3.94
4700
M2
10.21
89.79
5.97
3150
M3
3.63
96.37
3.82
5500
M4
10.20
89.80
5.85
3800
M5
16.76
83.24
7.85
2700
The properties of the cast elastomers prepared from mixtures Ml to MS and M6 and M7 with Baytec® XL 1604 (from Bayer MaterialScience AG; 3,5-diamino-4-chloroisobutyl benzoate) are indicated in Table 3.
Preparation of the Cast Elastomers:
100 parts by weight of the isocyanate mixture were degassed in vacuo at 90° C., with slow stirring, until free of bubbles. The whole was then mixed with Baytec® XL 1604, which had been preheated to 100° C. The homogeneous melt was poured into moulds preheated to 110° C. and was maintained at 110° C. for 24 hours. The mechanical properties of the cast elastomers were then measured.
M6 is a NCO prepolymer based on 2,4′-MDI and Terathane® 1000 from INVISTA (OH number: 112). This prepolymer is obtainable from Bayer MaterialScience AG under the name Desmodur® VP.PU ME 40TF04 (NCO content: 3.93%).
M7 is a NCO prepolymer based on 2,4′-MDI and a polyadipate (prepared from adipic acid and ethylene glycol; OH number 56). This prepolymer is obtainable from Bayer MaterialScience AG under the name Desmodur® VP.PU MS 40TF01 (NCO content: 3.95%).
TABLE 3
Preparation of cast elastomers
11
12
Example
6
7
8
9
10
(comp.)
(comp.)
Isocyanate mixture
M1
M2
M3
M4
M5
M6
M7
Amount of
[parts by wt.]
100
100
100
100
100
100
100
Amount of Baytec ®
[parts by wt.]
10.6
16
10.3
15.8
21.2
10
10
XL1604
Casting time
[sec.]
330
135
495
240
115
480
210
Mechanical
properties
Shore A (DIN 53505)
92
98
89
97
99
91
92
Shore D (DIN 53505)
34
47
33
45
56
34
35
Stress (100%)
[MPa]
7
9
7
10
13
8
7
(DIN 53504)
Stress (300%)
[MPa]
13
17
13
20
28
11
12
(DIN 53504)
Stress at break
[MPa]
57
53
47
53
49
29
45
(DIN 53504)
Ultimate elongation
[%]
700
650
550
480
420
600
680
(DIN 53504)
Graves
[kN/m]
79
100
42
66
91
60
79
(DIN 53515)
Rebound resilience
[%]
41
43
50
47
50
52
43
(DIN 53512)
Abrasion
[mm 3 ]
38
49
25
25
40
46
70
(DIN 53516)
Permanent set, 22° C.
[%]
18
28
16
25
36
26
22
(DIN 53517)
Permanent set, 70° C.
[%]
35
52
32
47
66
44
44
(DIN 53517)
A comparison of the elastomers of Examples 8 and 11 (same NCO content of the isocyanate component; same soft segment (polyol)) shows that the elastomer according to the invention of Example 8 has a longer casting time and, in particular, a markedly better permanent set, better resilience, lower abrasion and better stress at break. The mechanical properties of the elastomer according to the invention are therefore clearly better.
A comparison of the elastomers of Example 6 and Comparison Example 12 (same NCO content of the isocyanate component; same soft segment (polyol)) shows that the elastomer according to the invention of Example 6 has a markedly longer casting time, a better permanent set, lower abrasion and better stress at break, so that the elastomer of Example 6 is clearly superior to the elastomer of Comparison Example 12 in terms of its mechanical properties.
It will be appreciated by those skilled in the art that changes could be made to the embodiments described above without departing from the broad inventive concept thereof. It is understood, therefore, that this invention is not limited to the particular embodiments disclosed, but it is intended to cover modifications within the spirit and scope of the present invention as defined by the appended claims.
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Isocyanate mixtures comprising: (a) NCO prepolymers having an NCO content of 1.5 to 18 wt. %; and (b) 1 to 40 wt. % of monomeric 2,2′-diisocyanatodiphenylmethane, based on the isocyanate mixture; wherein the isocyanate mixture has a total NCO content of from 2 to 22 wt. %; polyisocyanate polyaddition products prepared therefrom; and methods of making the same.
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FIELD OF THE INVENTION
[0001] The invention pertains to communication systems, such as wireless local area networks and land mobile radio (LMR) systems, for wireless communication between a plurality of mobile nodes as well as between one or more geographically fixed nodes and the mobile nodes. More particularly, the invention pertains to a method and apparatus for distributing data to a plurality of mobile nodes utilizing a combination of communication with fixed access points and a peer-to-peer data passing scheme.
BACKGROUND OF THE INVENTION
[0002] Civilian public safety organizations, such as municipal police squads, municipal fire departments, private security organizations, and other public service organizations, commonly utilize two-way radio communication systems that allow mobile nodes, such as police squad cars, fire trucks, individual patrollers with two-way radios, etc., to communicate with each other as well as with one or more geographically fixed nodes, such as a headquarters or precinct building. Such systems are, in essence, wireless local area networks (WLANs). Such systems are commonly used to carry voice communications, often using encrypted digital channels, as well as other data. For instance, squad cars often have PCs, laptop computers or other computing devices that can connect to the WLAN to download various forms of data, such as motor vehicle records for a particular driver or license plate, arrest records for particular individuals, bulletins from headquarters, photographs (such as mug shots), etc, from one or more central servers coupled to the WLAN (typically through a wired LAN). Often, the mobile nodes, such as squad cars maintain local copies of certain types of data, such as mug shots and bulletins.
[0003] In addition, the mobile nodes may, not only receive data from a central server, but send data to the central server. For instance, police officers may prepare and transmit arrest reports and other reports to the central server using the WLAN so that coworkers working in a precinct building can have more immediate access to such reports, rather than waiting for officers to physically return to the precinct before such reports can be entered (in a database maintained on the central server). This may also make record keeping more efficient since an officer can directly create an electronic version of the record, rather than preparing a hard copy of the report, which would then need to be entered into the database in a separate manual step when the officer returned to the precinct.
[0004] These types of WLANs typically cover a specific geographic area, such as a municipality or county. The area that such a network must cover often is larger than can be covered by a single fixed antenna because the power with which two way radios and related fixed antennas can transmit data is limited, not only by practical weight and power considerations (especially for the mobile nodes), but also by local state or national regulation. Accordingly, a plurality of antenna nodes positioned at geographically separate locations in the municipality might commonly be coupled to a wired LAN, each antenna having full-time haul back capabilities to the central server(s) via the wired LAN. Of course, the wired LAN (which may also be considered the wired portion of an overall LAN that also includes the wireless LAN) also typically would include other fixed nodes in addition to the antenna nodes, such as dispatchers and desktop computers I that also communicate with the central server(s) and/or the mobile nodes. When a mobile node is within range of a fixed access point it communicates directly with the host (or central server) via the fixed access point. However, when a mobile node moves beyond transmission range of a fixed access point, it essentially cannot communicate with the WLAN until it returns within range of one of the fixed access points. Thus, if a central server has data to be transmitted to a particular mobile node or vice versa and that mobile node is out of radio transmission range of any fixed access point, that mobile node simply was unable to receive the data until the mobile node came back into radio range.
[0005] These types of WLANs commonly also incorporate a protocol by which two mobile nodes can directly communicate with each other on a peer-to-peer basis if they are within range of each other.
[0006] The cost of installing the infrastructure to support multiple remote fixed access points (e.g., antennas) for such WLANs can be substantial and includes costs such as leases on the lines necessary to connect the remote fixed access points to the wired portion of the LAN.
[0007] It often is economically infeasible to provide enough fixed access points (i.e., antennas) to fully cover an municipality. Accordingly, mobile nodes, e.g., squad cars, may be out of communication with headquarters and/or other mobile nodes for lengthy periods of time and, hence, be unable to receive potentially important data and updates.
[0008] Accordingly, it is an object of the present invention to provide an improved wireless communication system.
[0009] It is another object of the present invention to provide a WLAN that enables data to be indirectly transmitted between a mobile node and a server even when the mobile node is out of range of any fixed access point.
[0010] It is a further object of the present invention to provide a wireless communication system in which data can be transferred between a mobile node and a fixed access point through other mobile nodes.
SUMMARY OF THE INVENTION
[0011] The invention is a wireless communication method and apparatus by which, when a first mobile wireless node of a communication network is out of radio transmission range of any fixed antenna node, data that is to be transferred between that mobile node and the fixed antenna node is first transferred from the transmitting node (either the first mobile node or the fixed antenna node depending on the direction of data flow) to one or more second mobile nodes that are within radio range of the transmitting node and subsequently transferred from one of the second mobile nodes to the first mobile node if and when the first and second mobile nodes come within radio transmission range of each other.
[0012] While the protocol for assuring that appropriate data is passed at appropriate times to the mobile nodes and vice versa can take countless forms, one preferred scheme utilizes a software agent in each mobile node that maintains a list of files, directories or other forms of data that need to be synchronized with a central server periodically. The agent periodically checks to determine if those files, directories, etc. are up-to-date by querying the central server through a fixed access point for newer versions of those files, etc. If the mobile node establishes a link with the central server through a fixed access point (i.e., an antenna node), the mobile node compares its versions of the selected files, directories, etc. with the corresponding data maintained in the central server and downloads data corresponding to any updates from the central server in order to update its records. If the agent cannot establish communication with the central server through a fixed access point, it then searches for other peer mobile nodes within radio range. If a peer mobile node (or fixed access point) is discovered, the first mobile node compares its versions of the selected files, directories, etc. with those maintained in the peer with which it is communicating. If its version of any of those files, directories, etc. is older than the corresponding versions in the other peer (or the fixed access point), it downloads from the peer the necessary data for updating its own records and updates its corresponding outdated files, etc. accordingly. Preferably, the synchronization comprises full bidirectional synchronization. Specifically, it is possible that the mobile node that requested an update from another mobile node actually has more recent data than the responding mobile node. In such a case, the updating data should be sent from the requesting node to the responding node even though the responding node did not initiate the synchronization sequence.
[0013] The data passing also can occur in the opposite direction from mobile nodes to fixed access points. For example, a fixed access point can be provided in a remote area of a coverage zone in a locale that mobile nodes are expected to frequently visit. The access point can be set up inexpensively without providing direct, wired back haul to the central server, which can be extremely expensive. Rather, the fixed access point updates its files, etc. by running the same software agent as the mobile nodes thereby querying mobile nodes that come within radio range of it for updated data. The remote fixed access point can then turn around and provide that data to other mobile nodes that issue requests for updates within radio transmission range of the remote fixed access point.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] [0014]FIG. 1 is a diagram illustrating an exemplary municipality in which a WLAN in accordance with the present invention is operating.
[0015] [0015]FIG. 2 is a flow diagram illustrating operation of a radio unit in accordance with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0016] [0016]FIG. 1 is an overhead view of an exemplary geographic zone that is to be covered by a WLAN in accordance with the present invention. For sake of example, the discussion and descriptions below of specific embodiments of the invention will be set forth in connection with an exemplary police force using the WLAN for radio communication between multiple fixed nodes, such as a police headquarters, precincts and fueling depots, and a plurality of mobile nodes, e.g., squad cars. The wireless communication between the mobile nodes and the fixed nodes typically would be carried over encrypted digital channels in accordance with any reasonable LMR system. One standard for LMR is 802.11b DSSS WLAN established by the IEEE. However, the present invention can be employed in connection with any type of wireless LAN regardless of whether the communication channels are encrypted or not, whether the communication channels are digital or not or any particular communication protocol or standard.
[0017] Referring now to FIG. 1, the geographic zone 100 to be covered by the WLAN comprises a municipality in which the police department has a headquarters 102 , a secondary precinct 104 at a geographically remote location from the headquarters 102 and a fueling depot 106 where squad cars can refuel. In this example, a data server 108 physically located at the headquarters 102 is coupled to a wired local area network 109 . The headquarters also has a transceiver 111 including an antenna 112 for communicating with mobile nodes, such as squad cars 120 via a wireless LAN. The police department also maintains at least two other transceivers 113 , 114 that form nodes of the wired LAN and associated antennas 115 , 116 that can transmit data to and receive data from mobile nodes (and, accordingly, also are nodes of the wireless LAN). Each antenna 112 , 115 , 116 has a transmission coverage area 112 a , 115 a , 116 a , respectively, that can cover only a portion of the total geographic zone 100 . In this example, none of the transmission coverage areas of the three antennas overlap. In other embodiments, they could overlap somewhat. In this particular example, antenna 115 is positioned at the remote precinct house 104 and antenna 116 is located at the fuel depot 106 .
[0018] Finally, there is a fourth transceiver 117 and antenna 118 preferentially located in a location that the squad cars are expected to pass near on a regular basis. Antenna node 118 has a remote server 119 associated therewith that is intended to store data redundant of the data on central server 108 . However, antenna 118 , transceiver 117 , and server 119 are not coupled to the wired LAN 109 . The manner in which the data in server 118 is kept current is discussed in detail below and forms a significant aspect of one embodiment of the present invention. Blocks 120 - 1 , 120 - 2 , 120 - 3 , 120 - 4 , 120 - 5 , and 120 - 6 represent squad cars in various locations throughout zone 100 .
[0019] In addition to supporting real time, two-way voice communication between police officers in the field (e.g., in squad cars 120 ) and police personnel at headquarters 102 and the secondary precinct 104 , the WLAN also provides digital data communication between various mobile and fixed computing devices such as computers, servers and portable laptop computers in the squad cars, precint, and elsewhere. These various computing devices might store particular data files such as mug shots, lists of stolen vehicles, and other records. Such records may be centrally stored on the server 108 and updated therein on a regular basis. The mobile nodes (e.g., the computers in the squad cars) often also maintain local copies of such data. It is desirable to maintain the copies of those records in the mobile nodes as consistently as possible with the latest data in the central server 108 . Updates may include both modifications to previously existing files or other forms of data as well as the addition of new data, such as the addition of new files (e.g., mug shots) to a particular directory.
[0020] One common scheme for maintaining synchronization of the data files in the mobile nodes with the main server 108 is for the mobile nodes to maintain a list of files and/or directories that need to be synchronized to the files in the main server 108 . The mobile nodes periodically issue a request over the WLAN to synchronize to the files and/or directories in the central server. If the mobile node 120 is within transmission range of one of the fixed antennas 112 , 115 , and 116 , the transceiver coupled to that antenna acknowledges the request, retrieves the pertinent data from the control server 108 though the wired LAN 109 , and transmits the desired data to the requesting mobile node. For instance, squad car 120 - 2 is within radio transmission range 112 a of antenna 112 and therefore can synchronize directly to server 108 through antenna 112 , as illustrated at 131 . Likewise, squad car 120 - 5 is within radio transmission range 116 a of antenna 116 and therefore can synchronize directly to server 108 through antenna 116 , as illustrated at 134 . Finally, squad car 120 - 3 is within radio transmission range 115 a of antenna 115 and therefore can synchronize directly to server 108 through antenna 115 as illustrated at 133 . However squad cars 120 - 1 , 120 - 4 and 120 - 6 are not within the transmission ranges of any of the fixed antennas that are coupled to the wired LAN and, therefore, cannot communicate directly with the central server 108 . Squad car 120 - 1 is within transmission range of fixed antenna 118 , but that antenna is not directly coupled to the wired LAN. Antenna 118 and squad car 120 - 1 will be discussed later in this specification in connection with another feature of the present invention.
[0021] The specific protocol by which synchronization is performed can take any number of well known forms and is not a limitation of the present invention. In one exemplary embodiment, each mobile node 120 can maintain a time stamp indicating the last time its relevant files and/or directories were updated, which time stamp is sent to the central server along with the request for synchronization. The central server reads the time stamp and sends to the mobile node copies of any files and/or directories that have been modified since the time indicated in the time stamp. The mobile node then replaces the old file with the corresponding new file or adds any new files.
[0022] As can be seen in FIG. 1, there are large portions of zone 100 that are not within the coverage range of any of the fixed antennas 112 , 115 , and 116 . Accordingly, if a squad car 120 is not within one of the coverage range 112 a , 115 a , 116 a at the time its computer requests synchronization with the central server, the synchronization cannot be carried out as described above.
[0023] In order to alleviate this problem and provide more consistent and up-to-date data to all mobile nodes, a data passing scheme is provided in accordance with the present invention. In accordance therewith, if a mobile node is not within the coverage range 112 a , 115 a , 116 a of one of the fixed antennas that is directly coupled to the central server through the wired LAN, it still can synchronize with the central server 108 indirectly.
[0024] Particularly, in accordance with the invention, a mobile node 120 can synchronize with other mobile nodes within transmission range of it. More particularly, if a first squad car that has not been within a coverage range of one of the fixed antennas for a long period of time comes within transmission range of another squad car that has been within the coverage range of one of the antennas and synchronized with the central server more recently, the first squad car will be able to obtain a current version (or, at least, a more current version then it previously had) of the pertinent files and directories. For instance, consider squad car 120 - 4 whose assignment is a stake out in a portion of zone 100 that is not covered by the coverage area of any of the wired fixed access points (i.e., antennas) 112 , 115 , 116 . However, squad car 120 - 2 has a different task that occasionally takes it in close proximity to squad car 120 - 4 and also frequently passes through the coverage area 112 a of at least one of the fixed antennas 112 . Accordingly, squad car 120 - 2 has a current or almost current version of the pertinent files and directories. Thus, for instance, let us assume that, at the designated time for synchronization of squad car 120 - 4 , squad car 120 - 4 cannot contact one of the fixed antennas and therefore cannot directly update its records, but that, at that time, squad car 120 - 2 is within transmission range of squad car 120 - 4 .
[0025] In accordance with one embodiment of the invention, at the designated time, the computer in squad car 120 - 4 first issues a request to the central server for synchronization. However, because squad car 120 - 4 is out of the coverage area of any antenna, it is unable to communicate with the central server. Squad car 120 - 4 then switches over to a secondary scheme in which it issues a request for synchronization to any other mobile node within its transmission range. Mobile node 120 - 2 receives the request and responds to mobile node 120 - 4 . Mobile nodes 120 - 2 and 120 - 4 thereafter synchronize to each other, as illustrated at 136 in the Figure. Of course, it is possible that the requesting mobile node, e.g., 120 - 4 , may actually have more current information than the responding mobile node, e.g., 120 - 2 . Accordingly, in a preferred embodiment, the protocol allows two nodes that have contacted each other as described above to each synchronize to the most recent version of the files and/or directories regardless of the direction of data flow. This can be accomplished using a time stamp scheme as discussed above in connection with directly synchronizing with the central server.
[0026] In most practical embodiments, it is likely that, to the extent that any two mobile nodes are not already synchronized, all of the pertinent files and directories in one of the mobile nodes will be more current than the other. Accordingly, the data for synchronizing will flow in only one direction. However, in other embodiments, it may be possible for some of the pertinent files and directories in one of the mobile nodes to be more up to date than in the other mobile node, while other files and directories in the other node may be more up-to-date than in the first node. In such embodiments, synchronization data can flow in both directions.
[0027] Note that a mobile node that responds to the request of another mobile node may actually be within radio transmission range of a fixed antenna at the time it receives a request for synchronization. For instance, let us assume that squad car 120 - 6 requests synchronization with a mobile node when squad cars 120 - 6 and 120 - 3 are located as shown in FIG. 1, in which squad car 120 - 3 is within range 115 a of antenna 115 and also is within range to communicate directly with squad car 120 - 6 , but squad car 120 - 6 is not within range of any of the antennas. Accordingly, in at least one preferred embodiment of the invention, when a mobile node, such as squad car 120 - 3 , receives a request for synchronization from another mobile node, such as squad car 120 - 6 , it first attempts to synchronize directly with the central server 108 through a fixed access point, e.g., 115 , before proceeding with synchronization with the requesting mobile node 120 - 6 , regardless of whether it is the otherwise designated time for squad car 120 - 3 to do so. In this manner, both the requesting mobile node, e.g., squad car 120 - 6 , and the responding mobile node, e.g., squad car 120 - 3 , receive the most up-to-date data possible.
[0028] All of the steps of the various embodiments described above can be performed by any reasonable circuit, such as a digital signal processor, a microcontroller, a finite state machine, a microprocessor, a programmed general purpose computer. Most likely, the steps of the present invention are performed by a software agent running on the general purpose computer that already is in the squad cars for storing and processing the very data that is synchronized in accordance with the present invention.
[0029] [0029]FIG. 2 is a simple flowchart illustrating processing at a mobile node in accordance with one particular embodiment of the present invention. It should be apparent to persons of skill in the related arts that FIG. 2 represents merely one exemplary synchronization scheme and many others are possible while still practicing the present invention.
[0030] The software agent is invoked in step 201 , for instance, by an interrupt scheduled to be asserted at a fixed interval after the last synchronization process in accordance with the present invention. Then, in step 205 , the mobile node attempts to contact the central server through one of the fixed access points. In decision step 207 , if the mobile node makes contact with the central server through a fixed access point, processing jumps to step 215 , where the mobile node synchronizes to the central server.
[0031] If, on the other hand, contact cannot be established with a fixed access point, processing proceeds to step 209 in which the mobile node attempts to contact another mobile node with which to synchronize. In step 211 , if the mobile node makes contact with another mobile node, processing proceeds to step 215 , in which the two mobile nodes synchronize to each other. If, on the other hand, the mobile node cannot contact another mobile node. Processing proceeds to step 213 in which the node waits a predetermined amount of time and then returns to step 205 to attempt to synchronize again.
[0032] In accordance with a further aspect of the invention, a fixed node that is not directly coupled to the central server 108 through the wired LAN can be updated in exactly the same manner as described above for the mobile nodes. For instance, consider fixed antenna 118 . Let us assume that it is undesirable to provide direct back haul from antenna 118 to the central server 108 via wired LAN 121 . This could be for several reasons, such as the cost of providing the necessary infrastructure, including leased land lines, to provide back haul. In at least one embodiment of the invention, the fixed antenna node 118 is essentially identical in all operating aspects to the mobile nodes 120 described above, except that it is in a fixed location. This node includes an antenna 118 , a transceiver 117 and a data server 119 . As mobile nodes, such as squad car 120 - 1 , come within the coverage zone of antenna 118 , they can synchronize with the server 119 . In some cases, the squad car will have more recent data than the server 119 and, in other cases, the server 119 will have more recent data than the squad car (because it had previously synchronized with another squad car that synchronized with the central server 108 more recently than the present squad car). Accordingly, synchronization can occur in both directions.
[0033] Hence, the present invention provides a wireless communication system that utilizes a peer-to-peer data processing scheme as well as a server-client protocol to provide excellent coverage over a large area with a substantially reduced requirement for infrastructure, such as antennas and land lines.
[0034] Having thus described a few particular embodiments of the invention, various alterations, modifications, and improvements will readily occur to those skilled in the art. Such alterations, modifications and improvements as are made obvious by this disclosure are intended to be part of this description though not expressly stated herein, and are intended to be within the spirit and scope of the invention. Accordingly, the foregoing description is by way of example only, and not limiting. The invention is limited only as defined in the following claims and equivalents thereto.
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The invention is a method and apparatus in which data can be transferred between a mobile node and a fixed based node in a wireless local area network through a data passing scheme in which data can be bounced between a base node and an out-of-range mobile node through other mobile nodes.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates generally to a device for loading bales of biomass into a container for transporting to another location, and more particularly to a bale loading apparatus that simplifies and speeds up the loading process.
[0003] 2. Background Art
[0004] U.S. Pat. No. 8,408,857to a Bale Picking Truck by Kelderman shows a method and apparatus for quickly and efficiently picking up and removing biomass bales from a field in which the biomass was baled, compactly stacking the bales after picking the bales off the ground, and efficiently depositing the bales on the ground or platform at a staging area for later loading onto a semi-trailer, straight truck, or train car.
[0005] Published U.S. Patent Application No. 2012/0045310 to a Bale De-Stacker by Kelderman relates to a method and apparatus for efficiently unstacking square bales from a stack and conveying the square bales in small sets or individually once they arrive from their aforementioned staging area to the place they are to be used, such as in an ethanol production plant, a plant where the bales are to be burned for fuel, or a feedlot.
[0006] U.S. Pat. No. 8,734,077 to a Bale Loading Trailer and Method of Using Same by Kelderman relates to the step of picking sets of bales off the ground, such as at the aforementioned staging area, and loading said bales into a trailer via a moving floor. The aforementioned patents and Published U.S. Patent Application are hereby incorporated herein by reference in their entirety.
SUMMARY OF THE INVENTION
[0007] The present invention is an improvement over that disclosed in U.S. Pat. No. 8,734,077. The moving floor of the present invention comprises a hydraulic, electric, or other motor disposed approximately midway along the direction the bales are moved. The motor drives two sets of chains or belts, or any equivalent thereof. The first set of chains or belts is disposed rearmost in the container, while the second set is disposed front-most in the container. During loading from the rear of the container, the first set of chains can transfer sets of bales approximately up to the drive motor while the second set of chains can transfer sets of bales to the front of the container. In unloading, the second set of chains transfer sets of bales to the proximity of the drive motor, while the first set of chains deliver sets of bales to the rear of the container for unloading.
[0008] An advantage of locating the motor such that conveyors are disposed on both sides thereof is a reduction in strain in the conveyors compared to the case where the motor is disposed at an extreme end of the container, and therefore, the conveyor.
[0009] In other embodiments of the present invention, the bales are introduced into the container at the approximate center of the container. When the bales are introduced into the container near the drive motor location, the sets of conveyors must reverse direction in order to move the sets of bales to the extreme ends of the container.
[0010] A novel aspect of the present invention is the open platform on which to load sets of bales from the side. In the case where the open platform is in the rear, rear loading is another option. Of course, a container may be made to load from the front, approximate middle, and rear. In any case, sets of bales may be loaded from either side of the container.
[0011] The term open, for the purposes of this document, including the claims, is hereby defined as without sides. The container of the present invention includes sides—solid, barred, meshed, etc.—to contain the bales of biomass during transport. The loading port, in contradistinction, has no such sides. Bracing along the top of the loading port may or may not be incorporated, but this type of loading port is still termed open.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The above mentioned improvement is effected through provision of the method and apparatus described in the following detailed description, particularly when studied in conjunction with the drawings, wherein:
[0013] FIG. 1 is a side elevational view of a bale loading container in conjunction with a semi-tractor trailer and constructed for loading sets of bales generally into the rear of the container;
[0014] FIG. 2 is a side elevational view of a bale loading container in conjunction with a semi-tractor trailer and constructed for loading sets of bales generally into the approximate middle of the container;
[0015] FIG. 3 is a side elevational view of a bale loading container in conjunction with a semi-tractor trailer and constructed for loading sets of bales optionally into the rear or approximate middle of the container;
[0016] FIG. 4 is a side elevational view of a bale loading container in conjunction with a straight truck and constructed for loading sets of bales generally into the rear of the container;
[0017] FIG. 5 is a top plan form view of a container moving floor comprising chain conveyors;
[0018] FIG. 6 is a plan form view of a container moving floor comprising chain conveyors from the underside;
[0019] FIG. 7 is a top plan form view of a container moving floor comprising belt conveyors;
[0020] FIG. 8 is a plan form view of a container moving floor comprising belt conveyors from the underside;
[0021] FIG. 9 is a side elevational view of a bale loading container in conjunction with a semi-tractor trailer wherein sets of bales are shown being loaded generally into the rear of the container;
[0022] FIG. 10 is a flow diagram illustrating a procedure for loading the bale loading container;
[0023] FIG. 11 illustrates a remote control device;
[0024] FIG. 12 is a top plan form view of a container moving floor comprising chain conveyors illustrating a bale stack having been set on the moving floor;
[0025] FIG. 13 is a top plan form view of a container moving floor comprising chain conveyors illustrating the bales stack having been advanced out of the loading port area;
[0026] FIG. 14 is a top plan form view of a container moving floor comprising chain conveyors illustrating a full bale loading container; and
[0027] FIG. 15 is a view like FIG. 14 but with the bale loading container full of bales with the leading edge of the last bale stack between the squeeze flaps which have been actuated so they are in their narrowest position, clamping on the last bale stack, and with a single ratchet strap to secure the load in this configuration.
[0028] Elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the dimensions and/or relative positioning of some of the elements in the figures may be exaggerated relative to other elements to help to improve understanding of various embodiments 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. Certain actions and/or steps may be described or depicted in a particular order of occurrence while those skilled in the art will understand that such specificity with respect to sequence is not actually required. The terms and expressions used herein have the ordinary technical meaning as is accorded to such terms and expressions by persons skilled in the technical field as set forth above except where different specific meanings have otherwise been set forth herein.
DETAILED DESCRIPTION
[0029] Referring now to the drawings, wherein like reference numerals indicate identical or similar parts throughout the several views, FIGS. 1-15 show preferred embodiments of the present invention.
[0030] Referring now to FIG. 1 the bale loading container 10 of the present invention is shown in a configuration wherein it can be conveyed over public and/or private roads from place to place, either empty or loaded by a prime mover 100 , such as a semi-tractor, agricultural tractor, etc. The bale loading container 10 includes a loading port 110 disposed generally in the rear portion of the bale loading container 10 for loading and unloading.
[0031] Squeeze flaps 120 are included on both sides in the general front of the loading area to: (1) guide the bale stack 910 ( FIG. 9 ) into the container 10 , and (b) to reduce the width, if necessary, of the bale stack 910 by hydraulically actuating the squeeze flaps 120 using actuators 510 ( FIG. 5 ). To effect these goals, the squeeze flaps 120 comprise a front post 130 , operatively, pivotally affixed to the bale loading container 10 and a rear post 140 , made to swing outward and inward as the front post 130 is rotated about its axis of rotation 150 . The squeeze flaps 120 are preferably hydraulically actuated, but may also be electrically or pneumatically actuated.
[0032] Bale stacks 910 are transferred from and to the loading port 110 by virtue of conveyors, such as the chain conveyors 160 shown in FIGS. 1-6 and 9 . The chain conveyors 160 are driven by a driver 170 , which may be hydraulic, pneumatic, electric, or power-take-off driven.
[0033] In FIG. 2 , the loading port 110 is near the middle of the bale loading container 10 . This location of the loading port 110 will be referred to as the center of the container, and is hereby defined as a location such that bale stacks 910 may be transferred both toward the front of the trailer and toward the back of the trailer during loading. Therefore, there is space to store bale stacks 910 fore and aft of the loading port 110 . Specifically, the term center as referring to the location of the loading port 110 is not limited to the exact geometric center (one half the length) of the bale loading container 10 , nor is it limited to the exact geometric center of the chain conveyors 160 .
[0034] Squeeze flaps 120 are included on both sides in the general front of the loading area to: (1) guide the bale stack 910 into the container 10 , and (2) to reduce the width, if necessary, of the bale stack 910 by hydraulically actuating the squeeze flaps 120 .
[0035] To effect these goals, the squeeze flaps 120 comprise a front post 130 , operatively, pivotally affixed to the bale loading container 10 and a rear post 140 , made to swing outward and inward as the front post 130 is rotated about its axis of rotation 150 . The squeeze flaps 120 are preferably hydraulically actuated.
[0036] Squeeze flaps 220 are included on both sides in the general rear of the loading area to: (1) guide the bale stack 910 into the container 10 , and (b) to reduce the width, if necessary, of the bale stack 910 by hydraulically actuating the squeeze flaps 220 . To effect these goals, the squeeze flaps 220 comprise a rear post 230 , operatively, pivotally affixed to the bale loading container 10 and a front post 240 , made to swing outward and inward as the rear post 230 is rotated about its axis of rotation 250 . The squeeze flaps 220 are preferably hydraulically actuated, but may be pneumatically or electrically actuated, instead.
[0037] The bale loading container 10 shown in FIG. 3 allows for loading and unloading to be accomplished at two loading ports 110 . One is center located while the other is located generally at the rear of the bale loading container 10 .
[0038] Details of the chain conveyors 160 and the driver 170 are shown more completely in FIGS. 3 , 4 , and 9 where some of the floor of the bale loading container 10 has been made transparent. The driver 170 is located such that there are chains both fore and aft of the driver 170 . This location of the driver 170 will be referred to as the center of the container 10 , and is hereby defined as a location such that chain conveyors are driven thereby both fore and aft of the driver 170 . Specifically, the term center as referring to the location of the driver 170 is not limited to the exact geometric center (one half the length) of the bale loading container 10 , nor the exact geometric center of the chain conveyors 160 .
[0039] Compared to driving the chain conveyors 160 from one extreme end of the bale loading container 10 , an advantage to driving the chain conveyors 160 in the center of the bale loading container 10 is the strain on the chains is reduced.
[0040] Drive cogs 330 are employed at the driver 170 to engage the chain conveyors 160 and provide slipless drive. Outboard cogs 340 are engaged by the chain conveyors 160 at their respective extreme ends.
[0041] The term forward is herein defined for the purposes of this document, including the claims, as the principle direction the bale loading container 10 is conveyed by the prime mover 100 . An arrow indicating the forward direction 350 is shown in FIG. 3 . In particular, the forward chain conveyors 310 are located in the forward direction from the driver 170 . The term aft is defined as the opposite direction of forward.
[0042] A sensor 330 , 340 is included at each end of the bale loading container 10 toward which bale stacks 910 travel during loading. In a preferred embodiment, only one such sensor 330 , 340 is included, and that at the forward end of the bale loading container 10 , as shown in FIG. 9 . The sensor 330 , 340 signals the driver 170 to stop conveying the bale stacks 910 when the forward-most bale stack 910 reaches an associated far end of the bale loading container 10 . It should be clear that the bale loading container 10 of FIG. 1 needs only one sensor 330 , located at the forward end of the bale loading container 10 as this is the only end toward which bale stacks 910 travel upon loading.
[0043] An alternative configuration is shown in FIG. 4 , where the bale loading container 10 is transported on a straight truck. The bale loading container is not limited to any particular prime mover used to transfer the same from place to place.
[0044] The chain conveyors 160 are shown from the top in FIG. 5 . The chains appearing in this view contact the bale stacks 910 for the purpose of conveying the bale stacks 910 through the bale loading container 10 for loading and unloading.
[0045] It is noted that the conveyors 160 are illustrated as roller chain conveyors, but web chains or belts 710 , such as those shown in FIGS. 7 and 8 , may be used instead of the roller chain conveyor belts. Chain conveyor systems may be similar to the gathering chains 410 shown in FIG. 5 of U.S. Pat. No. 8,734,077 to a Bale Picking Truck by Kelderman, incorporated herein in its entirety by reference.
[0046] The underside of the chain conveyors 160 is shown in FIG. 6 . Here, it can be seen how each driver 170 simultaneously drives forward chain conveyors 310 and aft chain conveyors 320 via shafts 610 . Cogs 330 are affixed to the shafts 610 , which engage the chain conveyors 160 to provide drive without slip.
[0047] An alternate embodiment of the present invention is shown in FIGS. 7 and 8 . Instead of chain conveyors 160 , conveyor belts 710 are used to move bale stacks 910 into and out of the bale loading container 10 . The belts engage belt pulleys 810 , the belt pulleys 810 being driven by the driver 170 .
[0048] Stacks of bales 910 are shown being loaded into the open loading port 110 in FIG. 9 . A stack of bales may comprise, for instance, six bales—two wide and three high. The bales are set on the platform of the loading port 110 using a fork lift, bale spear, bale squeeze, or any other device capable of lifting at least one bale to the platform.
[0049] The procedure for loading the bale loading container 10 is illustrated in FIG. 10 . In step 1010 , a bale stack 910 is set on the platform of the bale loading container 10 . The operator, or other person involved in the loading process, uses a remote 1100 such as that shown in FIG. 11 , or a lever 920 , pushbutton (not shown), or other control action to actuate the drive 170 , causing the chain conveyors 160 to move the bale stack 910 adequately to clear the platform of the open loading port 110 to make room for another bale stack 910 , as shown in step 1020 . If the bale loading container 10 is full 1030 , as indicated by the sensor 330 , 340 , or by counting the bale stacks 910 already loaded, a final bale stack 910 is loaded onto the platform of the bale loading container 10 , as indicated in step 1040 . If possible, this last bale stack 910 is advanced sufficiently to enter the squeeze flaps 120 , and the squeeze flaps 120 narrowed at the end opposite the pivot axis 150 to hold the last bale stack securely for transport.
[0050] If the bale loading container 10 is not full at comparison block 1030 , the process is repeated, starting with step 1010 where a bale stack 910 is set on the platform of the bale loading container 10 .
[0051] The example remote control unit 1100 shown in FIG. 11 , includes a display 1110 for warnings and other feedback, forward (F) and reverse (R) chain conveyor controls 1120 , chain conveyor speed control 1130 , and squeeze flap control 1140 . It is to be understood, this is only an example. The remote control device 1100 is not limited to these functions, nor are all these functions necessarily part of the present invention. The remote control device 1100 may be wired or wireless.
[0052] The display 1110 of the remote control unit 1100 may be used to indicate the bale loading container 10 is full. However, that information may also be provided by a sound, emanating from a sound generator 1150 , or vibration, generated by a vibrator 1160 , both detectable by the operator.
[0053] Unloading the bale loading container 10 may be accomplished by reversing the loading process. The driver 170 is necessarily reversible. Typically, the bale stacks 910 are unloaded from the rear of the bale loading container 10 , even if they are loaded into the center.
[0054] The action of the squeeze flaps 120 is illustrated in FIGS. 12-15 . The bale stacks 910 in these figures are shown in a semi-transparent state so the conveyor system 160 , 170 and squeeze flaps 120 may be seen. In FIG. 12 , a bale stack 910 has been set on the platform of the bale loading container 10 , ready for loading. Note that the bales are not well aligned with the sides of the bale loading container 10 .
[0055] The bale stack 910 is then advanced in the direction of the arrow, as shown in FIG. 13 . Due to the need for alignment, the squeeze flaps 120 are pivoted inward on the pivot axis 150 (not shown in FIGS. 12-15 ), thus forcing the bales inward. The result is better alignment and a narrower footprint of the bale stack 910 . When individual bales have broadened due to being stacked on or other influences, the squeeze flaps 120 are brought to bear to reduce the breadth of the overall bale stack 910 , and hence, the individual bales.
[0056] In FIG. 14 , the bale stack has been aligned and cleared out of the loading port 110 . The squeeze flaps 120 have been returned to their broadened position where they can act as a funnel to direct bale stacks not needing much alignment or narrowing.
[0057] The bale loading container 10 has been filled in FIG. 15 . The sensor 330 has sensed the proximity of a bale stack and signaled the operator. In response to this signal, the operator has loaded a last bale stack 1510 and advanced it so the leading edge of the last bale stack 1510 resides between the squeeze flaps 120 . The squeeze flaps 120 have been actuated so they are in their narrowest position, clamping on the last bale stack 1510 . A single ratchet strap 1520 is typically all that is required to secure the load in this configuration.
[0058] In the event the last bale stack 1510 cannot be advanced sufficiently to bring its leading edge between the squeeze flaps 120 , a second ratchet strap 1520 is typically applied to the last bale stack 1510 in order to secure the same.
[0059] Those skilled in the art will recognize that a wide variety of modifications, alterations, and combinations can be made with respect to the above described embodiments without departing from the spirit and scope of the invention, and that such modifications, alterations, and combinations are to be viewed as being within the ambit of the inventive concept as expressed by the attached claims.
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An apparatus for loading a container with stacks of bales comprising biomass. Conveyors are driven from a mid-point between the ends of the container, thus reducing the strain on the conveyor material. Squeeze flaps help guide the stacks of bales into the container, and provide the ability to reduce the width of the bale stack by hydraulically actuating the squeeze flaps. A remote control device is used in the process of loading and a sensor senses when the container is full.
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BACKGROUND OF THE INVENTION
1. Technical Field
The present invention relates in general to drill bits and, in particular, to an improved system, method, and apparatus for a steel tooth drill bit having enhanced tooth breakage resistance.
2. Description of the Related Art
In the prior art, steel tooth drill bits are great tools for drilling multiple formations due to the ability of their teeth to flex when encountering hard formations. However, this ability to provide flexure can cause cracking at the base of the teeth in the weld deposit and carburized area under the iron-based hardfacing deposits. Moreover, the cracks can grow during service or can aggravate pre-existing thermal cracks from the initial manufacturing process.
The manufacturing cracks can be caused by a variety of sources, but are primarily from the thermal stresses induced during the welding process while using iron-based hardfacing materials at the base of the teeth and subsequent hardening and carburization of the cone. The hardfacing can relieve the stress in the form of a crack. The cracks can propagate directly into the base steel of the teeth and/or the cone shell. The extent of the cracking is dependent upon the thermal management of the cone during the heat-up, welding, and the cooling down of the cone. Another factor affecting the extent of the cracking is how brittle the carburized case is underneath the hardfacing deposit.
During operation, the combination of the flexing of the teeth, formations drilled, operating parameters, and the corrosive environment can cause the cracks to grow while the drill bit is in service. This crack propagation can cause the teeth to eventually break off or cause the cracks to grow into the cone shell, both of which impede performance.
It is known that nickel-based hardfacing minimizes the transport of carbon into the steel substrate and generally does not produce a carburized case in the steel underneath the hardfacing deposit. In addition, the thermal stresses in nickel-based hardfacing are not as great as in iron-based hardfacing, such that nickel-based hardfacing is less likely to have thermal cracks. Nickel-based hardfacing is also very corrosion resistant compared to iron-based hardfacing.
SUMMARY OF THE INVENTION
In general, if cracks occur in nickel-based hardfacing they typically arrest in the hardfacing deposit and generally do not propagate into the steel substrate. This is primarily due to the round blunt tip crack of nickel-based materials, contrasted with the sharp tip crack in iron-based materials. However, iron-based hardfacing materials are more durable than current nickel-based hardfacing materials. The area of the teeth that receives most of the damage due to impacting is at or near the top of the teeth. Therefore, the crest and a portion of the flanks require a highly durable iron-based hardfacing. Since the bases of the teeth do not receive significant impacting those portions are very suitable for nickel-based hardfacing. By placing the nickel-based hardfacing at least at the bases of the teeth and/or the surrounding cone shell, the overall durability of the drill bit is improved.
Typically, the hardfacing is applied by an oxygen acetylene welding process, but other welding or coating processes of applying the hardfacing material may be used. Some high-content nickel alloys with hard component materials also may be used.
The bases of the teeth are provided with nickel-based hardfacing to significantly reduce any potential cracking therein and in the adjacent areas of the cone. All other portions of the teeth are hardfaced with iron-based materials such that all surfaces of the teeth are protected with one or the other type of hardfacing. In addition, manufacturers of drill bits prefer to weld with nickel-based materials due to ease of heat management in the teeth base and cone surface areas of the cutting structure.
The foregoing and other objects and advantages of the present invention will be apparent to those skilled in the art, in view of the following detailed description of the present invention, taken in conjunction with the appended claims and the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
So that the manner in which the features and advantages of the present invention, which will become apparent, are attained and can be understood in more detail, more particular description of the invention briefly summarized above may be had by reference to the embodiments thereof that are illustrated in the appended drawings which form a part of this specification. It is to be noted, however, that the drawings illustrate only some embodiments of the invention and therefore are not to be considered limiting of its scope as the invention may admit to other equally effective embodiments.
FIG. 1 is an isometric view of one embodiment of a drill bit constructed in accordance with the invention;
FIG. 2 is an enlarged photographic image of one embodiment of a cutter on the drill bit of FIG. 1 and is constructed in accordance with the invention;
FIG. 3 is an enlarged photographic image of another embodiment of a cutter on the drill bit of FIG. 1 and is constructed in accordance with the invention; and
FIG. 4 is a high level flow diagram of one embodiment of a method constructed in accordance with the invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1 , one embodiment of a system, method, and apparatus for an earth boring bit 11 constructed in accordance with the invention is shown. Earth boring bit 11 includes a bit body 13 having threads 15 at its upper end for connecting bit 11 into a drill string (not shown). Bit 11 is depicted with three legs, and each leg of bit 11 is provided with a lubricant compensator 17 . At least one nozzle 19 is provided in bit body 13 for spraying cooling and lubricating drilling fluid from within the drill string to the bottom of the bore hole.
At least one cutter is rotatably secured to each leg of the bit body 13 . Preferably three cutters 21 , 23 (one cutter being obscured from view in the perspective view of FIG. 1 ) are rotatably secured to the bit body 13 . A plurality of teeth 25 are arranged in generally circumferential rows on cutters 21 , 23 . Teeth 25 may be integrally formed from the material of cutters 21 , 23 , which is typically steel.
Referring now to FIGS. 2 and 3 , two embodiments of earth boring bits having cutters 21 , 23 or roller cones that employ the novel elements of the invention are shown. Although the cutters 21 , 23 and teeth 25 are shown with certain types of geometry, those skilled in the art will recognize that the invention is not limited to the illustrated embodiments.
For example, in the enlarged view of FIG. 2 , the teeth 25 on the cutter 21 of the earth boring bit are shown with two different types of hardfacing materials 31 , 33 formed thereon. The invention may be applied to only some of the teeth or all of the teeth, and on one of the cutters or all of the cutters. Furthermore, the invention also may be applied to other teeth or other portions of the drill bit other than the cutters. The first type of hardfacing 31 is formed from a nickel-based material and is located on proximal or base portions 35 of at least some of the teeth 25 . Optionally, the first hardfacing may comprise an alloy, such as a nickel alloy, or an alloy having a high nickel content with some hard component materials such as, for example, monocrystalline WC, sintered WC (crushed or spherical), cast WC (crushed or spherical), and/or with a matrix of Ni—Cr—B—Si. In the embodiment of FIG. 2 , the first hardfacing 31 also is located on surfaces of the cutter 21 adjacent the aforementioned teeth 25 , such that the first hardfacing 31 smoothly transitions from the cutter 21 to the teeth 25 .
The second type of hardfacing 33 is formed from an iron-based material and is located on distal or upper portions of the same teeth with hardfacing 31 . Thus, all surfaces of the teeth 25 and, optionally, portions or the entire surface of the cutter 21 itself is protected with hardfacing materials. The second hardfacing 33 may be located at and adjacent to the top portions of the teeth 25 , such as on the crests and portions of the flanks of the teeth. Optionally, and as shown in FIG. 3 , only the base portions of teeth 45 on cutter 40 may be provided with the first hardfacing 41 (i.e., without application of hardfacing 41 directly to the surfaces of cutter 40 ). The remaining portions of teeth 45 are protected by the second hardfacing 43 , as described herein.
Referring now to FIG. 4 , the invention also comprises a method of fabricating a cutter for an earth boring bit. The method begins as indicated at step 51 , and comprises providing a cutter with teeth extending from the cutter (step 53 ); applying a first hardfacing on portions of at least some of the teeth (step 55 ); applying a second hardfacing that differs from the first hardfacing on other portions of said at least some of the teeth (step 57 ); before ending as indicated at step 59 .
Alternatively, the method may comprise one or more of the following steps, including: applying the first hardfacing on base portions of said at least some of the teeth, and/or on surfaces of the cutters adjacent said at least some of the teeth; and/or applying the second hardfacing to crests and portions of flanks of said at least some of the teeth. In addition, one embodiment of the method may comprise sequentially applying nickel-based hardfacing (e.g., a high-content nickel alloy with hard component materials) as the second hardfacing, after applying iron-based hardfacing as the first hardfacing.
While the invention has been shown or described in only some of its forms, it should be apparent to those skilled in the art that it is not so limited, but is susceptible to various changes without departing from the scope of the invention.
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A drill bit having steel teeth is provided with a combination of hardfacing materials on the teeth. The bases of the teeth are hardfaced with nickel-based materials to significantly reduce any potential cracking therein. Portions of the supporting cones adjacent the teeth also may be fabricated with the nickel-based hardfacing. All other portions of the teeth are hardfaced with iron-based materials.
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RELATED APPLICATIONS
This application is a continuation of U.S. application Ser. No. 12/987,822, filed Jan. 10, 2011, which application is a continuation of U.S. application Ser. No. 09/583,216, filed on May 30, 2000, which application are incorporated herein by reference in their entirety.
FIELD OF THE INVENTION
The present invention relates generally to the field of e-commerce. More particularly, the present invention relates to a method and system for reporting fraud and claiming compensation related to network-based transactions.
BACKGROUND OF THE INVENTION
A common type of network-based transaction is purchasing goods or services via a network-based transaction facility, e.g., a website on the Internet. A common problem associated with such network-based transactions is fraud. For example, a seller may defraud a buyer and vice versa a buyer may defraud a seller. One type of network-based transaction is an online-auction transaction. In an online-auction transaction, a seller may offer an item for sale via an auction website in which a number of bidders access the website and bid for the item. A transaction is completed after the winning bidder pays for the item and the seller delivers the item to the winning bidder.
However, a seller may defraud a winning bidder, e.g., by accepting payment of an auctioned item and not delivering the item, delivering the item defective, delivering the item that is different than an advertised description of the item, or delivering a counterfeit item. Alternatively, a winning bidder may defraud a seller, e.g., by sending an incorrect amount of payment, sending a form of payment that is defective, or sending a form of payment with insufficient funds.
Thus, there is a need to allow users to report and settle potential fraud cases and, if transactions are fraudulent, allow users to file insurance claims for such transactions in which financial loss has occurred.
SUMMARY OF THE INVENTION
A method and system for reporting fraud and claiming insurance related to network-based transactions are disclosed. For one embodiment, a submission of a complaint is facilitated to a network-based facility in which the complaint relates to a network-based transaction. The complaint is associated with an identifier. A resolution of the complaint associated with the identifier is facilitated, and if the complaint is not resolved, an insurance claim is facilitated for the unresolved complaint.
Other features of the present invention will be apparent form the accompanying drawings and from the detailed description that follows.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention is illustrated by way of example and not limited by the figures of the accompanying drawings, in which like references indicate similar elements and in which:
FIG. 1 is a block diagram illustrating an exemplary network-based transaction facility in the form of an internet-based auction facility;
FIG. 2 is a database diagram illustrating an exemplary database for the transaction facility;
FIG. 3 is a diagrammatic representation of an exemplary fraud/insurance claim table of the database illustrated in FIG. 2 ;
FIG. 4 is a diagrammatic representation of an exemplary complaint type table of the database illustrated in FIG. 2 ;
FIG. 5 is a diagrammatic representation of an exemplary contact information table of attorney generals of the database illustrated in FIG. 2 ;
FIG. 6 is a diagrammatic representation of an exemplary comments table of the database illustrated in FIG. 2 ;
FIG. 7 is a diagrammatic representation of an exemplary address and password table of the database illustrated in FIG. 2 ;
FIG. 8 is a diagrammatic representation of an exemplary insurance claim table of the database illustrated in FIG. 2 ;
FIG. 9 is a diagrammatic representation of an exemplary insurance claim details table of the database illustrated in FIG. 2 ;
FIG. 10 is a flow chart illustrating an exemplary operation for allowing a user to file a claim or complaint facilitated by a network-based transaction facility;
FIG. 11 illustrates an exemplary introduction interface for reporting fraud and claiming insurance;
FIG. 12 illustrates an exemplary interface providing options for a user to select relating to common problems surrounding a transaction;
FIG. 13 illustrates an exemplary interface of a claim or complaint form;
FIG. 14 illustrates an exemplary interface providing a user a tracking number and options checking the status of a complaint;
FIG. 15 is a flow chart illustrating an exemplary operation allowing users to view the status of a claim or to provide comments to a complaint;
FIG. 16 illustrates an exemplary interface allowing a user to select a claim to inquire the status of the complaint;
FIG. 17 illustrates an exemplary interface allowing a user to select to view or respond to a claim or report status of a complaint;
FIG. 18 illustrates an exemplary interface providing a user with information regarding a complaint and allowing a user to provide comments regarding the complaint;
FIG. 19 illustrates an exemplary interface allowing user to indicate if a complaint is resolved;
FIG. 20 illustrates an exemplary interface allowing a user to explain how a complaint was resolved;
FIG. 21 illustrates an exemplary interface providing a user with options for an unresolved complaint and allowing a user to file an insurance claim form;
FIG. 22 is a flow chart illustrating an exemplary operation allowing a user who identified as committing fraud to view the complaint against the user and provide comments;
FIG. 23 illustrates an exemplary interface providing a user who is identified as committing fraud options to view or respond to a complaint or obtain contact information of the party who filed the complaint;
FIG. 24 illustrates an exemplary interface providing a user a list of tracking numbers of complaints against the user;
FIG. 25 illustrates an exemplary interface providing contact information of a user who has filed a complaint;
FIG. 26 illustrates an exemplary interface for providing general information about a complaint and allowing a user to provide comments in response to comments from a complaining user; and
FIG. 27 is a diagrammatic representation of a machine, in an exemplary form of a computer system, in which a set of instructions for causing the machine to perform any of the methodologies of the present invention may be executed.
DETAILED DESCRIPTION
A method and system for reporting fraud and claiming insurance related to network-based transactions are described. For one embodiment, a submission of a complaint is facilitated to a network-based facility in which the complaint relates to a network-based transaction. The complaint is associated with an identifier. A resolution of the complaint associated with the identifier is facilitated, and if the complaint is not resolved, an insurance claim is facilitated for the unresolved complaint.
The method and system described herein allow users to report and settle potential fraud cases. For example, a network-based facility allows users to detail their complaints related to network-based transactions and to provide a process allowing users to resolve their complaints. Furthermore, if transactions are fraudulent, the method and system described herein allow users to file an insurance claim in which a financial loss has occurred. For example, if a complaint cannot be resolved, users are allowed to claim insurance for unresolved transactions under certain criteria.
In the following embodiments, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the present invention. It will be evident, however, to one skilled in the art that the present invention may be practiced without these specific details.
Terminology
In the following embodiments, the term “transaction” or “transactions” shall be taken to include any communications between two or more entities and shall be construed to include, but not limited to, commercial transactions including sale and purchase transactions, online-auction transactions and the like.
Transaction Facility
FIG. 1 is block diagram illustration of an exemplary network-based transaction facility 100 in the form of an “Internet” network-based auction facility 110 . While an exemplary embodiment of the present invention is described within the context of an auction facility, it will be appreciated by those skilled in the art that the invention will find application in many different types of computer-based, and network-based, commerce facilities.
The auction facility 110 includes one or more of a number of types of front-end servers, namely page servers 112 that deliver web pages (e.g., markup language documents), picture servers 114 that dynamically deliver images to be displayed within Web pages, listing servers 116 , CGI servers 118 that provide an intelligent interface to the back-end of facility 110 , and search servers 120 that handle search requests to the facility 110 . Email servers 121 provide, inter alia, automated email communications to users of the facility 110 . Auction facility 110 also includes administrative application(s) functions 128 for providing functions for applications running on auction facility 110 .
The back-end servers include a database engine server 122 , a search index server 124 and a credit card database server 126 , each of which maintains and facilitates access to respective databases 123 , 125 , and 127 , respectively.
The Internet-based auction facility 110 may be accessed by a client program 130 , such as a browser (e.g., the Internet Explorer distributed by Microsoft Corp. of Redmond, Wash.) that executes on a client machine 132 and accesses the facility 110 via a network such as, for example, the Internet 134 . Other examples of networks that a client may utilize to access the auction facility 110 include a wide area network (WAN), a local area network (LAN), a wireless network (e.g., a cellular network), or the Plain Old Telephone Service (POTS) network.
Database Structure
FIG. 2 is a database diagram illustration of an exemplary database 200 , maintained by and accessed via the database engine server 122 , which at least partially implements and supports the network-based auction facility 110 . Database 123 may, in one embodiment, be implemented as a relational database, and includes a number of tables having entries, or records, that are linked by indices and keys. In an alternative embodiment, database 123 may be implemented as collection of objects in an object-oriented database.
Central to the database 123 is a user table 240 , which contains a record for each user of the auction facility 210 . A user may operate as a seller, buyer, or both, within auction facility 110 . Database 123 also includes item tables 242 that may be linked to the user table 240 . Specifically, tables 242 include a seller items table 244 and data items table 246 . A user record in user table 240 may be linked to multiple items that are being, or have been, auctioned via auction facility 110 . A link indicates whether the user is a seller or a bidder (or buyer) with respect to items for which records exist within the item tables 242 . Database 123 also includes a note table 248 populated with note records that may be linked to one or more item records within the item tables 242 and/or to one or more user records within the user table 240 . Each note record within the table 248 may include, inter alia, a comment, description, history or other information pertaining to an item being auction via auction facility 110 , or to a user of auction facility 110 .
A number of other tables are also shown to be linked to the user table 240 , namely a user past aliases table 250 , a feedback table 252 , a feedback details table 253 , a bids table 254 , an accounts table 256 , an account balances table 258 , a transaction record table 260 , a complaint/insurance claims table 262 , and a complaint/insurance details table 264 .
Complaint and Insurance Transaction Record Tables
FIGS. 3-9 are diagrammatic representations of exemplary embodiments of transaction record tables that are populated with records or entries for complaints and insurance claims relating to transactions (e.g., Internet based auction transactions) that have been facilitated by auction facility 110 . Such transaction record tables may be stored in complaint/insurance claims table and/or complaint/insurance details table 264 .
FIG. 3 is a diagrammatic representation of an exemplary fraud/insurance claim table 300 of the database illustrated in FIG. 2 . Referring to FIG. 3 , fraud/insurance claim table 300 includes item number column 312 , complaintant column 314 , complaintee column 316 , contact info of complaintee column 318 , date complaint filed column 320 , tracking number of complaint column 322 , and feedback ratings and nature of complaint column 324 .
Item number column 312 stores item identifiers related to an item that is subject to a filed complaint. Complaintant column 314 stores the names of users who have filed a complaint for items identical in item number column 312 . Complaintee column 316 stores names of users in which a complaint has been filed against. Contact information of complaintee column 318 stores information, which may be used to contact the complaintee. For example, such contact information may include an email address and/or mailing address or phone number of the complaintee.
Date complaint filed column 320 stores the times and dates a complaint is filed within auction facility 110 . Tracking number of complaint column 322 stores tracking numbers that identify a filed complaint. The tracking number is used to track the status of a complaint. Feedback ratings and nature of a complaint column 324 stores information that describes the nature of the complaint, for example, how a fraud has been committed on a user.
FIG. 4 is a diagrammatic representation of an exemplary complaint type table 400 of the database illustrated in FIG. 2 . Referring to FIG. 4 , complaint type table 400 includes problem code column 474 , problem description column 476 , and problem type column 478 .
Problem code column 474 stores a code number related to a type of problem description. Problem description column 476 stores description information relating to the complaint. For example, a common problem description may be “I sent the money for the item, but never received it.” Problem type column 478 stores information used to tell whether the problem is specific to a buyer-bidder or a seller.
FIG. 5 is a diagrammatic representation of an exemplary contact information table of attorney generals 500 of the database illustrated in FIG. 2 . Referring to FIG. 5 , contact information table of attorney generals 500 includes an attorney general column 584 , state column 586 , and contact information column 588 .
Attorney general column 584 stores names of attorney generals in specific states to contact in reporting fraud. That is, a user may contact an attorney general to describe specifically a fraud that has occurred against the user in a particular state. State column 586 stores the name of the state of the corresponding attorney general in the attorney general column 584 . Contact information column 588 stores contact information for an attorney general in the attorney general column 584 . Such contact information may include the mailing address, telephone number, or emailing address of an attorney general.
FIG. 6 is a diagrammatic representation of an exemplary comments table 600 of the database illustrated in FIG. 2 . Comments table 600 may store comments placed by both parties in connection with a complaint. One record may be stored for each comment placed by each user. A limit on the number of comments may be placed for each user for each complaint. Referring to FIG. 6 , comments table 600 includes tracking number column 620 , user column 622 , date of comment column 624 , text of comment column 626 , and registered customer column 628 .
Tracking number column 620 stores tracking numbers that identifies filed complaints. User column 622 stores the names of users who have placed a comment in connection with a filed complaint associated with the tracking number stored in tracking number column 620 . The user may be a bidder or a seller. Date of comment column 624 stores date and time information indicating when the comment was entered. Text of comment column 626 stores the text of a comment provided by a user in user column 622 . For example, the user may provide information on how the user was defrauded in the online-auction transaction. Non-registered customer column 628 stores information relating to a non-registered commenting user of auction facility 110 . For example, if the commenting user is not a registered user or the complaint is based on an item, which has been removed from the database, the email address of the commenting party may be placed here.
FIG. 7 is a diagrammatic representation of an exemplary address and passwords table 700 of the database illustrated in FIG. 2 . Referring to FIG. 7 , address and passwords table 700 includes email address column 720 and password column 722 . Email address column 720 stores the email addresses of users involved with a complaint. Password column 722 stores the passwords corresponding to user email addresses in email address column 720 .
Address and passwords table 700 may also store addresses and passwords of users who are not registered or cannot be found. Table 700 may also store information for users who cannot remember the user name of the other party in order to contact the other party. Table 700 may also store information to file claims on items that have been removed from the database.
FIG. 8 is a diagrammatic representation of an exemplary insurance claim table 800 of the database illustrated in FIG. 2 . For one embodiment, item data is held for a limited amount of time (e.g., 30 days) and stores item data until the data is instructed to be taken off the database by auction facility 110 .
Referring to FIG. 8 , insurance claim table 800 includes item number column 820 , claim number 822 , and data column 824 . Item number column 820 includes item numbers related to filed complaints that have not been resolved. Claim number column 822 stores claim numbers that are associated with item numbers in item number column 820 . Data column 824 stores information relating to the item, e.g., what type of item is the subject of a complaint, the final bid price for the item, and other types of item data.
FIG. 9 is a diagrammatic representation of an exemplary insurance claim details table 900 of the database illustrated in FIG. 2 . Referring to FIG. 9 , insurance claims table 900 includes claim number column 920 , amount claimed column 922 , and date of claim column 924 .
Claim number column 920 stores claim numbers related to filed complaints that have not been resolved. Amount claim column 922 stores information on the amount of money lost resulting from an online-auction transaction conducted on auction-facility 110 . Date of claim column 924 stores dates in which an insurance claim was filed.
The above record tables are used by network facility 110 to provide services such that users of network facility 110 may file complaints and to claim insurance for transactions conducted on network facility 110 in which a financial loss has occurred.
In the following operations, users are allowed to file a complaint of fraud on an item they have sold or bought on the network facility. The complained against party in the transaction is notified that a complaint has been filed against that party. The complained against party is allowed to go to the network facility to explain the allegations and to resolve the complaint with the complaining party. If at any time, the complaint is resolved, the complaining party may return to the site and indicate this fact. If, after a certain period of time, the complaint is not resolved, the complaining party is given information about government agencies to contact as well as information on filing an insurance claim if the certain criteria are met.
Filing a Complaint
FIG. 10 is a flow chart illustrating an exemplary operation 1000 for allowing a user to file a claim or complaint facilitated by a network-based transaction facility. The following exemplary operation 1000 allows a user to file a complaint of fraud on an item that has been sold or bought on network facility 110 . The other party in the transaction may receive an email indicating that someone has claimed that the other party has committed a fraud.
Prior to a user filing a complaint, the user may be presented with various examples of when a complaint should be filed. For example, as shown in FIG. 11 , auction facility 110 may provide a user with a screen 1100 giving the user examples of when to report fraud and claim insurance. Screen 1100 may include information regarding agencies or entities that may deal with fraud and provide insurance for network-based transactions.
Referring to FIG. 10 , at operation block 1002 , to begin filing a complaint regarding a network-based transaction, a user inputs a user ID and password to access the complaint filing section of the auction facility 110 . The user ID and password is validated.
At operation block 1004 , if the user ID and password is valid, network facility 110 provides the user with an interface that details contact information of the user and asks the user to confirm the contact information.
At operation block 1006 , network facility 110 provides the user with an interface asking the user to indicate whether the user is a bidder or a seller in a transaction in which a complaint is to be filed.
Complaint by Bidder
At operation block 1008 , if the user is a buyer or a bidder, the bidder indicates the item number of the transaction the user believes is fraudulent.
At operation block 1010 , the bidder confirms the contact information of the seller who sold the item in question to validate that the information the bidder has on the seller is the same as the records stored in network facility 110 .
At operation block 1012 , the bidder indicates the type of problems that occurred in which the bidder considers fraudulent. Network facility 110 may provide an interface such as that shown in screen 1200 of FIG. 12 . Screen 1200 provides common problems that a bidder may select to describe the transaction. For example, one common problem a bidder may select is “I sent a payment but never received any merchandise.”
At operation block 1014 , the bidder fills out a complaint form and provides an explanation of occurrences during the transaction. For example, network facility 110 may provide a complaint form interface 1300 as shown in FIG. 13 . Complaint form interface 1300 may ask the user to input information related to the transaction and to provide a complete description of problem.
At operation block 1016 , after the bidder completes the complaint form such as complaint form 1300 , the complaint process is completed. Network facility 110 then creates a tracking number, which is associated with the filed complaint for users to use to track the status of the complaint. For example, network facility 110 may provide an interface 1400 , as shown in FIG. 14 , indicating a tracking number. Interface 1400 provides a user a tracking number 1402 and options for the user to select if the complaint is not resolved.
Complaint by Seller
The operations and interfaces provided to a seller who is claiming fraud is similar to the operations and interfaces provided to the bidder/buyer.
At operation block 1018 , if the user is a seller, the seller indicates the item number of the transaction the seller believes is fraudulent.
At operation block 1020 , the seller confirms the contact information of the bidder of the item in question to validate that the information the seller has on the bidder is the same as the records stored in network facility 110 .
At operation block 1022 , seller indicates the type of problems that occurred during the auction transaction that seller considers fraudulent. Network facility may provide an interface similar to screen 1200 of FIG. 12 for the seller to select common problems. For example, one common problem a seller may select is “I sent the item, but the payment was insufficient.”
At operation block 1024 , the seller provides an explanation of what occurred during the transaction. For example, network facility 110 may provide a complaint form interface such as interface 1300 of FIG. 13 that asks the user to input information to complete the complaint and to provide a complete description of the problem.
At operation block 1026 , after the seller completes the complaint form such as complaint form 1300 , the complaint is completed. Network facility 110 creates a tracking number in connection with the filed complaint for users to use to track the status of the complaint. For example, network facility 110 may provide an interface 1400 indicating a tracking number.
Complaint Status/Comments
The following operation 1000 allows users to resolve complaints by providing a messaging board where both parties may comment back-and-forth about the transaction in question and to resolve a complaint. Such operations may provide the messaging board for a certain period of time (e.g., 14 days or two weeks), and, if the complaint is not resolved, such operations may provide information to the users on contacting government agencies to deal with the fraud as well as information on filing an insurance claim.
FIG. 15 is a flow chart illustrating an exemplary operation 1500 allowing users to view the status of a claim or to provide comments to a complaint.
Referring to FIG. 15 , at operation block 1502 , a user inputs a user ID and password to access information regarding a filed complain within network facility 110 . The user ID and password are validated by network facility 110 . At this point, the user may be a bidder or a seller who has filed a complaint or complaints.
At operation block 1504 , if the user ID and password are valid, network facility 110 provides the user and interface listing complaints and status of complaints the user has filed. For example, network facility may provide interface 1600 as shown in FIG. 16 to the user. Interface 1600 lists tracking numbers of complaints and the status of the complaints. In the example of interface 1600 , a complaint associated with the tracking number 2629 has not been resolved.
At operation block 1506 , network facility 110 provides the user with interface to allow the user to choose to view current status/provide comments to a filed complaint or report the status of a filed complaint. For example, network facility 110 may provide the user with interface 1700 as shown in FIG. 17 . In the example of interface 1700 , the user may select option 1702 to “View or respond to complaints” or option 1704 to “Report status of complaint.”
View Status or Respond to Complaint
At operation block 1508 , if the user selects to view or respond to complaints, network facility 110 provides an interface for the user to view current dialog between the user and other party and can enter additional comments. For example, network facility 110 may provide an interface 1800 as shown in FIG. 18 . In the example of interface 1800 , a user may view all comments related to a complaint in window 1802 .
At operation block 1510 , the user may enter additional comments so that the other user may view in window 1804 of interface 1800 . This operation is optional.
Report Status of Complaint
At operation block 1512 , if the user selects to report the status of a complaint, network facility 110 provides an interface asking the user whether the complaint has been resolved. For example, network facility 110 may provide interface 1900 as shown in FIG. 19 allowing the user to select “Yes” if the complaint has been resolved and “No” if the complaint has not been resolved.
At operation block 1516 , if the user selects that the complaint has been resolved, network facility 110 may provide an interface to allow the user to describe how the complaint was resolved. For example, network facility 110 may provide interface 2000 as shown in FIG. 20 allowing the user to explain how the complaint was resolved. In the example of interface 2000 , a user may input the explanation in widow 2002 .
At operation 1518 , network facility 110 provides an interface thanking the user and sends emails to the users involved with complaint indicating that the complaint is resolved.
At operation block 1514 , if the complaint is unresolved and more than 14 days old, contact information for legal services is given, and if insurance requirements are met, an insurance claim form is given. If, however, the complaint is less than 14 days old, the user is told that the other party still has time to respond to the complaint. For example, after the 14 day period, network facility 110 may provide an interface 2100 as shown in FIG. 21 providing the user with attorney general information to file a complaint.
If after the 14 day period, interface 2100 may allow the user to fill out an insurance claim form either online or to obtain a printable insurance form if certain criteria are met. Exemplary criteria may be:
Request occurs within 45 day of auction end data;
Buyer and seller feedback >0 at time of complaint;
Final bid amount is >$25.00 dollars; and
Users may file no more than one insurance claim per month for the first six months.
Responding to a Complaint
The following operation allows the other party in a transaction in which a complaint has been filed to go to the facility and provide their explanation of the events that have transpired.
FIG. 22 is a flow chart illustrating an exemplary operation 2200 allowing a user who is identified as committing fraud to view the complaint against the user and to provide comments.
Referring to FIG. 22 , at operation block 2202 , a user who was complained against enters a user ID and password. Network facility 110 validates the user ID and password. If the user ID and password are valid, network facility 110 allows the user to proceed to operation block 2204 .
At operation block 2204 , network facility provides the user with an interface to choose a tracking number of a complaint in providing a response. For example, network facility 110 may provide interface 2300 as shown in FIG. 23 listing tracking number of complaint that have been filed against the user. In the example of interface 2300 , one complaint is listed 2302 to choose.
At operation block 2206 , network facility 110 provides an interface to the user such that the user who was complained against can choose to view contact information on complaining user or view/respond to the complaint. For example, network facility 110 may provide interface 2400 as shown in FIG. 24 that provides option 2402 to “View or respond to complaints” or option 2404 “Get other Party's Contact Information.”
At operation block 2208 , if the user who was complained against chooses to view the contact information of the other user, network facility 110 provides an interface allowing the user to view the contact information of the other user. For example, network facility may provide an interface 2500 as shown in FIG. 25 that allows the user who was complained against to view the complaining user's contact information.
At operation block 2210 , if the user selects to view/respond to complaint, network facility 110 provides an interface that allows the user to see information regarding the complaint, to view dialog of comments, and to place additional comments. For example, network facility 110 may provide interface 2600 as shown in FIG. 26 that allows the complained against user to view comments in window 2602 and allows the user to add additional comments in window 2604 .
At operation block 2212 , if the user inputs additional comments, network facility enters the additional comments into the database. The user may indicate that the complaint has been resolved. In such a case, network facility 110 will send emails to the complaining user that the complained against user has indicated that the complaint has been resolved.
Exemplary Computing System
FIG. 27 is a diagrammatic representation of a machine, in an exemplary form of a computer system 2700 , in which a set of instructions for causing the machine to perform any of the methodologies of the present invention may be executed. In alternative embodiments, the machine may comprise a network router, a network switch, a network bridge, Personal Digital Assistant (PDA), a cellular telephone, a web appliance or any machine capable of executing a sequence of instructions that specify actions to be taken by that machine.
The computer system 2700 includes a process 2702 , a main memory 2704 and a static memory 2706 , which communicate with each other via a bus 2708 . The computer system 2700 may further include a video display unit 2710 (e.g., a liquid crystal display (LCD) or a cathode ray tube (CRT)). The computer system 2700 also includes an alpha-numeric input device 2712 (e.g., a keyboard), a cursor control device 2714 (e.g., a mouse), a disk drive unit 2716 , a signal generation device 2720 (e.g., a speaker) and a network interface device 2722 .
The disk drive unit 2716 includes a machine-readable medium 2724 on which is stored a set instructions (i.e., software) 2726 embodying any one, or all, of the methodologies described above. The software 2726 is also shown to reside, completely or at least partially, within the main memory 2704 and/or within processor 2702 . The software 2726 may further be transmitted or received via the network interface device 2722 . For purposes of this specification, the term “machine-readable medium” shall be taken to include any medium that is capable of storing or encoding a sequence of instructions for execution by the machine and that cause the machine to perform any one of the methodologies of the present invention. The term “machine-readable medium” shall accordingly be taken to include, but not limited to, solid-state memories, optical and magnetic disks, and carrier wave signals.
Thus, a method and system for reporting fraud and claiming insurance related to network-based transactions have been described. Although, the present invention has been described with reference to specific exemplary embodiments, it will be evident that various modifications and changes may be made to these embodiments without departing from the broader spirit and scope of the invention. Accordingly, the specification and drawings are to be regarded in an illustrate rather than a restrictive sense.
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A method and system that allows a user to file a complaint related to a transaction completed over a network-based transaction facility. For example, a method can include the following operations conducted via a server: receiving a complaint from a first party, communicating information about the complaint to a second party, enabling an exchange of information regarding the complaint, and determining whether a criterion required for approval of the request for compensation has been satisfied.
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CROSS-REFERENCE TO RELATED APPLICATIONS
The present application has the same Assignee and shares some common subject matter with U.S. patent application Ser. No. 12/363,558, filed on even date herewith, by Johannes Kirschnick et al., U.S. patent application Ser. No. 12/363,597, now U.S. Pat. No. 8,055,493, filed on even date herewith, by Jerome Rolia et al., and U.S. patent application Ser. No. 12/252,395, filed on Oct. 16, 2008, by Jerome Rolia et al., which claims the benefit of priority to U.S. Provisional Patent Application No. 61/001,483, filed on Oct. 31, 2007. The disclosures of the above- identified applications for patent are hereby incorporated by reference in their entireties.
BACKGROUND
There has been substantial growth in the purchase of information technology as a service from internal and external service providers and this trend appears to be increasing rapidly. This growth is enabled by the trend towards cloud computing, in which, services run on shared virtualized resource pools that are accessible via Intranets or the Internet. As this cloud computing paradigm matures, there is also an increasing trend for businesses to exploit the paradigm to support business critical services such as sales and delivery, and supply chain management. Those services will have performance requirements and are likely to place significant loads on cloud infrastructures.
With the increasing loads currently being placed on cloud computing infrastructures, it is becoming increasingly important to create systems configured to accurately model the workloads imposed upon the systems contained in the cloud computing infrastructures. One modeling method utilizes benchmarks to impose a synthetic workload on the cloud computing infrastructures being tested. The use of benchmarks facilitates the management of the enterprise application system in areas such as capacity planning and service level performance.
A typical business process, for instance, ordering, may in turn invoke a number of discreet business objects in order to complete the business process. In addition, a given business object may be characterized by a particular sequence of interdependent requests which are exchanged between entities in the enterprise application system. In other words, the sequence of interdependent requests should be performed correctly in order to correctly implement the business process. Thus, a benchmark for modeling the enterprise application system should accurately reflect the correct sequence and volume of interdependent requests. Otherwise, an incorrect sequence of interdependent requests may cause an error condition that does not accurately model the demands placed upon the enterprise application system.
However, conventional stress testing of enterprise application systems is based upon a small number of pre-existing benchmarks which typically utilize a small subset of business objects. As a result, it is difficult to generate a synthetic workload that accurately models the actual request patterns expected at the enterprise application system. Alternatively, creating a customized benchmark that is representative of a given enterprise is typically too time consuming and expensive for many users.
In addition, conventional stress testing procedures generally require users to have a high level of skill to be able to understand how to size and tune the enterprise application systems to accurately model the actual request patterns. Moreover, manually studying the test results and selecting which change to make to an enterprise application system, to enact that change, and to generate new measurement results and repeating that process until a suitable configuration is determined, is typically too time consuming and complicated for users to perform.
It would thus be beneficial to be able to automatically size a system without suffering from all of the drawbacks and disadvantages of conventional sizing methods.
BRIEF DESCRIPTION OF DRAWINGS
The embodiments of the invention will be described in detail in the following description with reference to the following figures.
FIG. 1A illustrates a block diagram of an infrastructure configuration sizing system, according to an embodiment of the invention;
FIG. 1B illustrates a more detailed block diagram of the optimizer depicted in FIG. 1A , according to an embodiment of the invention;
FIG. 2 illustrates a flow diagram of a method of implementing the infrastructure configuration sizing system, and more particularly, the optimizer depicted in FIGS. 1A and 1B , to size an infrastructure configuration optimized for a workload mix, according to an embodiment of the invention; and
FIG. 3 illustrates a block diagram of a computing apparatus configured to implement the method depicted in FIG. 2 according to an embodiment of the invention.
DETAILED DESCRIPTION OF EMBODIMENTS
For simplicity and illustrative purposes, the principles of the embodiments are described by referring mainly to examples thereof. In the following description, numerous specific details are set forth in order to provide a thorough understanding of the embodiments. It will be apparent however, to one of ordinary skill in the art, that the embodiments may be practiced without limitation to these specific details. In some instances, well known methods and structures have not been described in detail so as not to unnecessarily obscure the embodiments.
Disclosed herein is an optimizer for sizing an infrastructure configuration optimized for a workload mix and a method for implementing the optimizer. The optimizer is configured to receive the workload mix of a particular customer, which includes one or more benchmarks that are relevant to the particular customer's requirements, which is described in the 12/252,395 application for patent. The optimizer is also configured to operate with a virtualized-aware testing service (VATS) test controller, which is described in the Ser. No. 12/363,558 application for patent, to identify results associated with various infrastructure configurations based upon the benchmark(s). In addition, the optimizer is configured to identify an infrastructure configuration that is able to perform a workload while satisfying predetermined requirements as defined in the workload mix. As discussed below, the optimizer is configured to perform a plurality of processes in an iterative manner to identify the infrastructure configuration.
The optimizer and method disclosed herein are highly customizable to customers' particular needs because the optimizer and method disclosed herein are able to identify optimized infrastructure configurations for the workload mixes of each particular customer's needs. In one regard, therefore, the optimizer and method disclosed herein enables the infrastructure configuration that remains below a predetermined threshold resource utilization requirement while performing the workloads defined in the workload mixes to be identified. Thus, by way of particular example, the predetermined threshold resource utilization requirement may be set to be a minimum resource usage requirement and the optimizer and method disclosed herein may identify the infrastructure configuration that requires the least amount of cost to perform the individual workload requirements of the customers.
With reference first to FIG. 1A , there is shown a block diagram of an infrastructure configuration sizing system 100 , according to an example. In one regard, the methods disclosed herein below may be implemented in the system 100 as discussed in greater detail herein below. It should be understood that the system 100 may include additional elements and that some of the elements described herein may be removed and/or modified without departing from a scope of the system 100 .
The infrastructure configuration sizing system 100 is depicted as including a virtualized-aware automated testing service (VATS) test controller 102 , an input source 110 , a service lifecycle (SLiM) tool 120 , cloud controller 122 , a service under test (SUT) monitor 125 , a load source 130 , a data store 140 , an output device 150 , and an optimizer 160 . Also shown in FIG. 1A is a shared virtualized resource pool 124 , which comprises a cloud computing environment where services run on shared virtualized resource pools that are accessible via Intranets or the Internet. The use of the cloud computing environment makes it possible for the VATS test controller 102 to rapidly change resource levels and infrastructure configurations and topologies and thus rapidly vary the parameters of the infrastructure configurations to be tested.
Many of the components depicted in the infrastructure configuration sizing system 100 are described in the Ser. No. 12/363,558 application for patent. The disclosure contained in that application for patent thus provides a more detailed discussion with respect to at least some of the components depicted in the infrastructure configuration sizing system 100 and the various manners in which the components interact with each other.
Each of the VATS test controller 102 and the optimizer 160 comprises a hardware device, such as, a circuit or multiple circuits arranged on a board, or, alternatively, each of the VATS test controller 102 and the optimizer 160 comprises software comprising code stored, for instance, in a volatile or non-volatile memory, such as DRAM, EEPROM, MRAM, flash memory, floppy disk, a CD-ROM, a DVD-ROM, or other optical or magnetic media, and the like. In the second example, each of the VATS test controller 102 and the optimizer 160 comprises a software module stored in a memory. In a further alternative, each of the VATS test controller 102 and the optimizer 160 comprises a combination of hardware and software modules. In addition, although the VATS test controller 102 and the optimizer 160 have been depicted as forming separate components, the VATS test controller 102 and the optimizer 160 may be formed as a single unit, such that the resulting configuration has the same functional characteristics, as discussed in greater detail herein below.
In any regard, the VATS test controller 102 and the optimizer 160 are generally configured to perform a number of functions in the system 100 . As discussed in greater detail herein below, the VATS test controller 102 comprises code or is otherwise configured to automatically execute tests, manipulate a virtualized infrastructure (for instance, a cloud computing environment) to perform the tests under multiple configurations and generate and collect performance information of resources in executing the tests under the multiple configurations.
The optimizer 160 comprises code or is otherwise configured to interact with the VATS test controller 102 to cause the VATS test controller 102 to perform the tests, and to collect test results 152 from the VATS test controller 102 . In addition, the optimizer 160 comprises code or is otherwise configured to analyze the test results 152 and to modify parameters of the infrastructure configuration until an infrastructure configuration that is optimally sized for a workload mix 112 is determined. The workload mix 112 may be defined as a description of how a client is expected to use different system functions in an infrastructure configured to perform a desired workload as well as the client's expectations in performing the workload. By way of particular example, the optimizer 160 determines an infrastructure configuration that satisfies a predetermined requirement, such as, a response time goal at a required throughput level, while performing the workload, as identified in the workload mix 112 , and interacts with the VATS test controller 102 to perform a test on the infrastructure configuration. In another example, the predetermined requirement comprises a requirement that the amount of resources utilized in performing the workload remain within a predetermined resource utilization requirement or that the utilized amount of resources be minimized while still meeting the other predetermined requirements of, for instance, response time and throughput goals.
A more detailed block diagram illustration of the optimizer 160 is depicted in FIG. 1B , which shows the optimizer 160 as including an input module 162 , an initial configuration module 164 , a VATS interaction module 166 , a test comparison module 168 , a parameter modification module 170 , and an output module 172 . The modules 162 - 172 may comprise software modules, hardware modules, or a combination thereof, as discussed above with respect to the optimizer 160 . The optimizer 160 is also depicted as being in communication with a data store 174 .
As shown in FIG. 1B , the input module 162 receives input from an input source 110 . According to an example, the input source 110 comprises a computer program stored on a computer readable storage medium configured to define a workload mix 112 and to input the defined workload mix 112 into the optimizer 160 . The workload mix 112 may generally be defined as being based upon a ratio of one or more predefined benchmarks, which correspond to a desired workload to be performed by resources in an infrastructure, and as including one or more predetermined requirements in performing the desired workload. The predetermined requirements include, for instance, desired throughput and response time requirements, resource utilization thresholds, minimum resource utilization requirements, etc., which may be client-defined. Thus, by way of particular example, the workload mix 112 may indicate that certain functions, such as, various business objects are to be implemented, as well as the sequence in which the certain functions are to be performed, and the VATS test controller 102 may identify an initial infrastructure configuration configured to perform those functions in the correct sequence.
The ratio of the one or more pre-defined benchmarks is described in greater detail in the Ser. No. 12/252,395 application for patent. As discussed in that application for patent, the predefined benchmark(s) are benchmark(s) configured to accurately reflect the sequences and dependencies of interdependent requests that are required to be performed correctly in order to correctly implement a client's business process. Generally speaking, therefore, the predefined benchmark(s) define workloads, including the order in which the workloads are to be performed, that are substantially similar to the workloads that a client is likely to require from the resources in an infrastructure.
The optimizer 160 may store the workload mix 112 , which includes the predefined benchmark(s) and the predetermined requirements, in the data store 174 , which comprises any device capable of storage of information or any combination of devices capable of storage of information, such as, a semiconductor device, a magnetic disk memory device, nonvolatile memory devices, such as, an EEPROM or CDROM, etc. The data store 174 may also comprise a fixed or removable data storage device.
The initial configuration module 164 is configured to receive the workload mix 112 information from the input module 162 and to optionally communicate the predefined benchmark information to the VATS interaction module 166 . In addition, the initial configuration module 164 is configured to identify a plurality of initial infrastructure configuration parameters to be tested by the VATS test controller 102 based upon the predefined benchmark(s). For instance, the initial configuration module 164 identifies demand estimates for the predefined benchmark(s) and, and based upon the identified demand estimates, identifies that the initial infrastructure configuration should include a particular combination of parameters or resources that is anticipated to meet the demand estimates, such as a particular number or kind of application servers, particular memory sizes of the application servers, concurrency parameters that govern each application's concurrency management mechanisms (e.g., threads), a particular number of network switches, a particular allocation of network bandwidth, etc.
Moreover, the initial configuration module 164 is configured to communicate the initial infrastructure configuration parameters to the VATS test controller 102 through the VATS interaction module 166 and to instruct the VATS test controller 102 . In this regard, the VATS interaction module 166 may comprise a hardware and/or software interface that enables communications between the optimizer 160 and the VATS test controller 102 .
In response to receipt of the instructions from the optimizer 160 , the VATS test controller 102 is configured to initiate performance of a test on the initial infrastructure configuration in a virtualized environment. In this regard, the VATS test controller 102 may employ the initial infrastructure configuration as the test description discussed in the Ser. No. 12/363,558 application for patent. In addition, although the initial configuration module 164 has been described herein as identifying the initial infrastructure configuration parameters, in other embodiments, the VATS test controller 102 may identify the initial infrastructure configuration parameters without departing from a scope of the optimizer 160 .
The VATS test controller 102 is thus configured to be instantiated and deployed to perform a test on the initial infrastructure configuration. Various manners in which the VATS test controller 102 interacts with the SLiM tool 120 and the load source 130 , which includes one or more load generators 132 and a load controller 134 , are described in the Ser. No. 12/363,558 application for patent. That disclosure is incorporated by reference in its entirety herein. Through performance of the test on the initial infrastructure configuration of resources contained in the shared virtualized resource pool 124 , as discussed in that application for patent, the VATS test controller 102 generates one or more test results 152 . The one or more test results 152 may include at least one of, for instance, a number of users supported, throughputs, response times, resource utilization levels, etc., associated with the initial infrastructure configuration.
The VATS test controller 102 communicates the test result(s) 152 to the optimizer 160 . More particularly, for instance, the VATS test controller 102 communicates the test result(s) 152 to the optimizer 160 through the VATS interaction module 166 . In addition, the test comparison module 168 compares the test result(s) 152 with one or more predetermined requirements, which may have been defined in the workload mix 112 received from the input source 110 . The predetermined requirement(s) may comprise, for instance, a throughput requirement, a response time requirement, a number of users supported requirement, etc., the workload to be performed, a minimum resource utilization level requirement, a threshold resource utilization level requirement, etc. By way of particular example, the test comparison module 168 is configured to determine whether the throughput associated with the initial infrastructure configuration is able to perform the workload while satisfying a predetermined throughput requirement as set forth in the workload mix 112 received from the input source 110 .
In the event that the test comparison module 168 determines that the test result(s) 152 meets the predetermined requirement(s), the test comparison module 168 may output the initial infrastructure configuration as a suitable configuration of an infrastructure that meets the workload mix 112 . In the event that the test comparison module 168 determines that one or more of the test results 152 fail to meet one or more of the predetermined requirements, the test comparison module 168 may communicate with the parameter modification module 170 to modify one or more parameters of the initial infrastructure configuration. Alternatively, the test comparison module 168 may communicate with the parameter modification module 170 to modify the one or more parameters even in instances where the test result(s) 152 meets the predetermined requirement(s) to, for instance, identify a more efficient infrastructure configuration that meets the predetermined requirement(s).
In either event, the parameter modification module 170 is configured to determine which of the parameters of the initial infrastructure configuration, which include the number or kind of application servers employed, concurrency parameters that govern each application server's concurrency management mechanisms (e.g., threads), network bandwidth, CPU speed, cache size, memory size, etc., to modify. In one example, the parameter modification module 170 is configured to select one or more of the parameters to modify based upon a historical knowledge of how the parameters affect the infrastructure configuration. For instance, the number of application servers may be known from prior iterations of the VATS to have the greatest impact on the results of the infrastructure configuration, while the memory sizes are known to have a second highest impact. In another example, the parameter modification module 170 is configured to modify some or all of the parameters or to randomly select one or more of the parameters to modify.
In any regard, the parameter modification module 170 is configured to communicate the modified infrastructure configuration having the modified one or more parameters to the VATS test controller 102 via the VATS interaction module 166 . In response, the VATS test controller 102 is configured to perform a test on the modified infrastructure configuration to generate another test result(s) 152 . In addition, the another test result(s) 152 are received through the VATS interaction module 166 and communicated to the test comparison module 168 , which again compares the another test result(s) 152 to the predetermined requirement(s) to determine whether the modified infrastructure configuration is associated with test result(s) 152 that satisfies the predetermined requirement(s).
In one embodiment, the VATS interaction module 166 , the test comparison module 168 , and the parameter modification module 170 are configured to repeat the operations discussed above until the test comparison module 168 identifies a final infrastructure configuration that satisfies the predetermined requirement(s). In addition, the test comparison module 168 is configured to output the infrastructure configuration that satisfies the predetermined requirement(s) to an output device 150 through the output module 172 . The output device 150 may comprise, for instance, a network interface, a display monitor, a printer, etc., that enables the optimizer 160 to communicate the test results 152 to one or more users.
In another embodiment, the predetermined requirement(s) further comprises a requirement that the amount of resources utilized in performing the workload remain below a predetermined threshold resource utilization level or that the utilized amount of resources be minimized. In this embodiment, the parameter modification module 170 is configured to modify at least one of the parameters of the infrastructure configuration to reduce at least one resource utilization of the infrastructure configuration to meet the predetermined requirement(s), while still meeting the other predetermined requirements of performing the workload and meeting the other requirements, such as, throughput, response time, etc. In one example, the parameter modification module 170 is configured to modify those parameters that are known to have a greater impact on the overall resource utilization, such as, power consumption, network bandwidth utilization, cooling power consumption, carbon emissions, etc., before modifying other parameters known to have a lower impact on the overall resource utilization.
In another example, the parameter modification module 170 is configured to randomly modify the parameters during a number of iterations to determine which infrastructure configuration is associated with resource utilization levels that remain below the predetermined threshold resource utilization level or with the lowest resource utilization levels. As discussed in the Ser. No. 12/363,558 application for patent, the VATS test controller 102 may cause multiple tests to be run in parallel to thus reduce the amount of time required in rigorously identifying the infrastructure configuration that is associated with the lowest resource utilization levels.
An example of a method of implementing the infrastructure configuration sizing system 100 , and more particularly, the optimizer 160 , to size an infrastructure configuration optimized for a workload mix 112 , will now be described with respect to the following flow diagram of the method 200 depicted in FIG. 2 . It should be apparent to those of ordinary skill in the art that the method 200 represents a generalized illustration and that other steps may be added or existing steps may be removed, modified or rearranged without departing from a scope of the method 200 .
The description of the method 200 is made with reference to the infrastructure configuration sizing system 100 illustrated in FIG. 1A and the optimizer 160 illustrated in FIG. 1B , and thus makes reference to the elements cited therein. It should, however, be understood that the method 200 is not limited to the elements set forth in the infrastructure configuration sizing system 100 and the optimizer 160 . Instead, it should be understood that the method 200 may be practiced by a system having a different configuration than that set forth in the infrastructure configuration sizing system 100 and the optimizer 160 .
At step 202 , the input module 162 receives a workload mix 112 that is based upon a ratio of one or more predefined benchmarks from the input source 110 . At step 204 , the initial configuration module 164 optionally communicates the predefined benchmark information to the VATS test controller 102 via the VATS interaction module 166 . Step 204 is considered optional because the initial configuration module 164 may not communicate the predefined benchmark information to the VATS test controller 102 in instances where the initial configuration module 164 identifies the initial infrastructure configuration.
At step 206 , an initial infrastructure configuration is identified and the VATS interaction module 166 instructs the VATS test controller 102 to perform a test on the initial infrastructure configuration in the virtualized environment to generate one or more test results 152 , as described in the Ser. No. 12/363,558 application for patent. According to a first example, the initial configuration module 164 is configured to identify the initial infrastructure configuration from the predefined benchmark information, as discussed in greater detail herein above. In another example, the VATS test controller 102 is configured to identify the initial infrastructure configuration from the predefined benchmark information, as discussed in greater detail herein above.
At step 208 , the optimizer 160 receives the test result(s) 152 from the VATS test controller 102 . In addition, at step 210 , the test comparison module 168 compares the test result(s) 152 with one or more predetermined requirements. More particularly, at step 210 , the test comparison module 168 determines whether the test result(s) 152 satisfies the predetermined requirement(s), for instance, as set forth in the workload mix 112 received at step 202 . By way of particular example, the predetermined requirement(s) comprises a response time requirement and the test comparison module 168 determines whether the response time as identified in the test result(s) 152 satisfies the response time requirement. As another example, the predetermined requirement(s) comprises a minimum resource utilization level requirement and the test comparison module 168 determines whether the resource utilization level of the initial infrastructure configuration satisfies the minimum resource utilization level requirement. In this example, a number of iterations of the following steps may be required prior to a determination of whether the minimum resource utilization level requirement has been satisfied may be made.
In the event that the test result(s) 152 satisfies the predetermined requirement(s) at step 210 , the test comparison module 168 outputs the initial infrastructure configuration as a suitable configuration of an infrastructure that meets the workload mix 112 , as indicated at step 212 . As discussed above, the test comparison module 168 may output this information to an output device 150 through the output module 172 .
If, however, one or more of the test results 152 fails to satisfy one or more of the predetermined requirements at step 210 , the test comparison module 168 communicates with the parameter modification module 170 to modify one or more of the infrastructure configuration parameters, and the parameter modification module 170 modifies one or more of the parameters, as indicated at step 214 . By way of example, if the predetermined requirement comprises a minimum resource utilization level requirement, the test comparison module 168 communicates with the parameter modification module 170 to modify one or more of the infrastructure configuration parameters in the event that the resource utilization level associated with the initial infrastructure configuration exceed the minimum resource utilization level requirement.
In addition, the parameter modification module 170 is configured to select the one or more of the parameters to modify according to any of a number of various manners as discussed above. In another example, the parameter modification module 170 modifies some or all of the parameters by setting some or all of the parameters to their respective maximum values and by reducing each of the plurality of parameters, in turn, during subsequent iterations of steps 208 - 218 , until a final infrastructure configuration that causes the another at least one test result to satisfy the predetermined requirement and utilizes a minimized amount of resources is identified.
In a further example, the parameter modification module 170 modifies a plurality of parameters by setting the plurality of parameters to have initial values and by variously increasing and decreasing the plurality of parameters to obtain a plurality of test results corresponding to the various modifications of the plurality of parameters to identify a plurality of interactions. In this example, the parameter modification module 170 develops a model of the interactions and selects the one or more of the plurality of parameters to modify prior to step 214 through implementation of the model of the interactions.
At step 216 , the parameter modification module 170 communicates the modified infrastructure configuration having the modified one or more parameters to the VATS test controller 102 via the VATS interaction module 166 . In addition, at step 218 , the VATS interaction module 166 instructs the VATS test controller 102 to perform a test on the modified infrastructure configuration, for instance as discussed in the Ser. No. 12/363,558 application for patent, to generate another one or more test results 152 .
Steps 208 - 218 are repeated until a final infrastructure configuration that results in the test result(s) 152 satisfying the predetermined requirement(s) is identified at step 210 . Steps 208 - 218 may be performed for a plurality of modified infrastructure configurations in parallel or in series with respect to each other. In addition, the final infrastructure configuration may be outputted as indicated at step 212 , in which the final infrastructure configuration comprises an infrastructure configuration that is optimally sized for the workload mix 112 . In addition, or alternatively, the method 200 may be terminated for additional reasons. For instance, the method 200 may be terminated after steps 208 - 218 have been repeated for a predetermined number of iterations without resulting in an infrastructure configuration that satisfies the predetermined requirement(s). In this example, the predetermined number of iterations may be based upon a predefined quantity of resources or costs have been expended or after a predefined number of iterations are performed that indicates that an infrastructure configuration that satisfies the predetermined requirement(s) is unlikely to be identified.
Through implementation of the method 200 , an infrastructure configuration composed of application servers, memories, network switches, bandwidth allocations, etc., configured to perform a workload configured to satisfy one or more predefined benchmarks while satisfying a predetermined requirement may automatically be identified. In addition, the infrastructure configuration may be optimally sized for the workload by minimizing the resource utilization level of the infrastructure configuration, while being configured to perform the workload.
The operations set forth in the method 200 may be contained as utilities, programs, or subprograms, in any desired computer accessible medium. In addition, the method 200 may be embodied by computer programs, which may exist in a variety of forms both active and inactive. For example, they may exist as software program(s) comprised of program instructions in source code, object code, executable code or other formats. Any of the above may be embodied on a computer readable storage medium.
Exemplary computer readable storage medium include conventional computer system RAM, ROM, EPROM, EEPROM, and magnetic or optical disks or tapes. Concrete examples of the foregoing include distribution of the programs on a CD ROM or via Internet download. It is therefore to be understood that any electronic device capable of executing the above-described functions may perform those functions enumerated above.
FIG. 3 illustrates a block diagram of a computing apparatus 300 configured to implement or execute some or all of the steps defined in the method 200 depicted in FIG. 2 , according to an example. In this respect, the computing apparatus 300 may be used as a platform for executing one or more of the functions described hereinabove with respect to the optimizer 160 depicted in FIGS. 1A and 1B .
The computing apparatus 300 includes a processor 302 that may implement or execute some or all of the steps described in the method 200 . Commands and data from the processor 302 are communicated over a communication bus 304 . The computing apparatus 300 also includes a main memory 306 , such as a random access memory (RAM), where the program code for the processor 302 , may be executed during runtime, and a secondary memory 308 . The secondary memory 308 includes, for example, one or more hard disk drives 310 and/or a removable storage drive 312 , representing a floppy diskette drive, a magnetic tape drive, a compact disk drive, etc., where a copy of the program code for the method 200 may be stored.
The removable storage drive 312 reads from and/or writes to a removable storage unit 314 in a well-known manner. User input and output devices may include a keyboard 316 , a mouse 318 , and a display 320 . A display adaptor 322 may interface with the communication bus 304 and the display 320 and may receive display data from the processor 302 and convert the display data into display commands for the display 320 . In addition, the processor(s) 302 may communicate over a network, for instance, the Internet, LAN, etc., through a network adaptor 324 .
It will be apparent to one of ordinary skill in the art that other known electronic components may be added or substituted in the computing apparatus 300 . It should also be apparent that one or more of the components depicted in FIG. 3 may be optional (for instance, user input devices, secondary memory, etc.).
What has been described and illustrated herein is a preferred embodiment of the invention along with some of its variations. The terms, descriptions and figures used herein are set forth by way of illustration only and are not meant as limitations. Those skilled in the art will recognize that many variations are possible within the scope of the invention, which is intended to be defined by the following claims—and their equivalents—in which all terms are meant in their broadest reasonable sense unless otherwise indicated.
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Sizing an infrastructure configuration optimized for a workload mix includes: a) instructing a virtualized-aware testing service (VATS) test controller to perform a test of an initial infrastructure configuration in a virtualized environment, in which the test provides at least one test result; b) determining whether the at least one test result satisfies a predetermined requirement as identified in the workload mix; c) modifying at least one parameter of the initial infrastructure configuration to create a modified infrastructure configuration in response to the at least one test result failing to satisfy the predetermined requirement; d) instructing the VATS test controller to perform another test on the modified infrastructure configuration to generate another at least one test result; e) repeating steps b)-d) until a final infrastructure configuration that causes the another at least one test result to satisfy the predetermined requirement is identified; and f) outputting the final infrastructure configuration.
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BACKGROUND TO THE INVENTION
The present invention relates to driers of wet granular material such as, for example, pre-drained coal leaving washing tanks.
Centrifugal driers have a rotatable drum in which an entry part is fixed to form the continuation of a fixed supply duct. The entry parts rotates at high speed together with the drying drum and is arranged to receive material to be dried from the supply duct and to direct this material towards the peripheral drying wall of the drum.
Hitherto, the entry part has generally consisted of a cone section fixed to the base of the drum by several supports. This cone section receives the material to be dried through its narrowest circular opening and directs it towards the drum drying wall through its widest circular opening.
Such a conventional cone section has several drawbacks:
(a) The material to be dried slides over its inner surface with a small degree of friction such that its circular accelerating effect vis-a-vis the material is small. This means that the material is unevenly distributed and "pockets" are formed within the drum, causing undesirable vibration of the drum and inefficient drying of the material.
(b) The material is introduced into the entry part at high speed and therefore causes rapid wear to the entry part which must therefore be frequently replaced.
(c) The supports of the cone section are prone to rapid wear.
(d) The material enters the drying drum at too low a circular speed compared to the speed of this drum. This results in rapid wear of the drum at its impact zone.
It is an object of the invention to reduce the above described drawbacks.
SUMMARY OF THE INVENTION
According to the invention, there is provided centrifugal drier drum comprising a peripheral drying wall arranged for rotation about an axis, an entry part within the drum for receiving material to be dried, and a plurality of supports fixing the entry part within the drum, the entry part having an impact zone and the peripheral drying wall having a projection zone at which material is received, wherein at at least one of said impact and projection zones, an annular retaining space is defined and is arranged during operation to retain a quantity of the material to be dried such that the material defines a surface onto which further material to be dried is deposited.
In a drum of the invention, wear is reduced, and the material to be dried is made to rotate more efficiently until it reaches a speed almost the same as, if not identical to that of the drying drum.
A drum of the invention may have only one or the other of the material retaining spaces, but it is greatly to be preferred for it to be provided with both the retaining spaces.
Preferably, each retaining space has a profile which is substantially triangular in cross-section such that the material retained therein forms a natural slope with a thickness which decreases parallel to the drum axis.
In this way, the material arriving and circulating through the drum successively encounters the material contained in each of the retaining spaces, this effectively protecting both the entry part and the peripheral wall against wear. Moreover, the considerable degree of friction which occurs between the material which is supplied via the fixed duct and the material contained in the retaining space at the impact zone results in the material being made to rotate in a suitable manner before being projected against the peripheral drying wall. This produces better distribution of the material and a considerable reduction in vibration.
In one embodiment of the invention, the entry part comprises, a ring arranged coaxially relative to the drying drum in a plane substantially perpendicular to the drum axis, the ring having an internal peripheral edge, intended to surround a duct supplying the material to be dried, and an external peripheral edge, and a cylindrical wall extending in the direction of material flow from a point on the said ring spaced from its internal peripheral edge, preferably from its external peripheral edge.
Preferably, the supports of the entry part are fixed to the cylindrical wall of the entry part and to the peripheral wall of the drum.
The ratio between the width of the ring, in the radial direction, and the length of the cylindrical wall, in the longitudinal direction, determines the gradient of the slope formed by the material residing in the retaining space. This ratio must be adjusted in accordance with the nature of the material to be dried so that rotation of the flowing material as a result of friction with the material contained in the retaining space occurs in a suitable manner.
As has been mentioned, when the material to be dried leaves the slope formed by the material contained in the retaining space, it is projected beyond one edge of the entry part against the peripheral wall of the drum in the projection zone. Advantageously, the supports for fixing the entry part to the drum are situated downstream of the said edge and the projection zone. Preferably, an annular partition is arranged in a substantially transverse plane downstream of this same edge and of the projection zone, with an external peripheral edge in contact with the peripheral wall of the drum and an internal peripheral edge located at a distance from the cylindrical wall of the entry part.
This annular partition defines a second annular retaining space provided so as to extend as far as the projection zone and so as to contain some of the material to be dried so that the circulating material is projected onto the material which has been retained.
This annular partition may be fixed directly to the peripheral wall of the drum. As it is not desirable to reduce the useful drying life of the peripheral wall of the drum, it is preferable to place the transverse partition as close as possible downstream of the projection zone and the free annular edge defined above.
In an embodiment, the annular partition defining the second retaining space is a flat plate arranged in a plane perpendicular to the axis of the drying drum, between the free annular edge and the support. Preferably, this flat plate is arranged against the supports.
BRIEF DESCRIPTION OF THE DRAWINGS
An embodiment of the present invention will hereinafter be described, by way of example, with reference to the accompanying drawings, in which:
FIG. 1 is a diagrammatic view, in meridional section along the axis XX', of the centrifugal drier drum having an entry part of a known type; and
FIG. 2 is a view, in meridional section along the axis XX', of a similar centrifugal drier drum to that of FIG. 1, but having a different entry part.
DESCRIPTION OF PREFERRED EMBODIMENTS
The drawings illustrate examples of centrifugal drier drums to which material to be dried is conveyed by way of a fixed curved duct 1 which supplies an entry part 2.
FIG. 1 illustrates a known entry part 2 formed of a metal cone section having an axis XX' and being joined, by way of supports 3, to the bottom 4 of a drying drum. The drum is arranged to be rotated at high speed, for example, at 450 revolutions/minute, about the axis XX'.
The drum has a tapered peripheral drying wall 5 which has a multiplicity of small openings. The drum is rotated within a fixed housing 6 to which the duct 1 is fixed in the region of its opening 7.
A material 8 to be dried is introduced into the drier drum by way of the duct opening 7. In the present example, the material to be dried is pre-drained granular coal from coal washing tanks. The material flows, by means of gravity, inside the duct 1 into the middle of the drum.
In the arrangement shown in FIG. 1, the material comes into contact, at an impact zone 9, with the entry part 2 which is rotated at high speed with the drum. This entry part 2 has the shape of a truncated cone, and only subjects the material to a very small degree of frictional force. The circumferential acceleration of the said material is therefore insufficient. The main outcome is that the material is distributed in pockets within the drum. Moreover, the supports 3 which rotate together with the drum strike the material and disperse it in a disorderly manner. All this results in vibration of the drum and poor drying conditions.
Moreover, with such an entry part 2, the drier drum has three zones which are subject to considerable and rapid wear, namely the cone section 2, the supports 3, and a projection zone 10 on the peripheral wall 5 of the drum against which the material within the drum is projected by the centrifugal force when it leaves the entry part 2. Because of its impact with the projection zone 10, the material leaves the entry part 2 with an inadequate circumferential speed compared to that of the drum.
Because of the rotation of the drum, the material from the entry part 2 travels along the entire length 11 of its peripheral wall 5. Dried material is discharged downwardly at 13, whilst the water and the sludge pass through the drum wall, over the entire surface of the drying section 5, as indicated by the arrows 12, and are then discharged via an opening (not shown) provided in the housing 6.
Reference will now be made to FIG. 2 which illustrates a drier drum of the invention. In FIGS. 1 and 2, the same reference numbers have been used to denote similar parts.
In the drum shown in FIG. 2, the entry part comprises a flat ring 14 arranged in a transverse plane perpendicular to the axis XX' of the drier drum. This ring is made of sheet metal having a thickness of 10 mm and it has an internal peripheral edge 14A which surrounds the fixed duct 1 and an external peripheral edge 14B. A cylindrical wall 15, also made of 10 mm thick sheet metal, extends from the external edge 14B of the ring 14 towards the bottom 4 of the drum but is spaced from this bottom 4. The wall 15 is concentric with the axis XX' and is preferably joined to the ring 14 by a welded joint at the contacting edges of the ring and the wall 14.
Circumferentially spaced supports 16 extend radially with respect to the axis XX' between the external surface of the cylindrical wall 15 and the peripheral wall 5 of the drum.
An annular partition formed by a flat ring 17 arranged in a transverse plane perpendicular to the axis XX' is located against the supports 16. The ring 17 is positioned on the upstream end edge of the supports 16 which is opposite the bottom 4 of the drum. This flat ring 17 has an external peripheral edge 17A in contact with the peripheral wall 5 of the drum and an internal peripheral edge 17B which is located at a considerable distance from the cylindrical wall 15. The flat ring 17 can be directly welded to the peripheral wall 5 of the drum. Alternatively, the ring 17 can be welded to the supports 16 so that it forms part of the entry piece, it being positioned with its external edge 17A against the peripheral wall 5 when the entry part is positioned within the drum. Since the entry part is a part prone to wear, the supports 16 are generally fixed by means of bolts (not shown) to the peripheral wall 5 of the drum, so that the entry part can be easily removed and replaced.
The cylindrical wall 15 ends in a free circular edge 15A which is located opposite the bottom 4 of the drum. The supports 16 and the flat ring 17 are set back in relation to this free edge 15A, in the direction of the flow of material.
During operation, the drum provides two spaces for retaining the material to be dried, which greatly reduce, or even eliminate, the wear of the most exposed zones. These spaces also enable improvement of the rotational movement imparted to this material before it reaches the drum. These improvements will now be explained.
At the start of a drying operation, some of the material arriving by way of the fixed duct 1 is retained within an annular space 18 which has a triangular cross-section and is defined by the flat ring 14 and the cylindrical wall 15.
In the space 18 which is, in a conventional entry part as shown in FIG. 1, the zone where the material strikes the entry part, the material collects and permanently forms a rotating slope having an inclined surface 19 over which the material arriving by way of the fixed duct 1 flows. The friction between the flowing material 9 and the material within the space 18 is sufficiently great that a considerable circumferential speed is imparted to the flowing material as it flows out beyond the free circular edge 15A of the cylindrical wall 15.
As it passes over the free circular edge 15A, the material is projected onto the cylindrical wall 5 of the drum in a zone which is the projection zone 10 on the conventional drum shown in FIG. 1. Because of the transverse flat ring 17, some of the material which travels along the cylindrical wall 5 is retained within an annular space 20 defined by this cylindrical wall 5 and the ring 17. In this retaining space the material forms an annular slope, onto the surface 21 of which the material arriving inside the drum is projected. The material then flows over the ring 17 and continues its journey along the peripheral drying wall 5.
The material is dried over the entire surface of the wall 5 of the drum, the dried material being discharged downwardly at 22, whilst the water and sludge exit in the direction of the arrows 23 and are then discharged via an opening (not shown) in the housing 6.
The advantages of a drum of the invention are numerous.
Firstly, the entry part is very simple to construct, using welded sheet metal for example, and, consequently, it is inexpensive.
The natural slopes of the material retained within the spaces 18 and 20 during operation absorb the impact of the flowing material, and this provides two advantages. First, the entry part is subject to very little wear and secondly the high degree of friction between the flowing material and the retained material causes an even distribution of the flowing material within the drum. Additionally, the flowing material rapidly attains a considerable circumferential speed. Thus, the formation of pockets of material and vibration of the drum are prevented, and the drying conditions are improved.
In tests, drying pre-drained coal from coal washing tanks, using a drier as shown in FIG. 2, reduced by 1% to 2% the moisture content of the product collected at the outlet 22 and produced a large degree of uniformity of this content compared to the same product dried in a conventional drum as shown in FIG. 1.
Another important advantage of the invention is that the impact of the flowing material against the supports 16 is much less violent than against the supports 3 of a conventional drum because of the new position of these supports 16 and because the improved circumferential acceleration of the flowing material ensures that the rotational speed of the material and of the supports are almost the same when impact occurs. Consequently, the supports 16 are subject to much less rapid wear than the supports 3 and, impact no longer causes disorderly and unequal dispersion of the material, which prevented a good drying action in known driers.
Another advantage of the invention arises from the formation of the second retaining space 20 by the transverse ring 17. The presence in the space 20 of material which receives the projected material increases a service life of the drum to a value which is more than double that of a conventional drum.
To summarise, the main advantages of the invention are an increase in the quality and uniformity of the drying action, an increase in the service life of the entry part and an increase in the service life of the drying drum.
Driers equipped with a drum of the invention are particularly useful for processing the products from small-coal washing tanks. However, they can also be used for most industrial products which must be dried.
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A centrifugal drier drum for wet granular material has a peripheral drying wall arranged for rotation about its axis and an entry part for receiving the material to be dried and directing this material to within the drum. The entry part is fixed to the wall of the drum by a number of supports. Material fed to the drum impacts the entry part at an impact zone, and is received within the drum at a projection zone. An annular retaining space for retaining the material to be dried is formed at both the impact zone and the projection zone such that the circulating material strikes the surfaces of material retained in these retaining spaces.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to Korean Application No. 10-2004-0097085, filed on Nov. 24, 2004, and the disclosure of which is incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
[0002] The present invention generally relates to a position changing apparatus for moving a vehicle body or a vehicle part.
BACKGROUND OF THE INVENTION
[0003] A position changing apparatus for moving a vehicle body or a vehicle part to a required position is generally used in a vehicle assembly line.
[0004] In order to move the vehicle body or the vehicle part, the position changing apparatus needs two actuators, two guides, two blocks, two solenoid valves, and four sensors. Therefore, a control circuit for controlling the two actuators becomes complicated. In addition, because two actuators, two guides, two blocks, and two solenoid valves are needed, the position changing apparatus has a problem in that time and costs for maintaining and repairing the components substantially increase. The position changing apparatus also has a problem in that an area of the position changing apparatus is enlarged.
[0005] The information disclosed in this section is only for enhancement of understanding of the background of the invention and should not be taken as an acknowledgement or any form of suggestion that this information forms the prior art that is already known in this country to a person of ordinary skill in the art.
SUMMARY OF THE INVENTION
[0006] The present invention provides a position changing apparatus having non-limiting advantages of moving a vehicle body or a vehicle part.
[0007] According to an embodiment of the present invention, an exemplary position changing apparatus includes a jig base, a guide unit forming a slanted guide surface and being mounted on the jig base, a driving block mounted to the guide unit to be movable along the slanted guide surface of the guide unit, an actuating unit for moving the driving block, and an attaching unit mounted to the driving block and configured to temporarily attach the vehicle body or the vehicle part.
[0008] The guide unit comprises a guide base mounted on the jig base, and a slanted guide forming the slanted guide surface and being mounted to the guide base.
[0009] Stoppers for limiting movement of the driving block are provided on both ends of the guide unit.
[0010] The actuating unit comprises an actuating cylinder. In particular, the actuating unit comprises a cylinder housing configured to receive operating fluid; a piston disposed in the cylinder housing to be movable depending on a pressure of the operating fluid supplied to the cylinder housing; a connecting rod connecting the piston with the driving block; a solenoid valve for regulating the pressure of the operating fluid supplied to the cylinder housing; a plurality of position sensors mounted to the cylinder housing, the plurality of position sensors detecting a position of the piston and outputting a corresponding signal; and a control unit for controlling an operation of the solenoid valve on the basis of the signals output from the plurality of the position sensors.
[0011] The plurality of position sensors comprises a first position sensor and a second position sensor that are respectively disposed on both ends of the cylinder housing.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The accompanying drawings illustrate exemplary embodiments of the present invention, and, together with the description, serve to explain the principles of the present invention, wherein:
[0013] FIG. 1 is schematic view of a position changing apparatus according to an embodiment of the present invention.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0014] An embodiment of the present invention will hereinafter be described in detail with reference to the accompanying drawings.
[0015] FIG. 1 is schematic view of a position changing apparatus according to an embodiment of the present invention.
[0016] As shown in FIG. 1 , the position changing apparatus includes a jig base 201 , a guide unit 207 , a driving block 270 , an actuating unit 209 , and an attaching unit 213 . The jig base 201 may form a lower portion of the position changing apparatus according to an embodiment of the present invention, and the guide unit 207 is mounted on the jig base 201 . The guide unit 207 forms a slanted surface 206 , both ends of which have different heights. In this embodiment of the present invention, an end of the slanted guide surface 206 that is closer to the actuating unit 209 than the other end is formed to be the lower of the two. However, it is easily understood that the shape of the slanted guide surface 206 is not limited thereto. The guide unit 207 includes a guide base 203 and a slanted guide 205 . The guide base 203 may be mounted on the jig base 201 , and the slanted guide 205 may be mounted on the guide base 203 such that the slanted guide surface 206 is formed.
[0017] In another embodiment of the present invention, the guide base may be formed to be slanted, and the guide may be formed as a flat plate. Therefore, by disposing the flat guide on the slanted guide base, the slanted surface can be realized.
[0018] The driving block 270 is mounted on the guide unit 207 such that the driving block 270 can move along the guide surface 206 of the guide unit 207 . More particularly, the driving block 270 is movably mounted on the slanted guide 205 of the guide unit 207 . The driving block 270 is tapered such that an upper surface of the driving block 270 is flat.
[0019] A bearing (not shown) can be disposed between the driving block 270 and the guide surface 206 to decrease friction between the driving block 270 and the guide unit 207 .
[0020] The actuating unit 209 is configured to move the driving block 270 . The actuating unit 209 is connected to the driving block 270 , and the driving block 270 is urged to move along the slanted guide 205 by the force transmitted from the actuating unit 209 .
[0021] The attaching unit 213 is fixed to the driving block 270 and is formed to temporarily attach the vehicle body or the vehicle part 300 . For example, as shown in FIG. 1 , the attaching unit 213 is fixed to the driving block 270 . Although in this embodiment the attaching unit 213 includes two members, the attaching unit 213 can also be realized as a single member.
[0022] The actuating unit 209 includes an actuating cylinder 217 for moving the driving block 270 . According to another embodiment of the present invention, the actuating unit 209 further includes a solenoid valve 223 , position sensors 227 and 225 , and an electronic control unit (ECU) 229 , in addition to the actuating cylinder 217 .
[0023] The actuating cylinder 217 can be realized as a pneumatic cylinder, a hydraulic cylinder, or any cylinder that can move the driving block 270 , and the cylinder can include a cylinder housing 233 , a piston 235 , and a connecting rod 221 . The cylinder housing 233 is formed such that it can be supplied with operating fluid, and the piston 235 is disposed within the cylinder housing 233 such that the piston 235 can move in response to the operating fluid pressure. The connecting rod 221 connects the piston 235 with the driving block 270 . Therefore, the driving block 270 is urged to move on the guide unit 207 by the pressure of the operating fluid supplied to the actuating cylinder 217 . The pressure of the operating fluid supplied to the cylinder housing 233 is regulated by the solenoid valve 223 .
[0024] A plurality of position sensors 225 and 227 are mounted to the cylinder housing 233 . The plurality of position sensors 225 and 227 detect a position of the piston 235 and output a corresponding signal to the ECU 229 . For example, when the piston 235 is located in front of the position sensors 225 and 227 , the position sensors 225 and 227 may detect the position of the piston 235 and output a corresponding signal.
[0025] The ECU 223 can be realized by one or more processors activated by a predetermined program, and the predetermined program can be programmed to perform each step of the method for controlling the solenoid valve 223 according to an embodiment of the present invention.
[0026] The plurality of position sensors 225 and 227 includes a first position sensor 225 and a second position sensor 227 that are respectively disposed on both ends of the cylinder housing 233 . Consequently, due to the first and second position sensors 225 and 227 , they can detect whether the piston 235 is positioned at an end of the cylinder housing 233 .
[0027] The ECU 229 controls the solenoid valve 223 on the basis of the signal transmitted from the plurality of position sensors 225 and 227 and an external signal.
[0028] In the case of receiving the signal output from the second position sensor 227 and an external position changing signal (e.g., from a driver or another control unit), such as when the position changing signal is transmitted from the outside in a state that the piston 235 is located in a position in which the second position sensor 227 is located, the ECU 229 outputs a control signal for controlling the solenoid valve 223 such that the operating fluid is supplied to the cylinder housing 233 .
[0029] If the operating fluid is supplied to the cylinder housing, the piston 235 is urged to move in the rightward direction in FIG. 1 . As the piston 235 moves in the rightward direction, the driving block 270 connected to the connecting rod 221 moves in a right upward direction along the slanted guide surface 206 . Thus, the driving block 270 and the attaching unit 213 also move in the right upward direction. Consequently, the vehicle body or the vehicle part 300 attached to the attaching unit 213 is moved from a first position 250 to a second position 260 (i.e., moved in the arrow direction shown in FIG. 1 ).
[0030] In addition, in the case of receiving the signal output from the first position sensor 225 and an external position changing signal (e.g., from a driver or another control unit), such as when the position changing signal is transmitted from the outside in a state in which the piston 235 is located in a position in which the first position sensor 225 is located, the ECU 229 outputs a control signal for controlling the solenoid valve 223 such that the operating fluid is exhausted from the cylinder housing 233 . In this case, the vehicle body or the vehicle part 300 is moved from the second position 260 to the first position 250 .
[0031] As described above, the vehicle body or the vehicle part 300 can be moved from the first position 250 to the second position 260 or from the second position 260 to the first position 250 by one actuating unit 209 in a slanted direction.
[0032] At both ends of the guide unit 207 , a stopper 215 for limiting movement of the driving block 270 may be mounted.
[0033] According to the embodiments of the present invention, because the position changing apparatus can change position of the vehicle body or the vehicle part by the slanted guide unit, the position changing apparatus can operate with one actuator. Therefore, components of the position changing apparatus are more simplified. In addition, because of the simplicity of the components, incidences of malfunctions and costs for maintenance and repair are reduced, and the position changing apparatus occupies a smaller area.
[0034] While this invention has been described in connection with the most practical exemplary embodiments, it is to be understood that the invention is not limited to the disclosed embodiments, but, on the contrary, it is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims.
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The present invention provides a position changing apparatus for moving a vehicle body or a vehicle part that includes a jig base, a guide unit forming a slanted guide surface, a driving block, an actuator, and an attaching unit. In addition, all components of the position changing apparatus are simplified, thereby reducing the incidences of malfunctions and the costs for maintaining and repairing. Moreover, the position changing apparatus occupies a smaller area than one of the prior art.
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RELATED APPLICATIONS
This application is divisional of application Ser. No. 09/761,985 filed Jan. 17, 2001 now U.S. Pat. No. 6,412,578 issued Jul. 2, 2002 which is a continuation-in-part of my application Ser. No. 09/643,306 filed Aug. 22, 2000 now U.S. Pat. No. 6,378,629 which is hereby incorporated by reference herein as if fully set forth in its entirety.
FIELD OF THE INVENTION
This invention relates broadly to the boring of a hole through the wall of a tube from the inside of the tube outwardly at an angle to a longitudinal axis of the tube. More specifically, this invention relates to apparatus for drilling through an oil or gas well casing at an angle to the longitudinal axis of the casing and into the earth strata surrounding the well casing. More particularly, this invention relates to an improved such drilling apparatus and to a means of transporting, deploying and retrieving the drilling apparatus.
BACKGROUND OF THE INVENTION
Oil and gas wells are drilled vertically down into the earth strata with the use of rotary drilling equipment. A tube known as a casing is placed down into the well after it is drilled. The casing is usually of made of mild steel and is in the neighborhood of 4.5 inches to 8 inches in external diameter (4 inches in internal diameter and up) and defines the cross-sectional area of the well for transportation of the oil and gas upwardly to the earth surface. However, these vertically extending wells are only useful for removing oil and gas from the terminating downward end of the well. Thus, not all of the oil and gas in the pockets or formations in the surrounding earth strata, at the location of the well depth, can be removed. Therefore, it is necessary to either make additional vertical drillings parallel and close to the first well, which is costly and time consuming, or to provide some means to extend the original well in a radial direction relative to the vertical longitudinal axis of the casing horizontally into the surrounding earth strata.
The most common means for horizontal extension of the well has been to drill angularly through the well casing at a first 45° angle for a short distance and then to turn the drill and drill at a second 45° angle thereby making a full 90° angular or horizontal cut from the vertically extending well. These horizontal drills have proved useful for extending the well horizontally but have proved to be relatively expensive.
Another solution to the problem is disclosed in U.S. Pat. Nos. 5,413,184 and 5,853,056, both of which are hereby incorporated by reference herein as if fully set forth in their entirety. In these patents there is disclosed an apparatus comprising an elbow, a flexible shaft or so-called “flex cable” and a ball cutter attached to the end of the flexible shaft. The elbow is positioned in the well casing, and the ball cutter and flexible shaft are passed through the elbow, turning 90°. A motor rotates the flexible shaft to bore a hole in the well casing and surrounding earth strata with the ball cutter. The flexible shaft and ball cutter are then removed and a flexible tube with a nozzle on the end thereof is passed down the well casing, through the elbow and is directed out of the casing through the hole therein. Water pumped through the flexible tube exits the nozzle at high speed and bores further horizontally into the earth strata.
Prototype testing of the device disclosed in U.S. Pat. Nos. 5,413,184 and 5,853,056 has proven less than satisfactory. In particular, a number of problems plague the device disclosed in U.S. Pat. Nos. 5,413,184 and 5,853,056. For example, the disclosed ball cutter is inefficient at best and ineffective at worst in cutting through the well casing. The inherent spherical geometry of a ball cutter causes it “walk” or “chatter” during rotation as it attempts to bore through the well casing which greatly increases the amount of time required to bore through the casing. Ball cutters are best utilized for deburring, and/or cutting a radius in an existing hole or slot for example and are simply not suitable for drilling holes.
Another problem is the torsional flexibility of the flexible shaft or flex cable. Rather than transmitting rotational displacement to the ball cutter at 100% efficiency the flex cable tends to “wind up” or exhibit “backlash,” thus reducing the already inefficient cutting efficiency of the ball cutter even more.
Yet another problem is the tendency of the elbow to back away from the hole in the casing during drilling with the ball cutter. Such backing away causes the elbow outlet to become misaligned with the hole in the casing thereby preventing smooth introduction of the nozzle and flexible tube into the hole in the casing.
Still another problem is the large amount of torsional friction generated between the elbow passageway and the flex cable which of course increases the horsepower requirements of the motor required to rotate the flex cable. The addition of balls, separated by springs, to the flex cable, in an effort to alleviate the resistance of the apparatus to being rotated, has not remedied this problem.
A further problem is the closed nature of the apparatus of U.S. Pat. Nos. 5,413,184 and 5,853,056. which prevents its being taken apart, inspected, cleaned and repaired as needed.
The invention of my application Ser. No. 09/643,306 overcomes the deficiencies of the apparatus disclosed in U.S. Pat. Nos. 5,413,184 and 5,853,056. That invention is apparatus for boring a hole from an inside of a tube outwardly perpendicular to a longitudinal axis of the tube. The apparatus comprises a drill shoe having a longitudinal axis and being positionable in the tube, the shoe having an inlet, an outlet perpendicular to the shoe longitudinal axis and a passageway connecting the inlet and outlet, a torsional load transmitting element having no torsional flexibility in relation to its bending flexibility, having a longitudinal axis and being disposed in the passageway, the torsional load transmitting element being movable relative to itself about first and second perpendicular axes both of which are perpendicular to the longitudinal axis of the torsional load transmitting element, a hole saw connected to one end of the torsional load transmitting element and a motor rotatably connected to the other end of the torsional load transmitting element. Rotation of the torsional load transmitting element by the motor rotates the hole saw to bore through the tube from the inside of the tube outwardly perpendicular to the longitudinal axis of the tube.
Further improvements in boring technology are nonetheless desired. For example, the invention of U.S. Pat. Nos. 5,413,184 and 5,853,056 is inefficient and time consuming to operate in that after the cutting tool has bored through the well casing the drilling operation must be interrupted so that the entire drilling apparatus can be retrieved to the earth surface in order to remove the well casing cutting tool and to install the earth strata boring water nozzle. The drilling apparatus must then be lowered back down into the well casing to resume the drilling operation.
SUMMARY OF THE INVENTION
The invention includes apparatus for boring a hole from an inside of a casing outwardly at an angle relative to a longitudinal axis of the casing. The apparatus comprises a drill shoe having a longitudinal axis and being positionable in the casing, the shoe having first and second passageways which converge into a third passageway exiting the shoe a torsional load transmitting element and a cutting element connected to one end of the torsional load transmitting element, the torsional load transmitting element and cutting element being positioned in the first passageway during non-use and in the third passageway during use, and a fluid conduit and a nozzle connected to one end of the fluid conduit, the fluid conduit and nozzle being positioned in the second passageway during non-use and in the third passageway during use.
The third passageway may exit the shoe at any desired angle of between 0° and 90° relative to the longitudinal axis of the drill shoe. The angle may be, for example, 75° or 90°. The apparatus may include an exit insert installable in the shoe to provide variability in the exit angle.
The torsional load transmitting element has a longitudinal axis, and preferably has no torsional flexibility in relation to its bending flexibility and is movable relative to itself about first and second perpendicular axes both of which are perpendicular to the longitudinal axis of the torsional load transmitting element. The torsional load transmitting element may be freely movable relative to itself about the first and second perpendicular axes. The torsional load transmitting element may be pivotable relative to itself about the first and second perpendicular axes. The torsional load transmitting element may be freely pivotable relative to itself about the first and second perpendicular axes.
The cutting element may be a hole saw. The apparatus may further comprise a drill bit connected to the end of the torsional load transmitting element centrally of the hole saw. The drill shoe may be fabricated in halves. The torsional load transmitting element may comprise a plurality of interconnected universal joints. The shoe may include an angled end surface adapted to cooperate with a matingly angled end surface of a drill shoe depth locator for locating the shoe at a selected depth in the casing such that an angular orientation of the shoe relative to the casing is establishable by positioning the depth locating device at an angular orientation relative to the casing.
A drill shoe depth locator for locating a drill shoe at a selected depth in a casing comprises a housing, at least one locking arm pivotally connected to the housing and an actuator for selectively pivoting the arm. The arm is pivotable to and between a retracted non-locking position in the housing and an extended locking position wherein at least a portion of the arm projects out of the housing and is adapted to contact a wall of the casing.
The actuator for selectively pivoting the arm may comprise a firing mechanism which fires a charge that propels the arm to the extended locking position. The firing mechanism may include a chamber adapted to accept a charge cartridge, a gas path between the chamber and the pivoting arm and a firing pin which is selectively activatable to strike the charge cartridge. The housing may include an angled end surface adapted to cooperate with a matingly angled end surface of the drill shoe such that an angular orientation of the drill shoe relative to the casing is establishable by positioning the depth locator at an angular orientation relative to the casing.
A tool for deploying a drill shoe depth locator in the casing comprises a housing, at least one locking arm pivotally connected to the housing and an actuator for selectively pivoting the arm. The arm is pivotable to and between a retracted non-locking position in the housing and an extended locking position wherein at least a portion of the arm projects out of the housing and is adapted to engage a surface of the drilling apparatus depth locator.
The actuator may comprise a rod movable longitudinally relative to the housing which cooperates with a cam surface on the pivoting arm to thereby move the arm.
A tool for retrieving a drill shoe depth locator from a casing comprises a housing, at least one locking arm pivotally connected to the housing and a resilient member normally biasing the locking arm to an extended locking position yet permitting upon application of sufficient force the locking arm to move to a retracted non-locking position. The arm is pivotable to and between the retracted non-locking position in the housing and an extended locking position wherein at least a portion of the arm projects out of the housing and is adapted to engage a surface of the drill shoe depth locator.
A mobile drilling apparatus comprises a wheeled trailer having a trailer bed, a drill shoe, a mast mounted on the trailer bed for suspending therefrom the drill shoe, a first reel rotatably mounted on the trailer bed for paying out and taking up a cable connected to the drill shoe, the cable supported by the mast, a second reel rotatably mounted on the trailer bed for paying out and taking up a first length of tubing which communicates fluid from a fluid source to a fluid motor in the drill shoe, the tubing supported by the mast, and a third reel rotatably mounted on the trailer bed for paying out and taking up a second length of tubing which communicates fluid from a fluid source to a fluid nozzle in the drill shoe, the tubing supported by the mast.
The mast may be pivotally mounted to the trailer bed for pivoting movement to and between an upright operable position and a lowered inoperable position. The mast may be mounted to a work platform and the work platform may be mounted to the trailer bed for movement transverse to a longitudinal axis of the trailer bed. The apparatus may further comprise a catwalk extending the length of the trailer bed on one side thereof and mounted to the trailer bed for pivoting movement to and between an upright inoperable position and a lowered operable position wherein the catwalk extends the width of the trailer bed. The catwalk may include a set of steps secure thereto such that when the catwalk is in the lowered operable position an operator may climb the steps from a ground surface to the trailer bed.
The apparatus may further comprise a motor rotatably driving each of the first, second and third reels, a brake mounted to each of the first, second and third reels, a sensor mounted to each of the first, second and third reels for sensing an angular velocity of each of the first, second and third reels and a controller which controls the brakes in response to signals received from the sensors. The apparatus may further include a sensor mounted on the mast for sensing a depth traversed by the drill shoe.
These and other advantages of the present invention will become more readily apparent during the following detailed description taken in conjunction with the drawings herein, in which:
BRIEF DESCRIPTION OF THE DRAWINGS OF THE INVENTION
FIG. 1 is a side view of a drill shoe of the invention;
FIG. 2 is an enlarged sectional side view of a portion of the drill shoe of FIG. 1;
FIG. 3 is a side view in partial cross section of the cooperatingly matingly angled end surfaces of the drill shoe and drill shoe depth locator;
FIG. 4 is an enlarged view of the end of the drill shoe with angle locating surface;
FIG. 5 is a side cross-sectional view of a device for locating the drill shoe at a selected depth in the casing, and a tool for deploying the drill shoe depth locator:
FIG. 6 is a view similar to FIG. 5 with the drill shoe depth locator fixed in position in the casing and the deploying tool being withdrawn from the casing;
FIG. 7 is a view similar to FIG. 5 but of a tool for retrieving the drill shoe depth locator engaging the drill shoe depth locator;
FIG. 8 is a view similar to FIG. 7 of the retrieving tool and drill shoe depth locator being withdrawn from the casing;
FIG. 9 is a side view of the mobile drilling apparatus of the invention; and
FIG. 10 is a top view of the mobile drilling apparatus of FIG. 9 .
DETAILED DESCRIPTION OF THE INVENTION
Referring first to FIG. 1 a boring apparatus 10 according to the principles of the present invention is illustrated. During use apparatus 10 is positionable inside a well casing 12 in the earth strata 14 (FIG. 3 ). The boring apparatus 10 includes a hollow carbon steel drill shoe 20 . Drill shoe 20 has a longitudinal axis which when inserted into casing 12 , is generally parallel to a longitudinal axis of the well casing 12 . Drill shoe 20 may preferably be fabricated in halves 20 a , 20 b securable together via bolts 22 . Drill shoe 20 may be connected to a ½ inch diameter 6×25 IWRC wire rope 24 which is utilized to lower drill shoe 20 down into casing 12 .
A fluid motor 26 imparts rotation to a motor coupling 28 which is connected to a drill bit shaft 30 itself connected to a plurality of interconnected universal joints 32 which terminate in a hole saw 34 with central pilot hole drill bit 36 . Above motor 26 is a motor locator 38 ; motor locator 38 and drill shoe 20 include cooperating structure (not shown; see U.S. patent application Ser. No. 09/643,306 for same) rotatably fixing the motor locator 38 and hence motor 26 relative to the shoe 20 thereby preventing relative rotation between motor 26 and shoe 20 during operation of motor 26 .
Shoe 20 further includes a first passageway 40 , a second passageway 42 and a third passageway 44 . The universal joints 32 , hole saw 34 and drill bit 36 reside in first passageway 40 during nonuse and in third passageway 44 during use. Similarly, a flexible fluid conduit 46 with a nozzle 48 connected to its end is positioned in the second passageway 42 during nonuse and in the third passageway 44 during use. Motor 26 may be suspended from and supplied with liquid through a ½ inch diameter 0.049 inch wall thickness 316L stainless steel tubing 50 . Similarly, fluid conduit 46 may be suspended from and supplied with liquid through a ⅝ inch diameter 0.049 inch wall thickness 316L stainless steel tubing 52 .
Third passageway 44 may exit the shoe 20 at any desired angle of between 0° and 90° relative to the longitudinal axis of the shoe 20 , depending on the drilling application. Preferably, the angle is in the general range of about 75° to 90°. To provide convenient variability and versatility in the exit angle of the third passageway 44 one of a number of exit angle inserts 54 may be utilized, each of which inserts would include a different exit angle. For example, two exit inserts 54 may employed, one of which is at 75° (FIG. 4) and the other of Which is at 90° (FIG. 3) thereby providing an operator with a ready means of quickly changing the exit angle depending on drilling conditions etc. Exit insert 54 may be removably installable in the shoe 20 via screws 56 .
Referring to FIGS. 1-4, shoe 20 may include an angled end surface 58 formed as part of an angular locator 60 secured to a lower end of shoe 20 with a bolt 62 and locating pin 64 . Angled end surface 58 is adapted to cooperate with a matingly angled end surface 66 of a drill shoe depth locator 68 (discussed in more detail below) for locating the shoe 20 at a selected depth in the casing 12 . An angular orientation of the shoe 20 relative to the casing 12 Is establishable by positioning the depth locator 68 at an angular orientation relative to the casing 12 . The matingly angled end surfaces 58 and 66 automatically determine the angular orientation of the shoe 20 to locator 68 and thus shoe 20 to casing 12 . The use thereof will be described below in more detail.
Referring now to FIGS. 3, 5 and 6 , the drill shoe depth locator 68 is illustrated which locates the drill shoe 20 at a selected depth in the casing 12 . The depth locator 68 comprises a housing 70 and may preferably comprise a pair of locking arms 72 pivotally connected to the housing 70 as by pivots 74 . The arms 72 are pivotable to and between a retracted non-locking position in the housing (FIG. 5) and an extended locking position wherein at least a portion of the arms 72 project out of the housing 70 and is adapted to contact the wall of the casing 12 . An actuator 76 may be included for selectively pivoting the arms 72 . The actuator 76 may comprise a firing mechanism, which fires a charge that propels the arms 72 to the extended locking position, which comprises a chamber 78 adapted to accept a charge cartridge 80 , a gas path 82 between the chamber 78 and each pivoting arm 72 and a firing pin 84 which is selectively activatable to strike the charge cartridge 80 thus releasing combustion gases which force the arms 72 upwardly into a locking position relative to the casing 12 . Gas vent paths 86 bleed excess gas out of housing 70 . Preferably the firing mechanism actuator 76 of the device 68 would be activated as the device 68 is being lowered into the casing 12 ; when the device 68 reaches the desired depth as indicated by, for example, a rotary encoder, the mechanism 76 is fired propelling the arms 72 upwardly into engagement with the casing 12 , the downward momentum of the device 68 further assisting in locking the arms 72 into the wall of the casing 12 . In the alternative, the charge cartridge 80 and firing pin 84 could be eliminated; the locking arms 72 can be forced upwardly into engagement with the casing 12 by simply lowering locator 68 at a sufficient velocity such that water in casing 12 moves forcefully up chamber 80 through paths 82 and into contact with arms 72 forcing them upwardly.
Firing pin 84 is spring loaded via compression spring 85 positioned within firing pin housing 87 . A firing pin blocking plate 89 normally blocks firing pin 84 from upward movement. Firing pin blocking plate 89 is maintained in its blocking position via a release rod 91 . Upon upward movement of release rod 91 aperture 93 in blocking plate 89 centers around firing pin 84 thereby freeing firing pin 84 to move upwardly under force of compression spinrg 85 .
As mentioned briefly above, the depth locator 68 preferably includes an angled end surface 66 which cooperates with the matingly angled end surface 58 of the drill shoe 20 . Once the device 68 is in position in the casing 12 , a plurality of radially extending horizontal borings can be made into the earth strata by adjusting the angular position of the angular locator 60 relative to the shoe 20 , it being contemplated that the shoe 20 and locator 60 would have a plurality of locating pins 64 positioned at, for example 5° to 10° increments. Thus, with each 5° or 10° readjustment of locator 60 relative to shoe 20 , the shoe 20 can bore a new radial path radially outwardly from the casing 12 but at a known increment relative to the previous boring. If desired, the shoe 20 and locator 60 can be repeatedly readjusted to drill radially outwardly from the well casing 12 in a full 360° circle.
Referring still to FIGS. 5 and 6, there is illustrated a tool 100 for deploying the drill shoe depth locator 68 in the casing 12 . The tool 100 comprises a housing 102 and a pair of locking arms 104 pivotally connected to the housing 102 as by pivots 106 . The locking arms 104 are pivotal to and between a retracted non-locking position (FIG. 6) generally within the periphery of the housing 102 and an extended locking position (FIG. 5) wherein at least a portion of the arms 104 project out of the housing 102 , and are adapted to engage a surface 110 of the depth locator 68 . An actuator 112 selectively pivots the arms 104 to and between the retracted non-locking position (FIG. 6) and the extended locking position (FIG. 5 ). The actuator preferably comprises a rod 114 which is movable longitudinally relative to the housing 102 and which cooperates with a cam surface 116 on each pivoting arm 104 to thereby move the arms 104 . Thus, to lower the depth locator 68 in the well casing 12 , the tool 100 is engaged with the depth locator 68 in that the rod 114 is in a downward position forcing arms 104 outwardly so as to engage underneath surface 110 of the device 68 . Once the depth locator 68 is at the desired depth in the casing 12 , the rod 114 is pulled upwardly thereby permitting upward force on the tool 100 to force the pivoting arms 104 inwardly and free of surface 110 thus permitting the tool 100 to be withdrawn from the casing 12 .
Referring now to FIGS. 7 and 8 there is illustrated a tool 200 for retrieving the depth locator 68 from the casing 12 . The tool 200 comprises a housing 202 and a pair of locking arms 204 pivotally connected to the housing 202 as by pivots 206 . The locking arms 204 are pivotable to and between a retracted non-locking position (FIG. 7) generally within the periphery of the housing 202 and an extended locking position (FIG. 8) wherein a portion of the arms 204 project out of the housing 202 and are adapted to engage the prior mentioned surface 110 of the depth locator 68 . A resilient member 210 normally biases the locking arms 204 to the extended locking position, yet permits upon application of a sufficient force the locking arms 204 to move to the retracted non-locking position, i.e. during initial insertion of housing 202 and locking arms 204 into depth locator 68 (FIG. 7 ).
Referring to FIGS. 9 and 10 a mobile drilling apparatus 300 is illustrated. The apparatus 300 comprises a wheeled trailer 302 having a trailer bed 304 , the prior described drill shoe 20 , a mast 308 mounted on the trailer bed 304 for suspending therefrom the drill shoe 20 , a first reel 310 rotatably mounted on the trailer bed 304 for paying out and taking up cable 24 connected to the drill shoe 20 , the cable 24 being supported by the mast 308 , a second reel 314 rotatably mounted on the trailer bed 304 for paying out and taking up the first length of tubing 50 which communicates fluid from a fluid source (not shown) to the fluid motor 26 in the drill shoe 20 , the tubing 50 supported by the mast 308 , and a third reel 318 rotatably mounted on the trailer bed 304 for paying out and taking up the second length of tubing 52 which communicates fluid from the fluid source to the fluid nozzle 48 in the drill shoe 20 , the tubing 52 supported by the mast 308 . Reels 310 , 314 and 318 may be five feet in diameter and capable of storing up to ten thousand feet of wire rope or tubing.
The mast 308 is preferably mounted to a work platform 340 . Work platform 340 is preferably mounted to the trailer bed 304 for pivoting movement of the mast 308 to and between an upright operable position and a lowered inoperable position, and is also mounted to the trailer bed 304 for movement transverse to a longitudinal axis of the trailer bed 304 thereby providing transverse alignment of drill shoe 20 to casing 12 . Hydraulic cylinder 342 may be operable between the trailer bed 304 and mast 308 to pivot the mast 308 relative to the bed 304 . Hydraulic cylinder 344 may be operable between the work platform 340 and trailer bed 304 to move the work platform 340 transversely to the longitudinal axis of the trailer bed 304 .
Trailer 302 may additionally comprise a catwalk 350 extending along the trailer 302 on one side thereof and mounted to the trailer bed 304 for pivoting movement to and between an upright inoperable position and a lowered operable position wherein the catwalk 350 extends the width of the trailer bed. A hydraulic cylinder 352 may be operable between the bed 304 and catwalk 350 to pivot the catwalk 350 and between the upright inoperable and lowered operable positions. Catwalk 350 may include a set of steps 354 secured thereto such that when the catwalk 350 is in the lowered position an operator may climb the steps from a ground surface to the trailer bed 304 .
With reference to FIG. 10 the apparatus may further preferably comprise hydraulic motors 400 , 402 and 404 rotatably driving each of the reels 310 , 314 and 318 respectively at up to 8 rpm. hydraulic disk brakes 410 , 412 and 414 mounted to each of the reels 310 , 314 and 318 respectively and sensors 420 , 422 and 424 mounted to each of the reels 310 , 314 and 318 respectively for sensing an angular velocity of each of the reels 310 , 314 and 318 . A controller 450 is operable to control the brakes 410 , 412 and 414 in response to signals received from the sensors 420 , 422 and 424 to insure that the cable 20 and tubing 50 and 52 all pay out and are taken back up at the same rate. Controller 450 also includes manually manipulable controls for the reels and brakes. To monitor the distance drill shoe 20 is being lowered into the casing 12 a sensor 460 may be mounted atop mast 308 to sense a depth traversed by the drill shoe 20 . Sensors 420 , 422 , 424 and 460 may take the form of, for example optical rotary encoders. A diesel engine driven 15,000 psi water pump and hydraulic fluid pump 470 supplies high pressure water to motor 26 and nozzle 48 and hydraulic fluid pressure to motors 400 , 402 , 404 , brakes 410 , 412 , 414 and cylinders 342 , 344 , 352 , respectively.
Those skilled in the art will readily recognize numerous adaptations and modifications which can be made to the present invention which will result in an improved boring apparatus, yet all of which will fall within the spirit and scope of the present invention as defined in the following claims. Accordingly, the invention is to be limited only by the scope of the following claims and their equivalents.
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Apparatus for boring a hole from an inside of a casing outwardly at an angle relative to a longitudinal axis of the casing comprises a drill shoe having a longitudinal axis and being positionable in the casing, the shoe having first and second passageways which converge into a third passageway exiting the shoe, a torsional load transmitting element and a cutting element connecting to one end of the torsional load transmitting element, the torsional load transmitting element and cutting element being positioned in the first passageway during non-use and in the third passageway during use, and a fluid conduit and a nozzle connected to one end of the fluid conduit, the fluid conduit and nozzle being positioned in the second passageway during non-use and in the third passageway during use.
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FIELD OF THE INVENTION
The invention relates to enzymatic pretreatment of wood chips to improve the chips for downstream processing, such as lowered energy consumption during refining of the chips.
BACKGROUND
Wood pulps are generally produced through multistep processes. Initially, logs can be subjected to grinding in which the logs are forced against a rotating abrasive stone which separates the fibers from the log and also the wood cell matrix. In a refining process, wood chips are fed between two metal discs, with at least one disc rotating. In both cases, essentially all of the constituents of wood are retained in the pulp that is eventually produced. Such pulp contains fiber bundles, fiber fragments and whole fibers. A lack of uniformity of pulp and constituents and the presence of lignin in the pulp give it certain desirable qualities, such as yield, paper bulk and opacity as well as good printability. The pulp also has less desirable properties for some paper types, such as low strength, relatively coarse surface and a lack of durability.
Chips to be refined can be destructured and impregnated with chemicals or enzymes prior to further mechanical treatment. This can help increase pulp quality or reduce energy consumption. These methods create slightly different pulps and also vary with the species of wood species, quality of the wood, processing conditions and the amount of energy applied. Various forms exist: thermomechanical pulping (TMP), refiner pulping, stone groundwood pulping, etc.
Chip “destructuring” is usually carried out in the first stage refiner where it occurs in combination with some fiber fibrillation. The difficulty of clearly separating these two steps can lead to an unnecessary increase in energy while no significant gain in pulp properties is obtained. Several pieces of equipment have been developed to overcome these drawbacks. U.S. Pat. No. 5,813,617 of Toma, for example, describes one such device. Other devices incorporate compressive forces along with the destructuring shear forces. These compressive forces along with the accompanied decompression can be used to enhance the penetration of chemicals or enzymes for impregnation prior to refining.
In TMP, steam is added to the chips being refined to facilitate pulping and lower electricity consumption. Steam is also produced during refining and heat recovery systems can help recoup some of the energy cost of the process. The electric motors used to operate these refiners require very large amounts of power. The TMP process generally involves several refining stages to produce a desirable pulp. However, only a small portion of the energy used in each refining stage is actually used to separate and develop the fibers. Screening is used after or between refining stages to separate adequately refined fibers from longer, coarser fibers. These tougher fibers are sent to “rejects” refiners for further development. Depending on the quality of refining, the amount of rejects needing additional refining can and usually is significant.
Woody biomass used in these mechanical pulping processes contains cellulose, hemicelluloses, lignin and extractives in varying amounts throughout the ultrastructure of its fibers. These various components act in conjunction to give these substrates mechanical strength and resistance to degradation. By selectively removing or altering certain components, it is possible to reduce the amount of energy required to separate and refine these fibers. The patent literature describes various approaches using different enzyme mixtures. For example US Patent Publication No. 2005/0000666, of Taylor et al., describes the use of mannanase and xylanase. Certain treatments have been found to significantly impact paper strength properties which have limited their applications. U.S. Pat. No. 5,865,949, of Pere et al., describes a process using an enzyme mixture containing endo-β-glucanase (EG), a limited mannanase and cellobiohydrolase (CBH) activity which reduces the negative effects on paper strength. U.S. Pat. No. 6,099,688, of Pere et al., describes the use of isolated cellobiohydrolase to increase the amount of relative amorphousness of the cellulose within the fibers. This process is said to cause even less damage to paper properties.
International patent publication No. WO 97/40194, of Eachus et al., suggests changing the structure or the composition of the wood by adding to compressed chips fungal or bacterial cultures or products, such as enzymes obtained from them, by means of pressure. The purpose of the compression is to make cracks and fractures in the wood. When the chips are released from the compression, microbes of their products, while the chips expand, are absorbed by the structures of the wood partially by the virtue of negative pressure, partially by the capillary action. The use of lipolytic, proteolytic, linginolytic, cellulolytic and hemicellulolytic enzymes is mentioned. The patent specification describes the absorption of the enzyme preparation Clariant Cartazyme HS™ into the compressed chips after releasing the pressure. Liquid was removed after the treatment, and mechanical pulp was prepared from the chips. In that case, the amount of energy consumed was 7.5% less than in the case of chips that were treated with a buffer only. In another test, the enzyme preparations Clariant Cartazyme NS™ and Sigma porcine pancreas Lipase L-3126 were used. In that case, the amount of energy consumed was 12.5% less than when treated with a buffer only.
A more recent pre-treatment of chips using an enzyme preparation containing cellobiohydrolase and endoglucanase was suggested by Pere in United States Patent Publication No. 2007/0151683. Here again, it was said to be preferable to carry out the enzymatic treatment by compressing the chips and by bringing the compressed chips in a liquid phase into contact with the enzyme composition to absorb the enzyme composition into the chips. The process is said to be useful for reducing the specific energy consumption (SEC) of mechanical pulp and to improve the technical properties of the fibers.
SUMMARY
The invention provides a method for preparing mechanical pulp. The method includes: (i) exposing compressed wood chips to an enzymatic solution comprising an endoglucanase (EG) and a cellobiohydrolase (CBH), wherein the ratio of enzymatic activity of EG:CBH is at least 3, and permitting the wood chips to decompress. The product of step (i) can be refined for further processing in the production e.g. of pulp for the manufacture of paper products.
The enzymatic activity of the CBH in the enzymatic solution is typically at least 0.5 FPU per gm of wood chips. The dry weight of the wood substrate can be measured according to standard T 258 om-06. It is possible use CBH in an amount that provides greater activity e.g., in a range from 0.5 to 200 FPU, or 1 to 150 FPU, or 5 to 150, or 10 to 150, or 20 to 150, or 30 to 150, or 40 to 150, or 50 to 150, or 70 to 150, or 100 to 150 FPU, or 50 to 130 FPU, or 50 to 110 FPU per gram of wood chips etc., or the activity can be about any of the foregoing values. A preferred range is between 0.1 and 5 FPU per gm of wood chips.
In embodiments, the enzymatic solution also contains a hemicellulase, typically the enzymatic activity of the hemicellulase being at least 1.5 times the activity of the CBH. A preferred hemicellulase is a mannanase (MAN).
As described in the examples, wood chips can be exposed to the enzymatic solution for sufficient time to reduce energy consumption during subsequent refining of the wood chips to pulp in which the freeness of the pulp (CSF) obtained is reduced by at least 5% in comparison to the freeness of pulp obtained by refining chips which have not been exposed to the enzymatic solution. The energy reduction can be at least 5%, but can be greater e.g., at least 6%, at least 7%, at least 8%, at least 9%, at least 10%, at least 11% or at least 12%, or can be about any of these amounts.
Suitable enzymatic activity is provided by EG, CBH, and MAN classified as EC 3.2.1.6, EC 3.2.1.91, and EC 3.2.1.78, respectively.
Enzymatic activity of the EG can be at least 1850 CMCU per gm of wood chips and/or MAN is at least 250 IU per gm of wood chips.
The enzymatic solution can contain enzymatic protein having of between 0.02 mg/g to 20 mg/g of the wood chips.
Wood chips can be softwood, for example, Black Spruce, Picea mariana , used in the examples described below. The chips can be made up of from 38 to 52% by weight cellulose, from 20 to 30% by weight lignin, from 20 to 30% by weight hemicellulose. The hemicellulose component can be from 15 to 20% mannans by total weight of the wood chips and from 15 to 20% xylans by total weight of the wood chips.
In preferred embodiments, the wood chips are destructured wood chips having an average weight per chip in the range of from 0.8 to 2 g.
The method can include the step of compressing wood chips to form the compressed wood chips that are to be permitted to be decompressed while exposed to the enzymatic solution.
The wood chips can be subjected to steaming prior to being compressed.
Wood chips having an average size of, prior to compression, between 15 to 35 mm long by 15 to 35 mm wide and between 2 to 8 mm thick are suitable.
Compressing the wood chips can include subjecting the chips to a pressure in the range of from 50 to 600 atm. A preferred minimum pressure is 100 atm.
In an embodiment, wood chips are compressed by at least 10% of their uncompressed volume.
Compression of the wood chips can be accomplished through the use of e.g., screw clamp, or press or, a hydraulic press. Compression can include the chips to pressure for a period of between 10 minutes and 5 hours. In many cases, 10 to 30 minutes is acceptable.
Compression of the wood chips can be conducted prior to exposing of the compressed wood chips to the enzymatic solution or in the presence of the enzymatic solution.
Decompression can take place at atmospheric pressure in an aqueous solution for a period of time in which a final consistency in the range of from 0.3 to 30% is reached, preferably a range of from 5 to 15%.
Refining the wood chips that have been enzymatically treated can be conducted to obtain a mechanical wood pulp having a drainability of at least 100 ml CSF.
The method can also include chipping raw wood material to form wood chips which can then be compressed and destructured for enzymatic treatment.
An embodiment of the invention is also a method for treating wood chips for eventual use in preparing mechanical pulp e.g., refining. In this sense, the embodiment can be regarded as a method for preparing feedstock for a mechanical pulping process. The method includes exposing compressed wood chips to an enzymatic solution comprising an endoglucanase (EG) and a cellobiohydrolase (CBH), wherein the ratio of enzymatic activity of EG:CBH is at least 3. Other features associated with the enzymatic treatment, described above, and below in connection with the examples, can of course be included in this treatment. Downstream processing can include subjecting treated wood chips to mechanical pulping, which can be a thermomechanical refining process or a chemithermomechanical refining process. A paper product can be manufactured downstream, be it in a separate mill or as part of an in-line process.
So, an aspect of the present invention is a method for reducing the amount of energy required to refine destructured chips by treating said chips with an enzymatic solution containing a plurality of enzymes and optionally stabilizer compound(s) during decompression. This solution can be a combination of CBH, EG, mannanase and stabilizer agents and surfactants containing mainly propylene glycol, glycerol, sorbitol and to a lesser degree proxel, potassium sorbate and ethoxylated fatty alcohols. The enzymatic treatment can be carried out at process temperatures of from 20° C. to 80° C., for example between 40° C. and 60° C. The enzymatic treatment can be carried out at a pH of from about 2 to about 10. The treatment time can be from 30 minutes to 10 hours. Other temperatures, pHs and or times can be used.
The reduction in energy can be manifest as reduced energy consumption during primary, secondary, tertiary, reject, post-refining or other mechanical treatment used to obtain a desired final pulp from a destructured wood chip that has been treated with the enzyme solution prior to refining.
The enzyme solution used herein preferably possesses the following relative activities: the EG should have a 10 fold greater activity than the CBH and the mannanase should have a 2 fold greater activity than the CBH. This enzyme solution is available commercially from Novozymes® under the name Celluclast 1.5L™.
Methods of refining chips with lower energy requirements to obtain a desirable degree of refining are set forth herein. Methods for refining the chips wherein the refining process includes mechanical destructuring including compression and decompression, of wood chips followed by treatment of the obtained destructured chips with a complex enzyme mixture are presented, wherein the resultant pulp and/or paper products have maintained tensile strength, improved optical properties and slightly reduced tear index as compared to untreated pulps or products therewith.
Pulp and paper products made therefrom having maintained tensile strength, improved optical properties and slightly reduced tear strength are provided. Pulp and papers made therefrom which require less energy to produce are provided.
It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are only intended to provide a further explanation of the present invention as claimed
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments illustrating the invention and establishing feasibility of various aspects thereof are described below with reference to the accompanying drawings, in which:
FIG. 1 is a bar graph showing the amount of sugars released per gram of oven dried chips (OD) into the liquor after a 1 hour enzyme hydrolysis (5 FPU/g OD Celluclast 1.5L™) at different compression conditions;
FIG. 2 is a bar graph showing freeness (CSF) after a 1 hour enzyme hydrolysis (5 FPU/g OD Celluclast 1.5L™) at different compression conditions; and
FIG. 3 is a bar graph showing specific energy consumption (SEC) during laboratory scale refining of wood chips that had been compressed at different conditions and subjected to enzyme hydrolysis (10 FPU/g OD Celluclast 1.5L™) for one hour during decompression i.e., at atmospheric pressure.
DETAILED DESCRIPTION
The present invention relates to a method of refining chips into pulps, wherein the method includes the use of an enzyme mixture containing cellulases and hemicellulase. Treatment with this solution following chip destructuring, compression and decompression prior to the entire refining process from primary, secondary, reject to post refining can reduce the energy required to reach a given degree of refining. This enzyme mixture is to contain a significant EG activity, a marked mannanase activity and a CBH activity that is lower than the first two but not negligible.
As used herein, an endo-β-glucanase is preferably a cellulase classified as EC 3.2.1.6—endo-1,3(4)-β-glucanase. This enzyme is preferably capable of endohydrolysis of 1,3- or 1,4-linkages in β-D-glucans when the glucose residue whose reducing group is involved in the linkage to be hydrolysed is itself substituted at C-3. This hydrolysis cleaves the O-glycosyl bond of the cellulose backbone.
As used herein, a “mannanase” is preferably a hemicellulase classified as EC 3.2.1.78, and called endo-1,4-β-mannosidase. Mannanase includes β-mannanase, endo-1,4-mannanase, and galactomannanase. Mannanase is preferably capable of catalyzing the hydrolysis of 1,4-β-D-mannosidic linkages in mannans, including glucomannans, galactomannans and galactoglucomannans. Mannans are polysaccharides primarily or entirely composed of D-mannose units.
As used herein, a cellobiohydrolase is preferably a cellulase classified as EC 3.2.1.91 and called cellulose 1,4-β-cellobiosidase (non-reducing end). This enzyme produces the hydrolysis of (1→4)-β-D-glucosidic linkages in cellulose and cellotetraose, releasing cellobiose from the non-reducing ends of the chains
EG activity can be determined following the carboxymethyl cellulose (CMC) method described in Measurement of Cellulase Activities by T. K. Ghose (Pure & Appl. Chem. Vol 69, No. 2, pp. 257-268, 1987). The amount of reducing sugars released from enzymatic hydrolysis of a 2% solution of a well characterized CMC is used to determine the enzymes EG activity. Sugar concentration is determined by the well known DNS method described by G. L. Miller (Analytical Chem., No. 31, p. 426, 1959).
CBH activity can be determined following the filter paper assay method described in Measurement of Cellulase Activities by T. K. Ghose (Pure & Appl. Chem. Vol 69, No. 2, pp. 257-268, 1987). The amount of reducing sugars released from enzymatic hydrolysis of Whatman No. 1 filter paper strip of known size is used to determine the enzymes CBH activity. Sugar concentration is determined by the well known DNS method described by G. L. Miller (Analytical Chem., No. 31, p. 426, 1959).
Mannanase activity can be determined following the method describer by M. Ratto and K. Poutanen (Biotechnology Letters, No 9, pp-661-664, 1988). The amount of reducing sugars released from enzymatic hydrolysis of a 0.5% solution of locust bean gum is used to determine the enzymes mannanase activity. Sugar concentration is determined by the well known DNS method described by G. L. Miller (Analytical Chem., No. 31, p. 426, 1959).
An enzyme solution containing EG, CBH and mannanase activities in the correct ratios is commercially available from Novozymes® under the name Celluclast 1.5L™. This solution contains between 40 mg and 50 mg of total protein per milliliter of solution. When kept at between 0° C. and 25° C., the solution is stable and its activity is maintained for about 18 months. Storage at higher temperatures will reduce this effective storage time.
The enzyme solution can vary slightly in ratio of activities which still give the desired energy reductions and paper qualities. The amount of total protein in the correct ratio should be between 0.02 kg and 5 kg per metric ton of oven dried wood. This amount of total protein can vary depending on the type of woody substrate being used, for example virgin hardwood kraft, virgin softwood kraft, recycled pulp, groundwood, refiner groundwood, pressurized refiner groundwood, thermomechanical, chemithermomechanical or a mixture thereof; or the species of wood which makes up this substrate, for example Populus sp., Acer sp., Picea sp., Abies sp., Pinus sp., Conium sp., etc.
The destructured chips of the present invention can be treated with one or more other components, including polymers such as anionic and non-ionic polymers, clays, other fillers, dyes, pigments, defoamers, microbiocides, pH adjusting agents such as alum or hydrochloric acid, other enzymes, and other conventional papermaking or processing additives. These additives can be added before, during or after introduction of the enzyme solution. The enzyme solution can be added, and is preferably added to the papermaking pulp before the addition of coagulants, flocculants, fillers and other conventional and non-conventional papermaking additives, including additional enzymes.
The destructured chips can be any conventional softwood or hardwood species used in mechanical pulp production, such as spruce, fir, hemlock, aspen, acacia, birch, beech, eucalyptus, oak and other softwood and hardwood species. The destructured chips can contain cellulose fibers at a concentration of at 35% by weight based on the oven dried solids content of the wood. The final pulp can be, for example, virgin pulp (e.g. spruce, fir, pine, eucalyptus, and include virgin hardwood or virgin softwood), hardwood kraft, softwood kraft, recycled pulp, groundwood, refiner groundwood, pressurized refiner groundwood, thermomechanical, chemithermomechanical or mixtures thereof.
According to various embodiments, the papermaking system can include chip handling equipment with a chip destructuring device which is capable of destructuring and compressing wood chips, a primary refiner, a secondary refiner, a screen, a mixer, a latency and/or blend chest, and papermaking equipment, for example, screens. The papermaking system can also include metering devices for providing a suitable concentration of the enzyme composition or other additives to the flow of pulp. Valving, pumps, and metering equipment as known to those skilled in the art can also be used for introducing various additives described herein to the pulp.
According to one embodiment, the enzyme solution can be added to the chips before or during destructuring, compression or preferably immediately after compression ends and decompression begins, added to pulp after the pulp leaves the first refiner (also known as the primary refiner) during the refining process. For example, the enzyme solution can be added before the second refiner (also known as the secondary refiner), after the second refiner, before the screen, after the screen, before the mixer, after the mixer, before the latency and/or blend chest, to the latency and/or blend chest. For example, the enzyme solution can be added after the second refiner, between the screen and the mixer, or after the mixer. Other additives as described can be added to the papermaking system as known to those skilled in the art.
The destructured chips can be treated with the enzyme solution when the chips are at a temperature of from 10° C. to about 75° C., from about 30° C. to about 70° C., or from about 40° C. to about 65° C. The chips can be at a pH of from 2 to 10, from about 4 to 7, or from 4.5 to 5.5. A treatment time can be from 10 minutes to about 10 hours, from about 30 minutes to about 5 hours or from 1 hours to 2 hours.
The enzyme treatment is carried out before, during or immediately after the destructuring process, but before completion of the refining process. The enzyme treatment is carried out on “destructured wood chips”. “Destructured wood chips” refers to a woody material used as the raw material of the mechanical pulp, which has been subjected to at least one mechanical destructuring process step. The term destructured wood chips therefore encompasses, e.g. chips of various sizes, compressed and uncompressed destructured wood chips, matchsticks and fiber bundles. Preferably, the enzyme treatment is carried out on destructured wood chips. More preferably the enzyme solution is carried out on destructured wood chips during decompression of the chips.
In another embodiment, the enzyme solution can be added during the chip handling prior to destructuring. As an example, the enzyme solution can be added after chip washing at the chip bin. In this embodiment, the chips are treated and directed to a destructuring device before compression-decompression prior to a primary refiner. The pulp is then refined to desired specifications before being returned to the papermaking system stream.
The introduction of the enzyme solution can be made at one or more points and the introduction can be continuous, semi-continuous, batch, or combinations thereof.
According to various embodiments, the chip to liquor ratio can be about 1 to 20, 1 to 10, or 1 to 5.
Various ranges of components such as enzymatic activities, times, pressures, and values of such are described herein. It is to be understood that additional combinations of such ranges and values are also disclosed by such descriptions. As a general example, a range of from 2 to 5 describes values of about 2 and about 5; values of about 2, 3, 4 and 5 describes ranges of 2 to 5, 3 to 4, 2 to 4, etc.
Chips processed as described herein can exhibit maintained tensile strength, while suffering some loss of tear strength. Paper products made from the pulp also maintain tensile strength while losing some tear strength. The addition of the enzyme solution creates fiber weaknesses which allow the formation of shorter fibers but also enhance fiber fibrillation which is why tear is affected while tensile strength is maintained. Fines production increases, thus lowering freeness at a given specific energy of refining SEC. The addition of the enzyme solution to chips reduces the amount of SEC needed to obtain a desired level of freeness.
A pulp produced by the methods described herein can be used in the production of paper products, including, for example, cardboard, paper towels, newspaper, and hygiene products. The methods described herein can also be suitable for textile manufacturing.
EXAMPLES
Example 1
Enzymatic Activities
The commercial enzyme product, Celluclast 1.5L™, was tested for several enzymatic activities and was found to have several different types of activities. The following table list all relevant and significantly measurable activities and protein concentration.
Carboxymethyl cellulase (CMC) activity, equivalent to endo-β-glucanase activity, was determined following the CMC method described in Measurement of Cellulase Activities by T. K. Ghose (Pure & Appl. Chem. Vol 69, No. 2, pp. 257-268, 1987). The amount of reducing sugars released from enzymatic hydrolysis of a 2% solution of a well characterized CMC during a 30.0 minute hydrolysis at pH 4.8 and 50° C. is used to determine the enzymes EG activity. Sugar concentration is determined by the well known 3,5-dinitrosalicylic acid (DNS) solution method described by G. L. Miller (Analytical Chem., No. 31, p. 426, 1959). The addition of the DNS solution to the hydrolysis filtrate stops the reaction. The mixture was boiled for 5.0 minutes to allow for color formation. After cooling, the absorbency is measured at 540 nm and the concentration is determined against a standard curve.
Mannanase activity was determined following the method describer by M. Ratto and K. Poutanen (Biotechnology Letters, No 9, pp-661-664, 1988). The amount of reducing sugars released from enzymatic hydrolysis of a 0.5% solution of locust bean gum during a 30.0 minute hydrolysis at pH 4.8 and 50° C. is used to determine mannanase activity. Sugar concentration is determined by the well known DNS method described by G. L. Miller (Analytical Chem., No. 31, p. 426, 1959) and described thoroughly above.
Filter paper activity, equivalent to CBH activity, was determined following the filter paper assay method described in Measurement of Cellulase Activities by T. K. Ghose (Pure & Appl. Chem. Vol 69, No. 2, pp. 257-268, 1987). This method uses the amount of reducing sugars released from enzymatic hydrolysis of Whatman No. 1 filter paper strip of known size during a 30.0 minute hydrolysis at pH 4.8 and 50° C. to determine the enzymes CBH activity. Sugar concentration is determined by the well known DNS method described by G. L. Miller (Analytical Chem., No. 31, p. 426, 1959) and described thoroughly above.
Protein concentration was determined using the Bradford assay. Bradford assay kits purchased from Sigma-Aldrich were used. This well known method uses the binding of protein with a solution of Coomassie Blue which allows colorimetric determination of protein concentration based on a standard curve produced using bovine serum albumin. Absorbency is measured at 595 nm.
Measured parameters of Celluclast 1.5L ™
Parameter
Value
Unit
Endo-β-glucanase
1860
CMC/ml
Mannanase activity
285
IU/ml
Cellobiohydrolase
150
FPU/ml
Total protein
43.4
mg/ml
Example 2
Sugars Released
The enzyme solution was added to destructured chips (200 g ODP) using the solutions filter paper activity as a dosage indicator. Different compression conditions at 5 FPU/g OD (10 and 20 minutes held under compression) and controls were done in duplicate and measured in duplicate for a total of four data sets. Hydrolysis was carried out at a consistency of 10%, a temperature of 50° C. and a time of 1 hour. After which, the samples were filtered and the filtrate was treated using the well known 3,5-dinitrosalicylic acid (DNS) solution method described by G. L. Miller (Analytical Chem., No. 31, p. 426, 1959). The addition of the DNS solution to the hydrolysis filtrate stops the reaction. The mixture was boiled for 5.0 minutes to allow for color formation. After cooling, the absorbency is measured at 540 nm and the concentration is determined against a standard curve. This is also shown in FIG. 1 .
Sugars released during lab-scale compression testing 5 FPU/g
OD Celluclast 1.5L ™
Standard
Sugars released into
deviation
Treatment
liquor (mg/g ODP)
(mg/g ODP)
Destructured chips 0 compression
0.08
0
0 FPU/g OD (−control)
Destructured chips 0 compression
2.27
0.31
5 FPU/g OD (+control)
Destructured chips 10 minutes
2.80
0.24
compression 5 FPU/g OD
Destructured chips 20 minutes
3.03
0.41
compression 5 FPU/g OD
Example 3
Freeness
The enzyme solution was added to destructured chips (200 g ODP) using the solutions filter paper activity as a dosage indicator. Different compression conditions at 5 FPU/g OD (10 and 20 minutes held under full compression) and a control were done in duplicate. Hydrolysis was carried out at a consistency of 10%, a temperature of 50° C. and a time of 1 hour. After this treatment, chips were dewatered to 20% consistency and refined in three stages using a KRK refiner with disc gaps of 0.5, 0.3 and 0.15 mm. Refined pulp was collected and moisture was checked prior to measuring Canadian Standard Freeness (CSF). Results are shown in the following table and FIG. 2 .
Freeness of pulp treated with Celluclast 1.5L ™ trials
before refining
Treatment
CSF (ml)
Standard deviation (ml)
Destructured chips 0 compression
182
3
0 FPU/g OD (−control)
Destructured chips 0 compression
176
4
5 FPU/g OD (+control)
Destructured chips 10 minutes
160
2
compression 5 FPU/g OD
Destructured chips 20 minutes
169
3
compression 5 FPU/g OD
Example 4
Energy Savings
The enzyme solution was added to destructured chips (200 g ODP) using the solutions filter paper activity as a dosage indicator. Different compression conditions at 10 FPU/g OD (10 and 20 minutes held under full compression) and a control were done in duplicate. Hydrolysis was carried out at a consistency of 10%, a temperature of 50° C. and a time of 1 hour. After this treatment, chips were dewatered to 20% consistency and refined in three stages using a KRK refiner with disc gaps of 0.5, 0.3 and 0.15 mm and a control were done in duplicate. Energy consumption was monitored with an online monitor and networked computer. Results are shown in the following table and in FIG. 3 .
Specific energy consumption (SEC) obtained during refining of
destructured wood chips treated with Celluclast ™ 1.5L
Net SEC
Standard
Energy
average
deviation
savings
Treatment
(kWh/t)
(kWh/t)
(%)
Destructured chips 0
3018.5
0
0
compression 0 FPU/g OD
(−control)
Destructured chips 0
3046
53.0
+0.91
compression 10 FPU/g OD
(+control)
Destructured chips 10 minutes
2671
102.5
−11.5
compression 10 FPU/g OD
Destructured chips 20 minutes
2873.5
99.0
−4.8
compression 10 FPU/g OD
* No-load energy consumption (3 minutes of warm up energy was calculated to be 0.12456 kWh) was subtracted from the meter reading to give the net energy consumption
All patents, applications and publications mentioned above and throughout this disclosure are incorporated in their entirety by reference herein.
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A process using a multicomponent enzyme preparation to treat chips that have been crushed using a device that combines shear and compressive forces where treatment occurs mainly during decompression and reduces the specific energy consumption and/or increasing production of subsequent refining while maintaining or increasing handsheet physical properties. The enzyme preparation is to have a major endoglucanase activity, a significant mannanase activity and a slight cellobiohydrolase activity. This enzyme mixture is prepared from a genetically modified strain of Trichoderma reseii.
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The invention relates to optical data signals processing methods of decoding a binary modulated light spectrum to recover intelligence encoded therein.
Commonly assigned and copending U.S. Pat. Nos. 4,233,261 and 4,778,270, disclose an optical spectrum analyzer and a spectral optic temperature sensor which utilize an ordinary wide band light beam as the transmitting medium for encoding and decoding data. The light beam is dispersed to generate an optical spectrum or individual elements of a modulated spectrum and are thereafter recombined into a beam of light. The recombined beam of light is again separated into its optical spectrum made up of modulated spectral elements. Thereafter, these individual spectrum elements are analyzed to recover the encoded intelligence. Typically, the spectral elements are transmitted or blocked as a function of an operational parameter such as position, temperature, speed, rotative torque, and etc.
In decoding data, the quantity of coded data typically monotonically increases and decreases as a function of the operational parameter increasing and decreasing. It has been discovered that the recovery of data can also vary as a function of temperature, dirt, electrical circuitry, mechanical and optical components associated with the encoding and decoding of the coded data. Further, excitation sources, such as light emitting diodes, exhibit changes in excitation magnitude as a function of the wave-length of the coded data. As a result when encoding an on/off binary state portions of the encoded spectrum, an "off-bit" may be larger in magnitude than an "on-bit" elsewhere in the coded data. This creates a difficult task in establishing threshold levels to be used with a binary level for any particular spectral element. Thus it is necessary to compensate for variations in spectral density.
U.S. Pat. 4,852,079 discloses a method of encoding and decoding relative spectral data. This method, while performing in an adequate manner imposes an intensive computational burden in decoding the encoded data.
The present invention discloses a simplified method for decoding relative spectrum data as a result of encoding data in the following manner: a fixed data or sync bit pattern is encoded immediately followed by the binary data under evaluation. The sync bit pattern can be encoded as two consecutive "on" bits and followed by spectral elements which are generated as "on/off" or "off/on" with respect to each data bit currently being decoded. That is, the binary 1 data would be represented as an "on" followed by an "off" and a binary 0 would be represented by an "off" followed by an "on" or vice versa. This type of encoding which utilizes transitions rather than levels is commonly referred as Manchester Encoding. The sync bit transition and length is used to determine if the first data bit is "on" or "off". The data is further coded such that only one data bit changes between any two adjacent positions in a manner similar to encoding through a method commonly referred to as Gray Code. It is noted that Gray Code does not require any extra data bits, that is 12 bits of data to be encoded, only 12 bits are required.
Once the data is encoded, it is decoded in the following manners: (1) determining the location of the falling edge of an initial start or sync bit pattern, the first encoded spectral data element, and a second or next sync bit transitions; (2) determining the expected position of the transition portion of the first data element based on predetermined expected length between the start bit transition position and the first data bit transition position; (3) finding the actual transition position and determining whether the data is raising or falling and then assigning a 0 or 1 value; (4) determining the next data element transition position based the first data element transition position; and (5) continuing the processes for each data spectrum element until the last data bit is reached. Should a data bit transition not occur in an expected position and the next data bit transition location is located and the missing bit is set to a 1 or 0, resulting in only a one half a bit error. However, if a second data bit transition in the same set is not detected, the data is no longer considered to be valid.
The broad spectrum is transmitted to the encoding elements by a fiber optic cable. The encoding process separates the spectral components and selectively transmits or blocks those components in accordance with the above described encoding method across the length of spectrum. Thereafter these encoded components are recombined in the fiber optic cable. The return spectrum is then focused onto an array of photo-detectors to develop electrical signals whose magnitude changes are proportional to the magnitude changes of the spectral components. Electrical magnitude curves are then processed to extract high/low and low/high transitions to determine coded data corresponding to the originally spectrally encoded data. The data is then decoded by inverting the coding process used for encoding the spectral data.
It is an object of this invention to provide a method of encoding data to simply the decoding of the data.
It is an object of the invention to provide a method for decoding relative encoded spectral data.
Another object of the invention is to provide a method which reduces the effect of an error introduced in encoding data.
A further object of the invention is to provide a method in which data spectrum is formed and segmented into a spectrum with clearly defined magnitude and spectral increments.
It is yet another object of the invention to provide a method which enables the accurate and reliable transition of coded spectral data.
Another object of the invention is to provide a method which enables the generation and transition of spectral data over a single optic fiber utilizing light emitted by light emitting diodes.
Yet another object of the invention is to provide a method of encoding and decoding data wherein each bit of binary data has both high and low level components with the relationship of high and low level determining if the data bit is a logic 0 or 1.
It is another object of the invention to disclose the method of encoding data by high/low level components in the arrangement of data such that only one data bit change states between any two adjacent positions.
Finally it is yet another object of the invention to provide a method of compensating for data variations in parameters of an optical system which may affect the apparent length of a data bit by continually updating the the length of an encoded pattern after a sync pattern.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other objects and purposes of the invention will both be understood in view of the following detailed description of the invention taken in conjunction with the appended drawings wherein.
FIG. 1 is a block diagram of a typical data generation system for using the method of decoding the binary modulated light spectrum according to the present invention; and
FIG. 2 is a multiaccess chart showing the relationship between encoded data or expected data as an example from, zero to seven, its binary equivalent, the coded value such that only one bit changes.
FIG. 3 is a code mask corresponding to the chart of FIG. 2 wherein on and off bits are represented as light and dark with always on and off start bits;
FIG. 4 is a chart showing an allowance for the excitation intensity changes for different wave lengths;
FIGS. 5(A), 5(B) and 5(C) are graphs showing typical outputs of spectral detectors for various positions of the encoding mask;
FIG. 6(A), 6(B) and 6(C) are graphs showing typical outputs for several data elements; and
FIG. 7(A), 7(B) and 7(C) are graphs showing transition points for the various outputs.
DESCRIPTION OF PREFERRED EMBODIMENT
FIG. 1 illustrates a typical optical system 100 wherein spectral binary data is encoded through a excitation broad band spectrum light 102 and transmitted through a fiber optic cable 104 to a defraction grading prism 106 or other type of dispersing element to produce the spectrum of light 108. The light spectrum 108 is focused onto encoding mask 16 which defines relative on and off spectral data. The encoded spectrum is recombined through lens 110 used to disperse the excitation. This recombined spectrum data is then passed through fiber optic cable 112 to a remote location where it is then spread into its spectral elements 114 and focused onto an array of photo-detectors 116. The intensity of these spectral elements 114 is used to determine the encoded data representing the position of mask 16.
Referring to FIG. 2, element 10 shows a decimal equivalent of a three-bit binary data with magnitudes from zero through seven, element 12 is the binary equivalent of the data of element 10 and element 14 is the data coded in a manner wherein only one bit of data changes between any consecutive positions according to Gray Code. For example, in element 12 between state 3 and 4, three bits change state whereas in element 14 only one bit changes state.
Encoded mask 16 shown in FIG. 3 is used for encoding the coded binary data of element 14. "On" is clear and represented by a logic 1 while "off" is dark and represented by a logic 0. Each data element in this code begins with an optional sync pattern elements 18 and 19 of on/off followed by another on/off then followed by data elements which are included as off/on to represent a logic 0 in this example and on/off to represent a logic 1. Each data element has a transition in the center of the bit location, elements 21, 21', . . . 21 n , and may or may not have a transition at the data edges, elements 23, 23', . . . 23 n .
FIG. 4 is a curve 20 which illustrates an example of intensity spectrum versus wave-length of the excitation light 102.
Curve 22 of FIG. 5(A) illustrates spectral intensity versus wave-length across the encoded spectrum that may be expected from the sampling process when the relative position of the mask 16 is in position A of FIG. 3. Curve 24 in FIG. 5(B) is similar to curve 22 except the pattern is for position B of FIG. 3 and curve 26 in FIG. 5(C) represents the spectral pattern for position C.
The processed output for position A from the spectral detectors 116 is shown by curve 28 in FIG. 6(A). The intersection of curve 28 with a preselected positive hysteresis curve 30 represent the magnitude of a raising edges above a base line which will be assigned a logic 1 value while the intersection with a preselected negative hysteresis curve 32 represent the magnitude of falling edges below a base line which will be assigned a logic 0. The intersection points are represented as 1's or 0's depending on the state and remain constant until the next intersection where such data changes again. FIG. 7(A) is a continuous graph of curve 28 which identifies significant transition for position A.
Curve 36 in FIG. 6(B) represents the processed output for position B while curve 38 in FIG. 7(B) illustrates further processing of the curve 36 to identify the transition positions. Similarly position C is illustrated by curve 40 in FIG. 6(C) while curve 42 in FIG. 7(C) represents further processing of curve 40 to detect the transition positions.
In conjunction, with, hysteresis curves 30 and 32 shown in FIG. 6(A), 6(B) and 6(C), this invention also uses the falling edges of 44 and 46 shown in FIG. 7(A) the two start-bits 18 and 19 of FIG. 3 to determine the expected location of the next transition represented by rising edge 48 of encoded positions 21 on mask 16 in FIG. 3. The length or distance across the detector is measured between 44 and 46 and a window is determined where the rising edge 48 may be expected with consideration variations due to noise, etc. Such variations may be wide in a relative sense since only at position 50 of encoded positions 21' on mask 16 in FIG. 3 may the next data bit transition be expected. After the transition at element 48, the difference between 44 and 46 is used to determine the expected transition of position 50 based on the transition position of 48 and the difference between the positions 44 and 46. In the case of curve 36 shown in FIG. 6(B), positions 54 and 56 shown in FIG. 7(B) the length difference is used to determine the expected position of position 58. However, position 58 shows no slope change and therefore the state of the data, logic 1 or 0 cannot be determined. As a result in order to determine position 60, the length between positions 54 and 56 is used rather than the length between positions 56 and 58. At most, only one data bit in the pattern is allowed to be missing. However this data can either be assumed to be 1 or 0 without incurring significant error in the output.
This invention discloses that by using a relative change based on the slopes of the spectral intensity computations are much simpler and reduces the number of possible errors. Likewise, this method allows for variation in the apparent length of the encoded spectrum since the distance between the start bit falling edges such as 44 and 46 or 54 and 56 is measured and its consistency is known to be constant through data lengths 48, 50, 52, . . . etc. This method of encoding may be extended for any number of data bits as required, to meet the required accuracy or resolutions.
The start bit pattern 18 and 19 shown in FIG. 3 is represented by the edges 44 and 46 may not necessarily need to be a 1010 but could be the inverse. Likewise, in systems where less spectral width or variations are found, only one start bit 18 may be necessary eliminating start bit 19 in the code pattern of mask 16. Also, the slope, detection pattern as illustrated in FIGS. 7(A), 7(B) and 7(C) could be modified by filtering the detector output shown in FIGS. 6(A), 6(B) and 6(C), respectively to remove the excitation bias and thus retain the data shape.
The primary requirement for this method of encoding and decoding is that the slope expected between the adjacent on/off elements is greater than the slope of the excitation spectrum.
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A method of decoding spectral data that has been encoding by modulation of a spectrum of light to produce data bits from a source using on/off and off/on transitions to represent each data bit. A start data bit with a constant width precedes each segment of light representing the data bits. The intersection of the output of spectral detectors and a hysteresis curve determines a transition through which information is obtained from the encoded data.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of application Ser. No. 08/961,514 filed on Oct. 30, 1997.
The present invention is related to the following commonly assigned U.S. applications and U.S. patents:
U.S. Pat. No. 6,098,049, entitled “Electronic Price Label System Including Groups Of Electronic Price Labels And Method Of Managing The Groups”, filed Oct. 30, 1997, and invented by Goodwin et al.;
U.S. Pat. No. 5,987,427, entitled “Electronic Price Label System Including Groups Of Electronic Price Labels And Method Of Managing The Groups”, filed Oct. 30, 1997, and invented by Goodwin et al.; and
Ser. No. 08/960,801, entitled, “Apparatus For Grouping Electronic Price Labels”, filed Oct. 30, 1997, and invented by Forsythe et al.
BACKGROUND OF THE INVENTION
The present invention relates to electronic price label (EPL) systems used in transaction establishments, and more specifically to an apparatus for grouping electronic price labels.
EPL systems typically include a plurality of EPLs for each merchandise item in a store. EPLs typically display the price of corresponding merchandise items on store shelves and are typically attached to a rail along the leading edge of the shelves. A store may contain thousands of EPLs to display the prices of the merchandise items. The EPLs are coupled to a central server from where information about the EPLs is typically maintained in an EPL data file. Price information displayed by the EPLs is obtained from the PLU file.
EPLs today may be wired or wireless. Wireless EPLs may employ infrared or radio frequency transmitters to transmit acknowledgment signals acknowledging receipt of messages and to relay acknowledgment signals from other EPLs to receiving devices coupled to a main EPL computer.
Current shelf mounting arrangements for EPLs work well in a typical store environment. However, they are not well-suited for displaying price information on a family of products or a plurality of styles associated with a single product. They are also not well-suited for promoting items located on end-aisles, walls, and other promotional structures besides standard store shelving. Mass merchants, including department store retailers desire more flexibility in mounting EPLs to better promote their products.
Therefore, it would be desirable to group EPLs in containers, such as cassettes. It would also be desirable to provide a method of managing the groups.
SUMMARY OF THE INVENTION
In accordance with the teachings of the present invention, apparatus for grouping electronic price labels is provided.
The apparatus primarily includes a frame member for mounting the EPLs including a plurality of bays arranged in a plurality of rows and columns. The apparatus additionally includes a product description sheet mounted to the frame member including apertures for exposing displays within the EPLs. Optionally included are a product description sheet holder which mounts to the frame member for retaining the product description sheet against the front surface and a base for supporting the frame member on a flat surface.
A method of grouping EPLs includes the steps of inserting the EPLs into rows and columns of bays arranged within a frame member, placing a product description sheet adjacent to the frame member, and orienting apertures in the product description sheet adjacent displays within the EPLs so as to expose the displays.
It is a feature of the present invention that a plurality of prices can be displayed for a plurality of related items. Thus, the groups are particularly suited for use in promotional signs.
It is also a feature of the present invention that the apparatus can be mounted vertically, such as on walls, and placed on horizontal surfaces, such as tables. Thus, the present invention provides an alternative to mounting EPLs on shelf edges.
It is accordingly an object of the present invention to provide an apparatus for grouping electronic price labels (EPLs).
It is another object of the present invention to provide an apparatus for grouping EPLs into rows and columns.
It is another object of the present invention to provide an apparatus for facilitating use of EPLs in promoting items that are not located on standard merchandise shelves.
It is another object of the present invention to provide a sign or other promotional apparatus containing groups of EPLs arranged in rows and columns.
It is another object of the present invention to provide a sign or other promotional apparatus containing groups of EPLs for displaying different prices associated with related items.
It is another object of the present invention to provide an electronic price label system including groups of EPLs and method of managing the groups.
It is another object of the present invention to provide a system and method of managing rows and columns of EPLs which display different prices for different items.
It is another object of the present invention to provide a system and method of managing rows and columns of EPLs which display different prices for different styles of a number of items.
It is another object of the present invention to provide a system and method of managing rows and columns of EPLs which display regular and special prices for different items.
BRIEF DESCRIPTION OF THE DRAWINGS
Additional benefits and advantages of the present invention will become apparent to those skilled in the art to which this invention relates from the subsequent description of the preferred embodiments and the appended claims, taken in conjunction with the accompanying drawings, in which:
FIG. 1 is a block diagram of a transaction management system, including an EPL system;
FIG. 2 is a diagram of a PLU data file;
FIGS. 3A and 3B are diagrams of EPL data files;
FIG. 4 is a diagram of an EPL group definition file;
FIG. 5 is a diagram of an EPL assignment file;
FIG. 6 is a flow diagram illustrating operation of group definition software;
FIG. 7 is a flow diagram illustrating operation of EPL assignment software;
FIGS. 8A and 8B form a flow diagram illustrating operation of a first embodiment of PLU assignment software;
FIG. 9 is a flow diagram illustrating operation of a second embodiment of PLU assignment software;
FIGS. 10A and 10B form an exploded view of a first sign incorporating a cassette; and
FIG. 11 is a second sign incorporating a cassette.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1, a transaction management system 10 primarily includes host computer system 12 , point-of-service (POS) system 14 , and EPL system 16 .
Host computer system 12 includes storage medium 36 , host PLU terminal 40 , and input device 42 .
Storage medium 36 stores PLU data file 44 . PLU data file 44 stores item prices and is available for distribution to POS terminal 20 by host PLU terminal 40 . Alternatively, provision may be made for bar code scanner 18 to directly access primary PLU file 44 from host PLU terminal 40 .
Here, terminals 20 , 24 , and 40 are shown as separate components that are networked together, but they may also be combined in different ways. For example, EPL terminal 24 and host PLU terminal 40 may be combined to form a single host computer. POS terminal 20 and host PLU terminal 40 may be combined to form a POS terminal which doubles as a host computer for a network of other POS terminals.
Host PLU terminal 40 executes PLU maintenance routine 50 . PLU maintenance routine 50 updates PLU data file 44 .
Input device 42 is preferably a keyboard.
PLU maintenance routine 50 may send changes in price in PLU file 44 directly to EPL terminal 24 and POS terminal 20 as they are entered in input device 42 (immediate processing) or store price changes within a batch file 51 in storage medium 36 for later batch updating (batch processing).
PLU data file 44 (FIG. 2) includes a line entry for each item sold in the store. Each line entry has an item identification entry (ITEM ID), and PLU price entries (PRICE 1 , PRICE 2 , etc.). Entry ITEM ID identifies a store item. Entry PRICE 1 typically identifies the regular price read by POS system 14 to determine the price of an item during scanning by bar code scanner 18 . When present, the additional prices (PRICE 2 , PRICE 3 , etc.) may include special or “sale” prices or additional version/style prices associated with an item.
POS system 14 includes bar code scanner 18 and terminal 20 .
EPL system 16 primarily includes EPLs 22 , host EPL terminal 24 , and EPL storage medium 26 .
EPLs 22 include EPLs 22 A and EPLs 22 B. EPLs 22 B are typically attached to shelves within a store. Grouped EPLs 22 A are assigned to a product having different versions or styles. Thus, each EPL 22 A displays prices of different versions or special prices associated with a single product's ITEM ID. EPLs 22 A may be arranged in a cassette 220 (FIG. 10B) or other suitable holder.
Host EPL terminal 24 executes EPL software 30 and group management software 34 . Host EPL terminal 24 obtains price information from PLU data file 44 and sends it to EPLs 22 . EPL software 30 schedules price change messages for transmission to EPLs 22 and manages communication between host EPL terminal 24 and EPLs 22 .
EPL software additionally maintains EPL data file 32 (FIGS. 3 A and 3 B). EPL data file 32 includes a line entry for each EPL 22 in EPL system 16 . Each line entry has an item identification entry (ITEM ID), an EPL identification entry (EPL ID), and may additionally include an EPL price checksum value entry (EPL CHECK).
Entry ITEM ID identifies a store item. Entry EPL ID identifies which EPL is assigned to the item. Entry EPL CHECK is a checksum value of the digits of the price information that is displayed by EPL 22 .
In a first embodiment (FIG. 3 A), a normally unused bit within an identification number for an item is used to identify a price for the item when a plurality of prices (PRICE 1 , PRICE 2 , etc.) are listed for the item in PLU data file 44 . Alternatively, an additional bit may be added to the item identification numbers to identify which prices to display.
In a second embodiment (FIG. 3 B), an additional entry for a price identifier (PRICE) is added to EPL data file 32 to identify a price for the item when a plurality of prices are listed for the item in PLU data file 44 . The price identifier equals “1” for PRICE 1 , “2” for PRICE 2 , etc.
Group management software 34 manages assignment of EPLs 22 A to groups and item identification numbers to EPLs 22 A. For this purpose, group management software 34 includes EPL assignment software 35 , group definition software 37 , and PLU assignment software 38 .
Group definition software 37 stores group definition information in group definition file 46 (FIG. 4 ). Group definition file 46 includes line entries for group numbers (GROUP#), a total number of EPLs 22 A in the group (EPLs), and the number of EPLs 22 A per line (EPLs/LINE). For example, a two-by-five grouping of EPLs 22 A would have two columns and five rows of EPLs 22 A. The total number of EPLs 22 A in the group would be ten. The number of EPLs 22 A per line would two.
EPL assignment software 35 stores EPL assignment information in EPL assignment file 52 (FIG. 5 ). EPL assignment file 52 includes line entries for group numbers (GROUP#), relative number of each EPL 22 A within the group (EPL#), and EPL identification numbers (EPL ID). In the preceding example, relative numbers are determined from left to right and top to bottom. Thus, the two EPLs 22 A in the first row would have relative EPL numbers of “1” and “2”.
PLU assignment software 38 assigns item identification numbers to EPLs 22 A within groups. Item assignments are stored within EPL data file 32 , along with item assignments of EPLs 22 B.
EPL storage medium 26 stores EPL data file 32 , group definition file 46 , and EPL assignment file 52 , and is preferably a fixed disk drive.
EPL system 16 additionally includes input device 47 and display 48 . Input device 47 records information to be stored within EPL data file 32 , group definition file 46 , and EPL assignment file 52 . Input device 47 is preferably a keyboard.
Display 48 displays program and recorded information during execution of EPL assignment software 35 , group definition software 37 , and PLU assignment software 38 .
Turning now to FIGS. 6-8, the operation of group management software 34 is illustrated in more detail.
With reference to FIG. 6, operation of group definition software 37 begins with START 60 .
In step 62 , group definition software 37 displays a prompt for an operator to select to create, delete, or modify a group using display 48 .
In step 64 , group definition software 37 records the operator choice entered using input device 47 .
In step 66 , group definition software 37 determines from the recorded choice whether a group is to created, deleted, or modified.
For deletion, operation proceeds to step 67 .
In step 67 , group definition software 37 displays a prompt for a group number using display 48 .
In step 68 , group definition software 37 records a group number (GROUP #) entered by the operator using input device 47 .
In step 70 , group definition software 37 deletes group definition information for the selected group from group definition file 46 .
Operation proceeds to step 82 .
Returning now to step 66 , for creation, operation proceeds to step 71 .
In step 71 , group definition software 37 displays a prompt for the operator to enter group definition information.
In step 72 , group definition software 37 records a group number (GROUP #), total number of EPLs in the group (EPLs), and number of EPLs per line (EPLs/LINE) for the group entered by an operator.
In step 74 , group definition software 37 stores the group definition information in group definition file 46 .
Operation proceeds to step 82 .
Returning now to step 66 , for modification, operation proceeds to step 75 .
In step 75 , group definition software 37 displays a prompt for a group number (GROUP #).
In step 76 , group definition software 37 records a group number entered by an operator.
In step 77 , group definition software 37 displays a prompt for group definition information.
In step 78 , group definition software 37 records group definition information, including total number of EPLs in the group (EPLs), and number of EPLs per line (EPLs/LINE) for the group entered by an operator.
In step 80 , group definition software 37 stores the group definition information in group definition file 46 .
Operation proceeds to step 82 .
In step 82 , group definition software 37 displays a prompt for program return to create, delete, or modify another group, or for program end.
In step 84 , group definition software 37 records the operator choice entered using input device 47 .
In step 86 , group definition software 37 determines from the recorded choice whether to create, delete, or modify another group or end.
For return, operation returns to step 62 .
For end, operation ends in step 88 .
With reference to FIG. 7, operation of EPL assignment software 35 begins with START 90 .
In step 92 , EPL assignment software 35 displays a prompt for a group number (GROUP #) using display 48 .
In step 94 , EPL assignment software 35 records a group number entered by an operator using input device 47 .
In step 96 , EPL assignment software 35 determines the number of EPLs (EPLs) in the selected group from group definition file 46 .
In step 98 , EPL assignment software 35 displays the a list of relative numbers (EPL #) of all EPLs 22 A in the selected group.
In step 100 , EPL assignment software 35 displays a prompt for a relative EPL number from the list.
In step 102 , EPL assignment software 35 records a relative EPL number entered by the operator.
In step 104 , EPL assignment software 35 displays a prompt for an EPL identification number (EPL ID) to be assigned to an EPL 22 A.
In step 105 , EPL assignment software 35 records an EPL identification number entered by the operator.
In step 106 , EPL assignment software 35 stores the EPL identification number for the EPL in EPL assignment file 52 .
In step 108 , EPL assignment software 35 displays a prompt for program return to assign an EPL identification number to the next EPL in the relative number list, or for operation to continue.
In step 110 , EPL assignment software 35 records the operator choice entered using input device 47 .
In step 112 , EPL assignment software 35 determines from the recorded choice whether to return or continue.
For return, operation returns to step 98 to assign an EPL identification number to the next EPL in the relative number list. Operation returns to step 100 until the last EPL in the relative number list has been assigned an EPL identification number.
Otherwise, operation continues in step 114 .
In step 114 , EPL assignment software 35 displays a prompt for program return to select another group, or for program end.
In step 116 , EPL assignment software 35 records the operator choice entered using input device 47 .
In step 118 , EPL assignment software 35 determines from the recorded choice whether to return to select another group, or to end.
For return, operation returns to step 92 to select another group.
Otherwise, operation ends at END 120 .
With reference to FIGS. 8A and 8B, operation of a first embodiment of PLU assignment software 38 begins with START 130 . In this embodiment, prices for different versions of the same item are identified by a special bit in the item identification number. Thus, each EPL 22 A receives a unique item identification number. EPL data file 32 of FIG. 3A is employed.
In step 132 , PLU assignment software 38 displays a prompt for a group number using display 48 .
In step 134 , PLU assignment software 38 records a group number entered by an operator using input device 47 .
In step 136 , PLU assignment software 38 determines the number of EPLs (EPLs) in the selected group from group definition file 46 .
In step 138 , PLU assignment software 38 displays a list of the determined EPLs and their relative number assignments (EPL #).
In step 140 , PLU assignment software 38 displays a prompt for a relative EPL number (EPL #) within the selected group.
In step 142 , PLU assignment software 38 records the relative EPL number entered by the operator.
In step 144 , PLU assignment software 38 reads a corresponding EPL identification number (EPL ID) for the selected relative EPL number from EPL assignment file 52 .
In step 146 , PLU assignment software 38 displays a prompt for an item identification number (ITEM ID) to be assigned to the selected relative EPL number.
In step 148 , PLU assignment software 38 records an item identification number entered by the operator.
In step 149 , PLU assignment software 38 displays a list of modified item identification numbers and their prices. The modified item identification numbers include the item identification number and special bits to identify prices within PLU data file 44 for the same item.
In step 150 , PLU assignment software 38 displays a prompt for a modified item identification number to be assigned to the selected relative EPL number.
In step 151 , PLU assignment software 38 records a modified item identification number entered by the operator.
In step 152 , PLU assignment software 38 stores the modified item identification number for the relative EPL number in EPL data file 32 in the record of the EPL identification number.
In step 154 , PLU assignment software 38 displays a prompt for program return to assign another item to another relative EPL number, or for operation to continue.
In step 155 , PLU assignment software 38 records the operator choice entered using input device 47 .
In step 156 , PLU assignment software 38 determines from the recorded choice whether to return or continue.
For return, operation returns to step 138 to assign another item identification number to another relative EPL number in the selected group.
Otherwise, operation continues in step 158 .
In step 158 , PLU assignment software 38 displays a prompt for program return to select another group, or for program end.
In step 160 , PLU assignment software 38 records the operator choice entered using input device 47 .
In step 162 , PLU assignment software 38 determines from the recorded choice whether to return to select another group, or to end.
For return, operation returns to step 132 to select another group.
Otherwise, operation ends at END 164 .
Advantageously, PLU assignment software 38 assigns merchandise items to relative EPL numbers by automatically determining the EPL identification numbers. The operator does not need to know any EPL identification numbers in order to assign items to relative EPL numbers within groups.
With reference to FIG. 9, operation of a second embodiment of PLU assignment software 38 begins with START 170 . In this embodiment, prices for different versions of the same item are identified by a relative price entry PRICE in EPL data file 32 . Thus, each EPL 22 A within a group receives the same item identification number. Prices are differentiated using the relative price entry PRICE. EPL data file 32 of FIG. 3B is employed.
In step 172 , PLU assignment software 38 displays a prompt for a group number using display 48 .
In step 174 , PLU assignment software 38 records a group number entered by an operator using input device 47 .
In step 176 , PLU assignment software 38 determines the number of EPLs (EPLs) in the selected group from group definition file 46 .
In step 178 , PLU assignment software 38 displays a list of the determined EPLs and their relative number assignments (EPL #).
In step 180 , PLU assignment software 38 displays a prompt for a relative EPL number (EPL #) within the selected group.
In step 182 , PLU assignment software 38 records the relative EPL number entered by the operator.
In step 184 , PLU assignment software 38 reads a corresponding EPL identification number (EPL ID) for the selected relative EPL number from EPL assignment file 52 .
In step 186 , PLU assignment software 38 displays a prompt for an item identification number (ITEM ID) to be assigned to the selected relative EPL number.
In step 188 , PLU assignment software 38 records an item identification number entered by the operator.
In step 190 , PLU assignment software 38 stores the item identification number for the relative EPL number in EPL data file 32 in the record of the EPL identification number.
In step 192 , PLU assignment software 38 displays a list of prices for the item in PLU data file 44 .
In step 194 , PLU assignment software 38 displays a prompt for a relative price number (PRICE) to be assigned to the selected relative EPL number.
In step 196 , PLU assignment software 38 records a relative price number entered by the operator.
In step 198 , PLU assignment software 38 stores the relative price number for the relative EPL number in EPL data file 32 in the record of the EPL identification number.
In step 200 , PLU assignment software 38 displays a prompt for program return to assign another item to another relative EPL number, or for operation to continue.
In step 202 , PLU assignment software 38 records the operator choice entered using input device 47 .
In step 204 , PLU assignment software 38 determines from the recorded choice whether to return or continue.
For return, operation returns to step 178 to assign another item identification number to another relative EPL number in the selected group.
Otherwise, operation continues in step 206 .
In step 206 , PLU assignment software 38 displays a prompt for program return to select another group, or for program end.
In step 208 , PLU assignment software 38 records the operator choice entered using input device 47 .
In step 210 , PLU assignment software 38 determines from the recorded choice whether to return to select another group, or to end.
For return, operation returns to step 172 to select another group.
Otherwise, operation ends at END 212 .
Advantageously, PLU assignment software 38 assigns merchandise items to relative EPL numbers by automatically determining the EPL identification numbers. The operator does not need to know any EPL identification numbers in order to assign items to relative EPL numbers within groups.
Turning now to FIGS. 10A and 10B, sign 220 includes EPL cassette 222 , product description sheet holder 223 , and product description sheet 224 .
Cassette 222 includes rows and columns of bays 226 for installing EPLs 22 A. Here, two columns and five rows of bays 226 are shown. However, the present invention envisions other numbers of rows and columns as well. Not all bays 226 need be filled with EPLs 22 A. The number of EPLs 22 A is determined by the product or products associated with sign 220 and the product description sheet 224 . Cassette 222 is preferably made of plastic.
In more detail, each bay 226 includes left wall 228 , right wall 230 , top wall 232 , bottom wall 234 , and back wall 236 . Walls 228 - 234 are planar and form a frame for openings having substantially similar dimensions as the perimeters of EPLs 22 A.
EPLs 22 A include feet 238 and locking tabs 240 for retaining EPLs 22 A within bays 226 . EPLs 22 A are inserted within bays 226 by inserting the bottom edge and feet 238 first, and the inserting the top edge and locking tabs 240 last. Removal is accomplished in reverse after using a key to depress locking tabs 240 .
Bottom walls 234 include bottom support members 242 upon which EPLs 22 A sit. Bottom support members 242 include end portions 244 which retain feet 238 in place within bays 226 .
Back walls 236 include a include feet viewing apertures 246 and tab viewing apertures 248 . Feet viewing apertures 246 allow an operator to access feet 238 and end portions 244 . Tab viewing apertures 248 are located near the upper edges of back walls 236 and allow an operator to access locking tabs 240 .
Each bay 226 is deep enough so that the front surfaces 254 of EPLs 22 A are substantially flush with front surface 256 of cassette 222 .
Cassette 222 may additionally include base 252 for supporting cassette 222 on a table or other flat surface. Here, base 252 is attached to cassette 222 , however, base 252 may also be integrally manufactured with cassette 222 . The disclosed cassette 222 with base 252 allows product description sheet 226 to be inclined, but other cassette orientations, including substantially vertical orientations, are also envisioned. Cassette 222 may also be manufactured without base 252 so that cassette 222 may be mounted on walls and other substantially vertical surfaces.
Cassette 222 additionally includes top and bottom retaining members 258 and 260 which retain product description sheet holder 223 against front surface 256 of cassette 222 and front surfaces 254 of EPLs 22 A. Product description sheet holder 223 is inserted into cassette 222 by first placing bottom edge 262 behind bottom retaining member 260 and then pressing top edge 264 under top retaining member 258 . Once in place, product description sheet holder 223 is held snugly in place by bottom retaining member 260 and top retaining member 258 , but can be easily removed by applying a removal force to top edge 264 and top retaining member 258 . Thus, reconfiguration with a different product description sheet 224 is easily accomplished.
Product description sheet holder 223 retains product description sheet 224 . For this purpose, product description sheet holder 223 is generally U-shaped, having first and second panels 270 and 272 . Panels 270 and 272 join at top edge 264 . Product description sheet holder 223 is preferably made of transparent Plexiglas or plastic.
Product description sheet 224 slides between panels 270 and 272 of product description sheet holder 223 . Product description sheet 224 includes item identification information, such as product name, brand, and style, and may additionally include other promotional information. Product description sheet 224 includes apertures 274 which line up with displays 280 of EPLs 22 A when sign 220 is assembled with installed EPLs 22 A.
Advantageously, sign 220 is particularly suited for promoting items that are not located on standard store shelving, such as end-aisle structures. Sign 220 may be mounted on a wall or placed on a table.
FIG. 10A illustrates a product description sheet 224 which includes promotional information for a special or “sale” promotion for different items. For each line, one of EPLs 22 A displays a regular price and the other EPL 22 A displays a sale price.
FIG. 11 illustrates a product description sheet 224 which includes promotional information for different styles or types of a single product. Each style has a corresponding EPL 22 A for displaying the regular price of the style and the sale price of the style.
Although the present invention has been described with particular reference to certain preferred embodiments thereof, variations and modifications of the present invention can be effected within the spirit and scope of the following claims.
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An apparatus for grouping electronic price labels (EPLs) which facilitates installation of electronic price labels in signs and promotional displays rather than standard shelf edges. The apparatus primarily includes a frame member for mounting the EPLs including a plurality of bays arranged in a plurality of rows and columns. The apparatus additionally includes a product description sheet mounted to the frame member including apertures for exposing displays within the EPLs. Optionally included are a product description sheet holder which mounts to the frame member for retaining the product description sheet against the front surface and a base for supporting the frame member on a flat surface.
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CROSS-REFERENCES TO RELATED APPLICATIONS
This application claims priority of U.S. provisional application Ser. No. 60/352,007 filed Jan. 23, 2002 entitled “Silicone Rubber Materials Containing Phase Change Material”. The international application Serial No. PCT/US03/01785 entitled “Material made from silicone rubber, production process, and application” was filed Jan. 21, 2003 and published Aug. 21, 2003.
BACKGROUND OF THE INVENTION
The invention relates to a silicone rubber material containing finely divided phase change materials and a process for producing such a material. The application of materials, which absorb, store and release large quantities of heat during a phase transition, into those materials which do not undergo such a phase transition within the same temperature range, leads to a thermo-regulating effect. This thermo-regulating effect can be used to enhance the thermal performance characteristics and the thermal comfort sensation of a variety of products such as sport garments, diving suits, protective garments, blinds, building materials, medical products, automotive products, etc. substantially.
Phase change material possesses the ability to change its physical state within a certain temperature range. When the melting temperature is obtained during a heating process, the phase change from the solid to the liquid state occurs. During this melting process, the phase change material absorbs and stores a large amount of latent heat. The temperature of the phase change material remains nearly constant during the entire process. In a cooling process of the phase change material, the stored heat is released into the environment in a certain temperature range, and a reverse phase change from the liquid to the solid state takes place. During this crystallization process, the temperature of the phase change material also remains constant. The high heat transfer during the melting process and the crystallization process, both without any temperature change, is responsible for the phase change material's appeal as a source of heat storage.
In order to contrast the amount of latent heat absorbed by a phase change material during the actual phase change with the amount of sensible heat in an ordinary heating process, the ice-water phase change process will be used. When ice melts, it absorbs an amount of latent heat of about 335 J/g. When the water is further heated, it absorbs a sensible heat of only 4 J/g while its temperature rises by one degree C. Therefore, the latent heat absorption during the phase change from ice into water is nearly 100 times higher than the sensible heat absorption during the heating process of water outside the phase change temperature range.
In addition to ice (water), more than 500 natural and synthetic phase change materials are known. These materials differ from one another in their phase change temperature ranges and their heat storage capacities.
Currently, only crystalline alkyl hydrocarbon phase change materials having different chain lengths are used for finishing yarns, textiles and foams. Characteristics of these phase change materials are summarized in Table 1.
TABLE 1
Crystalline alkyl hydrocarbons
Crystalline
Melting
Crystallization
Latent
alkyl
temperature,
temperature,
heat storage
hydrocarbons
Formula
° C.
° C.
capacity, J/g
Heneicosane
C 21 H 44
40.5
35.9
213
Eicosane
C 20 H 42
36.1
30.6
247
Nonadecane
C 19 H 40
32.1
26.4
222
Octadecane
C 18 H 38
28.2
25.4
244
Heptadecane
C 17 H 36
21.7
16.5
213
Hexadecane
C 16 H 34
16.7
12.2
237
The crystalline alkyl hydrocarbons are either used in technical grades with a purity of approximately 95% or they are blended with one another in order to cover specific phase change temperature ranges. The crystalline alkyl hydrocarbons are nontoxic, noncorrosive, and nonhygroscopic. The thermal behavior of these phase change materials remains stable under permanent use. Crystalline alkyl hydrocarbons are byproducts of petroleum refining and, therefore, inexpensive.
Salt hydrates are alloys of inorganic salts and water. The most attractive properties of salt hydrates are the comparatively high latent heat values, the high thermal conductivities and the small volume change during melting. Salt hydrates often show an incongruent melting behaviour which results in a lack in reversible melting and freezing making them unsuitable for permanent use. Salt hydrates with reversible melting and freezing characteristics are summarized in Table 2.
TABLE 2
Salt hydrates
Melting
Latent heat storage
temperature,
capacity,
Salt hydrates
° C.
J/g
Calcium Cloride Hexahydrate
29.4
170
Lithium Nitrate Trihydrate
29.9
236
Sodium Sulfate Decahydrate
32.4
253
In the present applications of the phase change material technology in textiles, only crystalline alkyl hydrocarbon are used which are microencapsulated, i.e., contained in small micro-spheres with diameters between 1 micron and 30 microns. These microcapsules with enclosed phase change material are applied to a textile matrix by incorporating them into acrylic fibers and polyurethane foams or by coating them onto textile surfaces.
U.S. Pat. No. 4,756,958 reports a fiber with integral micro-spheres filled with phase change material which has enhanced thermal properties at predetermined temperatures.
U.S. Pat. No. 5,366,801 describes a coating where micro-spheres filled with phase change material are incorporated into a coating compound which is then topically applied to fabric in order to enhance the thermal characteristics thereof.
U.S. Pat. No. 5,637,389 reports an insulating foam with improved thermal performance, wherein micro-spheres filled with phase change material are embedded.
The micro-encapsulation process of crystalline alkyl hydrocarbon phase change materials is a very time-consuming and complicated chemical process running over several stages making the microcapsules with enclosed phase change material very expensive.
In addition to the micro-encapsulation of phase change material, several attempts have been made to contain crystalline alkyl hydrocarbons as well as salt hydrates in certain macro-structures such as a silica powder, or a polyolefin matrix.
U.S. Pat. No. 5,106,520 describes a dry silica powder comprising phase change material.
U.S. Pat. No. 5,053,446 reports a polyolefin composition containing a phase change material and possesses enhanced thermal storage properties.
However, applications of these containment structures have shown that they are not providing a durable containment and the phase change material often disappears while in its liquid stage.
SUMMARY OF THE INVENTION
The invention pertains to silicone rubber materials, which contain finely divided phase change materials such as crystalline alkyl hydrocarbons or salt hydrates. By either heat absorption or heat emission, the phase change material provides a thermo-regulating system which enhances the thermal performance of silicone rubber materials substantially. The structure of the silicone rubber allows for a loading capacity of up to 60 wt. % of crystalline alkyl hydrocarbons or salt hydrates. The newly-invented product can be used, for instance, for building products, cable insulations, thermal protection of technical products, protective garments, medical devices, automotive products and sporting goods such as diving suits.
DETAILED DESCRIPTION OF THE INVENTION
It has been discovered, that crystalline alkyl hydrocarbons and salt hydrates can be durably contained in a silicone rubber matrix whereby the phase change materials are cross-linked into the silicone rubber structure. For this purpose, the phase change material does not need to be microencapsulated. Finely-divided phase change materials emulsified or dispersed in the silicon rubber structure do not flow out of the silicon rubber structure while in a liquid stage. The composition remains stable under substantial temperature variation over a long service time.
There are several methods that can be applied in order to produce silicone rubber. For containing phase change material inside the silicone rubber matrix, the most appropriate method uses liquid silicone rubbers. Liquid silicone rubbers are paste-like flow-able, two-component blends. Liquid silicone rubbers possess a lower viscosity than solid rubbers which especially supports forming the product into a desired shape. Phase change materials (available in a liquid form after melting) can be easily mixed into the two liquid components the basic silicone rubber components consist of.
Liquid silicon rubbers are available in different versions. Some of the standard types provide an exceptional mechanical strength and elasticity. There are liquid silicone rubbers available which cure in a very short period of times. Another liquid silicone rubber system possesses a very high flame resistance. They are all supplied ready for processing. One of the two components contains, for instance, a platinum catalyst and the other component a hydrogen-functional polysiloxane cross-linking agent.
The crystalline alkyl hydrocarbons or the salt hydrates create a third component which needs to be mixed into the system. In principle, all phase change materials with phase transition temperatures in the required temperature ranges for a certain application can be used for incorporation into the silicone rubber matrix. For many applications, the melting temperature of the phase change materials needs to be in a temperature range between 20° C. and 60° C. For most of the garment applications, the melting temperatures of the phase change materials preferably lie in a temperature range between 30° C. and 36° C. For some technical heat protective applications, higher melting temperatures of up to 100° C. may be required.
The crystalline alkyl hydrocarbons or the salt hydrates may be incorporated into the silicone rubber matrix in a weight portion of up to 60 wt. % based on the material's total weight. Preferably, the phase change materials are incorporated into the silicone rubber matrix in weight portions between 20 wt. % and 50 wt. %. These quantities of phase change material ensure a substantial increase in thermal performance. On the other side, the desired mechanical strength, flexibility and hardness characteristics of the silicone rubber material can also be maintained. The hardness could be decreased, if necessary, by further adding silicone fluid.
Before mixing the crystalline alkyl hydrocarbons or the salt hydrates into the two components of the silicone rubber matrix, they need to be liquid. If crystalline alkyl hydrocarbons or salt hydrates are used, which are solid at the processing temperature, they need to be melted first. In order to obtain a certain appearance, color pigments will be added. Otherwise the end product will be vary between transparent and opaque. In order to receive a sufficient adhesion to a prospective carrier structure (textiles, wallpaper etc.), adhesion supportive substances will be added.
All the components are usually transferred by a metering pump from the containers into the metering cylinder of an injection moulding machine. As soon as the components are mixed, the addition-curing mixture starts to cure. The rate of curing depends on the temperature. The higher the temperature, the faster the curing process will be performed. In order to avoid a water separation and evaporation of the water component of salt hydrates, silicone rubber with incorporated salt hydrates should be cured at temperatures below 80° C. Preferable, most silicone rubber systems with incorporated phase change materials shall be cured at room temperature or at a higher temperature of up to 75° C. Addition-curing components do not release any by-products that have to be removed by any form of after-treatment or post-curing.
The silicone rubber with the incorporated phase change material can be poured into moulds and formed into desired shapes preferably without an external pressure. In addition, the silicon rubber material with incorporated crystalline alkyl hydrocarbons or the salt hydrates can be coated onto a textile or another material. Bonding the silicon rubber material with incorporated phase change material to metals or plastics, a primer should be used to achieve a sufficient adhesion between the silicone rubber material and the carrier material.
The silicone rubber made of the described components possesses a very high flame retardancy. Toxic gases are not released during combustion. Furthermore, the silicone rubber possesses a good weathering resistance, UV resistance, and aging resistance. The material can be applied in a temperature range between −50° C. and 200° C.
The structure of the silicone rubber material allows, for instance, a loading capacity of 40 wt. % of crystalline alkyl hydrocarbon phase change materials. In a silicone rubber (standard type) material with a thickness of 2 mm and a weight of 2200 g/m 2 , a latent heat storage capacity of about 180 kJ/m 2 can be obtained by applying crystalline alkyl hydrocarbon phase change materials with a latent heat storage capacity of about 200 J/g. The latent heat storage capacity, which can be obtained in that way, greatly exceeds those of common polyurethane foam materials with microencapsulated phase change materials, which range from 20 kJ/m 2 to 40 kJ/m 2 . Textiles coated with microencapsulated phase change materials possess latent heat storage capacities between 5 kJ/m 2 and 15 kJ/m 2 . The latent heat storage capacity of a polyolefin structure of the same thickness containing crystalline alkyl hydrocarbon phase change materials was determined to be in the range of 80 kJ/m 2 to 100 kJ/m 2 .
Crystalline alkyl hydrocarbons or salt hydrates are permanently locked in the silicone rubber structure and, therefore, can not disappear while in a liquid stage. The mechanical properties, as well as the special features of the silicone rubber material, are not changed by adding these phase change materials in the given quantities. The high thermal conductivity of the silicon rubber material, about 0.2 W/m K, allows for an exceptional heat transfer to and from the phase change material incorporated therein.
EXAMPLES
The following examples describe specific aspects of the invention to illustrate and provide a description of the invention for those of ordinary skills in the art. The examples shot not be constructed as limiting the invention, as the examples merely provide specific methodology useful in understanding and practicing the invention.
Example 1
A liquid silicon rubber supplied as ELASTOSIL® RT 621 by Wacker Silicones Corporation, Adrian, Mich. was used for all of the following investigations. The silicon rubber ELASTOSIL® RT 621 is a pourable, addition-curing, two-component rubber system that vulcanizes at room temperature. The selected silicon rubber shows a fast and non-shrinking cure at room temperature which can be accelerated considerably by the influx of heat. Additional product features are a low hardness, a high tear strength, good adhesion forces and an excellent flow.
In this first example, a technical grade eicosane was used as a phase change material which melts at a temperature at about 36° C. Because the phase change material is solid at room temperature, it was first melted at a temperature above the melting point. The liquid phase change material was than carefully mixed into the component A of the ELASTOSIL® RT 621, the silicone hydrogen-functional polysiloxane cross-linking agent. The catalyst component B was finally added to the two other components in a quantity of 10 wt. % (in reference to the quantity of the component A) and mixed into them. Then, the three-component system was poured into a form and cured for about one hour.
The finished product, i.e. a silicone rubber with 30 wt. % technical grade eicosane was tested in comparison to a silicon rubber made of ELASTOSIL® RT 621 without phase change material. The technical grade eicosane possesses a lower density (about 850 kg/m 3 ) than the silicone rubber (about 1120 kg/m 3 ). This leads to an approximately 8% lower density of the ELASTOSIL® RT 621 silicone rubber with 30 wt. % technical grade eicosane compared to the ELASTOSIL® RT 621 silicone rubber without phase change material. In reference to the same thickness of the test products, the ELASTOSIL® RT 621 silicone rubber with 30 wt. % of technical grade eicosane also shows a weight reduction of about 8% compared to the ELASTOSIL® RT 621 silicone rubber without phase change material.
Both ELASTOSIL® RT 621 silicone rubber plates (with 30 wt. % phase change material and without phase change material) showed a hardness of about 25°, a tensile strength of about 7.3 N/mm 2 and a tear strength of about 32 N/mm.
The latent heat storage capacity of technical grade eicosane is about 165 J/g. A loading level of 30 wt. % technical grade eicosane in an approximately 8 mm thick silicon rubber plate leads to a latent heat storage capacity of about 50 J/g or 353 kJ/m 2 .
Thermal transfer characteristics such as thermal conductivity, thermal resistance (based on a material thickness of 8 mm), and specific heat capacity are summarized in Table 3.
TABLE 3
Thermal transfer and thermal storage characteristics of the silicone
rubber material with and without phase change material
Thermal
Thermal
Specific heat
conductivity
resistance,
storage capacity,
Material
W/mK
m 2 K/W
J/g K
Silicone rubber
0.1932
0.0414
1.671
plate without phase
change material
Silicone rubber
0.1744
0.0459
1,832
plate with 30 wt. %
eicosane
Example 2
In the second example, a technical grade hexadecane was used as a phase change material which possesses a melting temperature of about 17° C. Because the phase change material is liquid at room temperature it has been mixed directly into the component A of the ELASTOSIL® RT 621, the silicone hydrogen-functional polysiloxane cross-linking agent. The catalyst component B was then added to the two other components in a quantity of about 10 wt. % (in reference to the quantity of the component A) and mixed into them. Then, the three-component system was poured into a form and also cured for about one hour.
The latent heat storage capacity of technical grade hexadecane is about 220 J/g. A loading level of 30 wt. % technical grade hexadecane phase change material in the about 8 mm thick silicone rubber plate totals a latent heat storage capacity of about 65 J/g or 458 kJ/m 2 .
Example 3
In the third example, ELASTOSIL® RT 621 silicone rubber with 30 wt. % technical grade hexadecane was made using the procedure described in Example 2. However, the three-component system was immediately coated onto the surface of different textile carrier structures and were cured for about one hour.
The thickness of the silicone rubber layer applied to different textile structures, such as an open-cell polyurethane foam product, a spacer fabric and a neoprene/fabric composite, was always enhanced by about 1.7 mm, leading to a total weight increase of about 1500 g/m 2 . The latent heat storage capacity of the phase change material incorporated in this 1.7 mm silicone rubber with 30 wt. % technical grade hexadecane totals a latent heat storage capacity of about 100 kJ/m 2 . Thus, the silicone rubber coating with 30 wt. % of technical grade hexadecane (not micro-encapsulated) provides a substantially higher latent heat storage capacity than the common textile products with microencapsulated phase change material.
Example 4
In this fourth example, a lithium nitrate trihydrate salt hydrate was used as a phase change material which melts at a temperature of about 30° C. Because the phase change material is solid at room temperature, it was first melted at a temperature above the melting point. The liquid phase change material was than carefully mixed into the component A of the ELASTOSIL® RT 621, the silicone hydrogen-functional polysiloxane cross-linking agent. The catalyst component B was finally added to the two other components in a quantity of 10 wt. % (in reference to the quantity of component A) and mixed into them. Then, the three-component system was poured into a form and cured for about one hour.
The lithium nitrate trihydrate phase change material possesses a higher density (about 1550 kg/m 3 ) than the silicone rubber (about 1120 kg/m 3 ). This leads to an approximately 12% higher density of the ELASTOSIL® RT 621 silicone rubber with 30 wt. % lithium nitrate trihydrate compared to the ELASTOSIL® RT 621 silicone rubber without phase change material. In reference to the same thickness of the test products, the ELASTOSIL® RT 621 silicone rubber with 30 wt. % lithium nitrate trihydrate shows also an weight increase of about 12% compared to the ELASTOSIL® RT 621 silicone rubber without phase change material.
The latent heat storage capacity of lithium nitrate trihydrate is about 235 J/g. A loading level of 30 wt. % lithium nitrate trihydrate phase change material in the about 8 mm thick silicone rubber plate leads to a latent heat storage capacity about 70 J/g or 620 kJ/m 2 .
A silicon rubber matrix with incorporated phase change material can be used, for instance, to enhance the thermal mass of normal roof constructions and membrane roof constructions significantly, which will lead to a better thermal comfort inside such buildings and to substantial energy savings. The silicone rubber with incorporated phase change material may also improve the thermal performance of car seats, bicycle saddles, diving suits, and medical devices, to mention a few examples.
Other objects, features and advantages will be apparent to those skilled in the art. While preferred embodiments of the present invention have been illustrated and described, this has been by way of illustration and the invention should not be limited except as required by the scope of the appended claims.
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Silicone rubber materials comprising finely divided phase change materials such as crystalline alkyl hydrocarbons or salt hydrates facilitate thermo-regulation due to latent heat absorption and latent heat release in the phase transition range of the phase change material, which improves the thermal performance and enhances the comfort sensation when using the silicon rubber material in item such as car seats, bicycle saddles, diving suits, building materials or medical devices.
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FIELD OF THE INVENTION
Embodiments of the disclosure relate to thermal switches, specifically switches for transferring heat and/or tuning the rate of heat transfer between two structures on command.
BACKGROUND OF THE INVENTION
There are many thermal switching means to transfer heat between structures, such as in cryogenic refrigeration systems, also known as cryocoolers. These means are passive and operate by isolating the cryocooler and associated hardware from outside heat leaks. These devices depend on principles of thermal expansion of materials to create or tear down a thermally conductive path between structures. Thus, when a desired temperature is reached, a conductive material either expands or contracts thereby connecting or isolating a structure to be cooled or heated. A significant limitation of these thermal switches is that they can not initiate thermal transfer on command or be tuned to control the rate of thermal transfer. For a system in which the desired thermal transfer between structures in the system is not known when the system is designed or manufactured, these types of thermal switching means will not work. Also, because these thermal switches can not be commanded to initiate or suspend thermal transfer, or be dynamically tuned to alter the rate of thermal transfer, these switches will not work in an environment or system where the thermal transfer or flow requirements between elements may change over time.
SUMMARY OF THE INVENTION
Embodiments of the present invention solve the problem of initiating and/or varying heat transfer between two structures on command. In a Thermally-Integrated Fluid Storage and Pressurization System, heat may need to be moved advantageously between cryogenic liquid tanks, supercritical fluids bottles, rocket engines, spacecraft structures, and other devices. These components may be physically separated and require heat to be transferred in an efficient manner. Also, the desired thermal transfer characteristics may change depending on the operation of the system. For example, it may be necessary or advantageous to raise the temperature of a structure at one time to a first temperature, and to lower the temperature of the same structure at another time to a second temperature either higher or lower than the first temperature. Alternatively, it may be necessary and/or advantageous to transfer heat between the structures rather than separately cooling one structure and heating another to allow the system to be more energy efficient. Thus, embodiments of the present invention can be practiced to initiate thermal transfer on command and/or tune the rate of heat transfer between two structures.
Various embodiments of the present invention may involve methods of causing, in response to a signal, a first one or more thermally conductive members in thermal-conductive contact with a first structure to be placed within sufficient proximity to one or more thermally conductive members in thermal-conductive contact with a second structure. Thus, thermal transfer may be advantageously commanded.
In various embodiments, methods may include moving the first one or more thermally conductive members to be placed within a sufficient proximity to the second one or more members to facilitate a selected radiative thermal transfer rate between the first and second structures via the first and second one or more thermally conductive members. Radiative thermal transfer may be slower than other forms of thermal transfer such as, for example, conductive thermal transfer. Therefore, depending on a desired rate of thermal conductivity, radiative thermal transfer may be advantageous.
In various embodiments, the positioning of the first one or more thermally conductive members may cause the first one or more members to make physical contact with either the second one or more thermally conductive members or a third one or more thermally conductive members attached to the second structure thereby facilitating a thermally conductive transfer between the first and second structures. Conductive thermal transfer may be faster than, for example, radiative thermal transfer. Therefore, depending on a desired rate of thermal conductivity, conductive thermal transfer may be advantageous.
In various embodiments, adjusting the position of the first one or more members may advantageously increase or decrease a selected rate of radiative thermal transfer between the first and second structures.
In various embodiments, the adjacent positioning of the first and second one or more thermally conductive members may cause a portion of the surface area of the first one or more members to make physical contact with the second one or more members and advantageously open a thermally conductive path between the first and second structures.
In various embodiments, the thermally conductive members may be translating plates and a gear-driven electric motor of the thermal switch may translate a rotational motive force into a linear motion of the translating plates by acting on a plurality of gear teeth of the translating plates.
In various embodiments, the first one or more thermally conductive members may be rotating plates operatively coupled to a gear-driven electric motor of the thermal switch, and the electric motor may advantageously cause the plates to rotate.
In various embodiments, the second one or more members may be fixed plates, and adjusting the angle of the rotating plates to a selected angle may advantageously achieve the selected rate of thermal transfer by varying the surface area of the rotating plates that are in proximity to the fixed plates. The rate of radiative thermal transfer may be directly correlated to this surface area.
Embodiments of the invention may be a thermal switch for transferring thermal energy between a first and a second structure having a casing with a travel slot and an opening aligned with the travel slot. A thermally conductive member may be disposed at least partially within the travel slot and an actuator may provide a motive force to the thermally conductive member to move the thermally conductive member along the travel slot and extend the thermally conductive member a pre-determined length out of the opening of the casing, thus facilitating thermal transfer when the thermally conductive member is thermally conductively connected to a first structure and it is placed within proximity to a second structure.
In various embodiments, the thermally conductive member may be a translating plate having an end section adapted to fit into, and make physical contact with, a corresponding section of a contact plate attached to the second structure. Thus, the surface area of the thermally conductive member that forms the conductive path may be increased. Also, small alignment issues of the thermally conductive member may be advantageously resolved by providing a corresponding section for the member to slide into.
In various embodiments, the actuator is a gear-driven electric motor and the translating plate further may have a plurality of gear teeth adapted to fit a corresponding plurality of teeth of the gear-driven electric motor and a rotational motive force of the electric motor may be translated into a linear motion of the translating plate by an action of the plurality of teeth of the motor against the plurality of gear teeth.
In various embodiments, an electric solenoid actuator may provide a motive force for the thermally conductive member.
In various embodiments, the thermally conductive member may be coupled to the casing of the switch via a thermally conductive and flexible ribbon or wire thereby advantageously facilitating a thermal conduction path between the first and second structure when the thermally conductive member is extended and in contact with the contact plate.
Various embodiments of the present invention may include thermal switches for transferring thermal energy between a first and a second structure with a cover comprising an opening. The switch may be adapted to be attached to the first structure and an actuator may be disposed within the cover. In embodiments, at least one thermally conductive rotating member may be operatively coupled to the actuator, and may be rotatable by the actuator to a selected one of a plurality of angles such that, when rotated to a selected angle, it may be rotated out of the casing and positioned proximate to at least one thermally conductive fixed member that may be thermal-conductively coupled to the second structure thereby advantageously facilitating a radiative thermal transfer between the first and second structures.
In various embodiments, the actuator may be operated to rotate the rotating member to the selected one of a plurality of angles in order to advantageously control the rate of radiative thermal transfer.
In various embodiments, the rotating plate(s) may be further adapted to be rotatable so that it contacts a thermally conductive stop attached to the second structure, thereby advantageously facilitating a conductive thermal transfer between the first and second structures in addition to the radiative thermal transfer.
In various embodiments, switches may be adapted for use in zero gravity conditions and in vacuum and/or near-vacuum conditions. Thus, embodiments of the invention may be advantageously used in man-made orbiting spacecraft.
The features, functions, and advantages can be achieved independently in various embodiments of the present inventions or may be combined in yet other embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the disclosure will be readily understood by the following detailed description in conjunction with the accompanying drawings. Embodiments of the disclosure are illustrated by way of example and not by way of limitation in the figures of the accompanying drawings.
FIG. 1 depicts a block diagram of a thermal switch device for transferring thermal energy between two structures in accordance with various embodiments of the present invention.
FIG. 2 depicts an exploded view of a thermal switch utilizing a translating plate in accordance with various embodiments.
FIGS. 3A and 3B depict side views of a thermal switch utilizing a translating plate with gear teeth in an open position for little or no heat transfer and a closed position for high conductive heat transfer, respectively.
FIG. 4 depicts an exploded view of a thermal switch utilizing rotating plates for providing either conductive or radiative thermal transfer.
FIGS. 5A , 5 B, and 5 C depict side views of a thermal switch utilizing rotating plates in an open position with little or no heat transfer, a partially rotated position for a variable radiative heat transfer, and a closed position for conductive heat transfer, respectively.
DETAILED DESCRIPTION
In the following detailed description, reference is made to the accompanying drawings which form a part hereof and in which is shown, by way of illustration, embodiments of the disclosure. It is to be understood that other embodiments may be utilized and structural or logical changes may be made without departing from the scope of the disclosure. Therefore, the following detailed description is not to be taken in a limiting sense, and the scope of embodiments in accordance with the disclosure is defined by the appended claims and their equivalents.
Various operations may be described as multiple discrete operations in turn, in a manner that may be helpful in understanding various embodiments; however, the order of description should not be construed to imply that these operations are order dependent.
The description may use perspective-based descriptions such as up/down, back/front, and top/bottom. Such descriptions are merely used to facilitate the discussion and are not intended to restrict the application of the embodiments.
The terms “coupled” and “connected,” along with their derivatives, may be used. It should be understood that these terms are not intended as synonyms for each other. Rather, in particular embodiments, “connected” may be used to indicate that two or more elements are in direct physical or electrical contact with each other. “Coupled” may mean that two or more elements are in direct physical or electrical contact. However, “coupled” may also mean that two or more elements are not in direct contact with each other, but yet still cooperate or interact with each other.
For the purposes of the description, a phrase in the form “A/B” means A or B. For the purposes of the description, a phrase in the form “A and/or B” means “(A), (B), or (A and B).” For the purposes of the description, a phrase in the form “at least one of A, B, and C” means “(A), (B), (C), (A and B), (A and C), (B and C), or (A, B and C).” For the purposes of the description, a phrase in the form “(A)B” means “(B) or (AB),” that is, A is an optional element.
The description may use the phrases, “various embodiments,” “in an embodiment,” or “in embodiments,” which may each refer to one or more of the same or different embodiments. Furthermore, the terms “comprising,” “including,”“having,” and the like, as used with respect to embodiments as described in the present disclosure, are synonymous.
FIG. 1 depicts a block diagram of a thermal switch 100 for transferring heat between first structure 101 and second structure 103 in accordance with various embodiments. First thermally conductive member 105 may be thermally coupled to first structure 101 through, for example, flexible conductive element 113 . Second thermally conductive member 107 may be coupled or connected to second structure 103 . An actuator 109 disposed within housing 111 may be adapted to move first thermally conductive member 105 towards second thermally conductive member 107 through opening 115 . In embodiments, first thermally conductive member 105 may be adapted to be positioned adjacent to, but not in physical contact with, second thermally conductive member 107 . In that case, the thermal switch of FIG. 1 may facilitate a radiative thermal transfer between first structure 101 and second structure 103 .
In other embodiments, first thermally conductive member 105 may be positioned such that it physically contacts second thermally conductive member 107 facilitating a conductive thermal transfer between first structure 101 and second structure 103 .
In embodiments, first and second thermally conductive members 105 and 107 may be a translating plate and an opposing contact plate, respectively. In embodiments, a translating plate may have a shaped feature at its distal end that fits into a corresponding shaped feature of a contact element which may, in embodiments, correct any misalignment of the travel path of the translating plate and increase the surface area of contact between the two plates to increase conductive thermal transfer. Such shaped features may be, for example, a wedge or other shape. In embodiments, actuator 109 may provide linear motion to first thermally conductive member 105 . In embodiments, first and second thermally conductive members 105 and 107 may be a rotating plate and a fixed plate, respectively. In those embodiments, actuator 109 may act to rotate the rotating plate to place it into a position adjacent to the fixed plates to facilitate radiative thermal transfer. In embodiments, a linear translating plate may be used to facilitate radiative thermal transfer.
In embodiments, actuator 109 may be a gear-driven electric motor or a solenoid actuator or other actuators known in the art. In embodiments, gears of a gear-driven electric motor may be made of materials that have low thermal transfer characteristics thereby minimizing thermal transfer between thermally conductive member 105 and actuator 109 . In embodiments, actuator 109 may generate rotational motion. In embodiments, actuator 109 may generate rotational motion which may be translated into linear motion of first thermally conductive member 105 . In embodiments, conductive element 113 may be a flexible and thermally conductive wire, ribbon, or other implement. In embodiments, the various conductive elements may be composed of materials suitable for thermal conduction and/or radiation such as, for example, metallic materials known in the art and/or composite materials, as well as other suitable thermally conductive materials. One of ordinary skill in the art will recognize that embodiments of the present invention are not limited to any particular material or materials.
FIG. 2 depicts an exploded view of thermal switch 100 utilizing a translating plate 116 in accordance with various embodiments of the present invention. Translating plate 116 may be adapted to move within travel slot 106 of base plate 104 . Also, conductive ribbon 118 may assist translating plate 116 in maintaining thermally conductive contact with the thermal switch 100 . In embodiments, conductive ribbon 118 may be replaced with a conductive wire. Base plate 104 may be in contact with a first structure (not shown). In this way, thermal switch 100 may be in thermally conductive contact with the first structure. In other embodiments, thermal switch 100 may utilize a conductive ribbon or wire to make contact with the first structure. In still other embodiments, thermal switch 100 may be adjacent to the first structure with features (not shown) adapted to radiate heat to and from the first structure.
Electric motor 108 may comprise drive shaft 110 connected to gear 112 . Rotational motion generated by electric motor 108 may be translated into linear motion of translating plate 116 by the motion of gear 112 acting on the plurality of gear teeth 114 of translating plate 116 . Translating plate 116 may then be moved along travel slot 106 and into contact with contact plate 102 attached to a second structure (not shown), thus facilitating a thermal conduction path between the first structure and second structure when translating plate 116 has been moved into contact with contact plate 102 . An end region of translating plate 116 may be adapted to fit into a correspondingly shaped region of contact plate 102 to facilitate the alignment of translating plate 116 with contact plate 102 and to increase the total surface area of translating plate 116 that contacts contact plate 102 thereby increasing the rate of thermal transfer. As shown in FIG. 2 , the end region of translating plate 116 may be wedge-shaped, but one of ordinary skill in the art would appreciate that other shapes may also be used. Cover 117 may be disposed on top of base plate 104 and cover the various components of thermal switch 100 . In embodiments, gear 112 and drive shaft 110 may be made of materials with low thermal conductivity properties to minimize heat transfer to electric motor 108 . Electric motor 108 may be selected to operate in the expected temperature conditions. In embodiments, thermal switch 100 may be adapted to operate in both vacuum conditions and atmospheric conditions.
FIGS. 3A and 3B depict a side view of thermal switch 100 in accordance with various embodiments. FIG. 3A depicts thermal switch 100 in an open position with translating plate 116 completely retracted inside thermal switch 100 . In this position, there may be little or no heat transfer between a first structure (not shown) attached to thermal switch 100 and a second structure (not shown) attached to contact plate 102 . In the vacuum conditions of space, only radiative thermal transfer may occur between translating plate 116 and contact plate 102 which may be minimal in the configuration shown. In embodiments, a hinged flap or other cover (not shown) may be placed over opening 115 that may open when translating plate 116 moves through opening 115 . In embodiments, the flap may be made of material with low thermal conductivity, thereby minimizing the radiative heat loss out of opening 115 . A radiative thermal transfer rate of the open system shown in FIG. 3A may, in any event, be much smaller than the conductive thermal transfer rate achieved when thermal switch 100 is in the closed position (shown in FIG. 3B ). In an atmospheric environment, a convective heat transfer rate between translating plate 116 and contact plate 102 may occur which may be greater than the radiative heat transfer rate that may occur in vacuum-like conditions.
Also shown are temperature sensors 119 which may facilitate monitoring and operation of thermal switch 100 .
FIG. 3B depicts thermal switch 100 in a closed position with translating plate 116 having been moved into contact with contact plate 102 . Motor 108 may be energized on command to move translating plate 116 down a travel slot (not shown). Thus, a thermally conductive path may be created between the first and second structure (not shown). Heat may flow to or from the first structure into thermal switch 100 , to translating plate 116 via conductive ribbon 118 and, in some embodiments, base plate 104 . Heat may then flow to or from translating plate 116 into contact plate 102 as the two are now in thermal conductive contact. From there, heat may flow into or out of the second structure. In embodiments, the wedge-shaped end of translating plate 116 may not be as deep as the corresponding wedge-shaped feature of contact plate 102 . In this way, the contact area of translating plate 116 may contact the contact area of contact plate 102 before reaching the end of its range of motion. In embodiments, this may ensure sufficient contact area to facilitate thermal conduction. When heat transfer is no longer desired, motor 108 may be adapted to be energized and spun in reverse causing translating plate 116 to travel back down the travel slot and be fully retracted inside thermal switch 100 .
In embodiments, closed loop motor control using sensors (not shown) or other instruments may be optionally included to turn off motor 108 once thermal switch 100 is fully open or fully closed. Alternatively, an open-loop timed approach may be used to control motor input power. Also, a latching mechanism may be added to prevent motor 108 from moving once power is removed.
FIG. 4 depicts an exploded view of tunable thermal switch 400 in accordance with various embodiments. Cover 401 may be attached to base plate 403 when thermal switch 400 is constructed. Active base plate 403 may have attached to it electric motor 405 , inner shaft support 407 , outer shaft support 409 as well as other components. Connected to electric motor 405 may be drive shaft 421 . Gears 411 may be adapted to translate rotational motion of electric motor 405 to axle 413 which may be attached to a plurality of parallel rotating plates 415 .
Rotating plates 415 may be adapted to be rotated through cover opening 425 and into the gaps in between the plurality of parallel fixed plates 417 thus interleaving rotating plates 415 with fixed plates 417 without making contact. This may allow radiative thermal transfer between rotating plates 415 and fixed plates 417 . The resistance to thermal transfer between the two sets of plates, and thus the rate of radiative thermal transfer between them, may depend on the radiative view factor achieved by the angle of rotation of rotating plates 415 . The radiative view factor may depend, among other things, on the surface area of each of rotating plates 415 that has been rotated into the gaps between fixed plates 417 . This surface area is determined by the angle of rotation of rotating plates 415 . Thus, by varying the angle of rotation of rotating plates 415 , and thereby varying the surface area of rotating plates 415 that are within the gaps between fixed plates 417 , the rate of thermal transfer between rotating plates 415 and fixed plates 417 may be selected by an operator of thermal switch 400 .
In embodiments, active base plate 403 may be adapted to be attached to a first structure (not shown) in a way as to provide for conductive heat transfer between the first structure and thermal switch 400 . Also, fixed plates 417 may be adapted to be attached to passive base plate 419 which may be adapted to be attached to a second structure (not shown). In this way, conductive thermal transfer between the second structure and fixed plates 417 may occur. Thus, when rotating plates 415 are rotated and interleaved with fixed plates 417 , the radiative thermal transfer between them may open a thermal transfer path between the first and second structures. Also, in embodiments, varying the angle of rotation of rotating plates 415 , and thus the radiative view factor, a desired rate of thermal transfer between the first and second structures may be achieved.
Additionally, rotating plates 415 may be adapted to be rotated to a maximum angle and contact a thermally conductive stop (not shown) attached to passive base plate 419 . Thus, depending on the angle of rotation of rotating plates 415 , thermal conduction may be facilitated in addition to the radiative thermal transfer.
In embodiments, active base plate 403 , passive base plate 419 , rotating plates 415 , fixed plates 417 , axle 413 , conductive stop block (not shown), outer shaft support 409 , and inner shaft support 407 may be made from materials with high thermal conductivity characteristics. These materials may be metallic or any high conductivity material. In embodiments, cover 401 , drive shaft 421 , and gears 411 may be made of low conductivity materials to minimize thermal transfer to electric motor 405 . Parallel rotating plates 415 may be welded to axle 413 to maximize conductive heat transfer between rotating plates 415 and axle 415 , outer shaft support 409 , and inner shaft support 407 .
In embodiments, rotating plates 415 may be quarter circle shape, as shown in FIG. 4 , which may allow them to be fully retracted into cover 401 . One of ordinary skill will recognize that rotating plates 415 may be other shapes including circular segments that are more or less than a quarter circle. In embodiments, there may only be one rotating plate and one fixed plate. In embodiments, there may be one rotating plate and two fixed plates. In embodiments there may be two rotating plates and one fixed plate. In embodiments, there may be a plurality of both rotating plates 415 and fixed plates 417 as shown in FIG. 4 . One of ordinary skill in the art will recognize that any number of plates of both types may be selected based on the desired operating characteristics of thermal switch 400 . In alternative embodiments of the present invention, one or more translating plates, rather than rotating plates, may be moved into an interleaved fashion with one or more base plates. In these embodiments, the degree of overlap between the two sets of plates may allow the rate of radiative thermal transfer to be tunable.
In embodiments, fixed plates 417 may be welded to passive plate 419 to maximize thermal transfer. Fixed plates 417 may be, as shown in FIG. 4 , rectangular with a 2:1 length-to-width ratio; however, other shapes and/or ratios may be selected as desired. Fasteners may be used to attach active base plate 403 and passive base plate 419 to structures as desired to promote conductive thermal transfer. Also, two temperature sensors 423 may be included to monitor temperature. In embodiments, more than two temperature sensors may be included to improve or alter the monitoring capabilities. In embodiments, one or no temperature sensors may be included.
In embodiments, closed loop motor control using limit sensors (not shown) or other instruments may be used to turn motor 405 off once thermal switch 400 is fully open or fully closed. In alternative embodiments, an open loop timed approach may be used to control motor input power. In embodiments, a latching mechanism (not shown) may be used to prevent motor 405 from moving once power is removed.
FIGS. 5A-C depict a side view of tunable thermal switch 400 in accordance with various embodiments. FIG. 5A shows thermal switch 400 in an open position with little or no heat transfer. Rotating plate 415 is shown rotated as far away as possible from fixed plate 417 . In this position, radiative thermal transfer rate is minimized. FIG. 5B shows tunable thermal switch 400 in a position with a moderate radiative thermal transfer rate. The angle of rotating plate 415 may be adjusted by energizing electric motor 405 and rotating drive shaft 421 to the desired angle. Therefore, the angle of rotation of rotating plate 415 may be adjusted to tune thermal switch 400 to a desired level of radiative thermal transfer by increasing or decreasing the radiative view factor as discussed above. In this way, the overall thermal transfer rate may between the first and second structures (not shown) may be tuned by an operator of thermal switch 400 .
FIG. 5C depicts thermal switch 400 in a closed position with conductive and radiative thermal transfer. Here, rotating plate 415 has been rotated to a maximum angle thereby maximizing the radiative view factor between rotating plate 415 and fixed plate 417 . Also, rotating plate 415 may be adapted to contact conductive stop block 427 in order to facilitate conductive heat transfer which may, in embodiments, be a greater rate of thermal transfer than radiative heat transfer. Thus, tunable switch 400 may be tuned to a maximum rate of thermal transfer.
In embodiments, radiative heat transfer may perform best in the vacuum conditions of space as there is negligible gas present to permit convection between rotating plates 415 and fixed plates 417 . When thermal switch 400 is used in these conditions, a greater difference in heat transfer characteristics may be observed between the open and closed positions compared with the same switch used in atmospheric environments.
Thus, tunable thermal switch 400 may provide, in accordance with various embodiments, a variable resistance to heat transfer that may be tuned to achieve a desired radiative thermal transfer rate and be adapted to be activated on command. Also, tunable switch 400 may be activated, according to some embodiments, to achieve conductive thermal transfer.
Although certain embodiments have been illustrated and described herein for purposes of description of the preferred embodiment, it will be appreciated by those of ordinary skill in the art that a wide variety of alternate and/or equivalent embodiments or implementations calculated to achieve the same purposes may be substituted for the embodiments shown and described without departing from the scope of the disclosure. Those with skill in the art will readily appreciate that embodiments in accordance with the present disclosure may be implemented in a very wide variety of ways. This application is intended to cover any adaptations or variations of the embodiments discussed herein. Therefore, it is manifestly intended that embodiments in accordance with the present disclosure be limited only by the claims and the equivalents thereof.
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A method of controlling thermal transfer between a first structure and a second structure includes sending a command signal to a thermal switch and actuating an electric motor in response to receiving the signal. The electric motor may move a first thermally conductive member toward and/or in contact with a second thermally conductive member. The first and second thermally conductive member may be in thermally conductive contact with respective ones of the first and second structure.
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FIELD OF THE INVENTION
The present invention relates to an apparatus for improving the thrust produced by a marine propeller.
BACKGROUND AND SUMMARY OF THE INVENTION
Marine propulsion systems generally operate to move a vessel through the water by producing an accelerated column of water. The column of water, known as the slipstream, provides a thrust against the propeller, nozzle or other propulsive device to push the vessel through the water.
The present invention, generally, provides an apparatus for increasing the thrust of a marine propulsion system without increasing the load on the engine.
More particularly, the present invention provides an apparatus for increasing the thrust of a conventional marine propulsion system by providing a blanket or layer of air encircling a slipstream produced by a propulsion system. According to a preferred embodiment, the invention comprises a cowling for a conventional marine propeller that radially encloses the propeller and extends downstream of the propeller to encircle the slipstream of the propeller. An inner part of the cowling is shaped as a section of a cone, with the propeller disposed in a front end of the cone section, and the cone section axially converging (or narrowing) in the rearward direction. An outer part of the cowling is tubular shaped and is longer than the inner part. A front end of the outer part is joined with a front end of the inner part so that the inner and outer parts form a rearward opening annular chamber. Means for providing air to the annular chamber is included to form a blanket of air around the propeller slipstream.
The means for providing air comprises at least a conduit leading engine exhaust to the annular chamber. Additional means includes a duct to lead ambient air to the annular chamber. Movement of the slipstream causes a vacuum in the annular chamber that draws air through the ambient air duct. Other suitable means may also be provided.
The invention is described in terms of a conventional propeller, however, it is understood that any apparatus which produces an accelerated column of water to move a vessel could be substituted with advantageous results in the invention, for example, a bow or stern thruster on the side of a vessel used for positioning the vessel for docking.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
The present invention can be further understood with reference to the following description in conjunction with the appended drawings, wherein like elements are provided with the same reference numerals. In the drawings:
FIG. 1 is a sectional view of an air-encircling thruster cowling according to the present invention;
FIG. 2 is a rear view of the thruster cowling of FIG. 1;
FIG. 3 is a graph of static thrust tests comparing a thrust produced by an engine having a conventional propeller and the same propeller equipped with an air-encircling thruster cowling according to the present invention; and,
FIG. 4 is a graph of dynamic thrust tests comparing the speed of a boat with an outboard motor having with a conventional propeller and the same propeller equipped with the air-encircling cowling.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
FIG. 1 is a sectional view of an air encircling marine propeller apparatus, or thruster cowling, according to the present invention. A propeller cowling 20 is shown installed on a conventional outboard motor. FIG. 2 is rear view of the propeller 10 and cowling 20 of the present invention. Only as much of the outboard motor apparatus as is necessary to describe the invention is illustrated. The direction of flow of water and air are indicated by arrows.
Although the invention is described in conjunction with an outboard motor having a propeller, it is understood that the invention may be used with an inboard motor, or any other propulsion device that produces a column of water to provide thrust to move a vessel in the water.
The outboard motor includes a propeller 10 supported in a manner as is known. The propeller gearbox and rudder are not illustrated. The cowling 20 is a generally cylindrical body having an inlet end 22 and an outlet end 28. The cowling 20 is mounted to a suitable support structure 12 of the outboard motor adjacent to the propeller 10, so that the propeller is positioned in the cowling 20 adjacent to the inlet end 22.
The cowling 20 comprises two coaxially arranged, hollow elements, an inner body 24 and an outer body 26. The inner body 24 surrounds the propeller 10 and has a predetermined length extending downstream of the propeller. The inner body 24 is formed as a section of a cone, or frustoconical, shape that narrows in the downstream direction. A slipstream produced by the propeller, indicated by arrows 40, moves downstream of the propeller within the inner body 24.
The outer body 26 is formed with a cylindrical shape, and the inner body 24 is disposed within the outer body. The outer body 26 is longer than the inner body 24 extending in the downstream direction a predetermined distance farther than the downstream length of the inner body.
The inner 24 and outer 26 bodies are joined at a common front end 28 to form an annular space 30 the encircles the inner body 24. Means for providing air in the annular space 30 is arranged so that a blanket or layer of air, indicated by arrows 45, flows from the annular space 30 and encircles the slipstream 40 of the propeller 10.
Means for providing air in the annular space 30 includes a conduit 50 that carries exhaust from the outboard motor engine (not illustrated) to the annular space 30. The exhaust, indicated by arrows 52, passes from the conduit 50 to a chamber 56 through a series of openings 54. The chamber 56 communicates with the cowling 20, and the exhaust air 52 then travels to the annular chamber 30. An additional duct 60 is provided to lead ambient air into the chamber 56. Movement of the slipstream past the annular space 30 results in low pressure in the annular space, and consequently, the chamber 56. Air drawn by the duct 60 passes through the chamber 56 to the annular space 30, as indicated by the arrows 62.
The annular stream of air 45 surrounds the slipstream 40 of the propeller 10 as the slipstream exits the inner body 24 of the cowling 20. The encircling air is believed to facilitate the movement of the slipstream 40 into the surrounding water, increasing the thrust generated by the slipstream.
A series of tests has indicated that the present invention can significantly increase the thrust produced by a conventional outboard motor propeller at the same engine speed. The tests were performed for both static thrust and speed through the water for a 15 foot bass boat equipped with a 70 horsepower outboard motor.
In the static thrust test, the boat was attached to a set of hydraulic scales mounted on a fixed support to measure the thrust produced by the propeller. The engine was run through a range of speeds and the resulting thrust recorded. The test was repeated with the propeller equipped with a cowling according to the present invention. The tests were again repeated with the air injection means blocked to test the effect of the cowling alone.
The results of the tests are shown in FIG. 3. As can be seen, the propeller with a thruster cowling produced thrust significantly higher than a conventional propeller throughout the range of speeds tested, and was greatest in the upper engine speed region. The use of a cowling without an annular air stream around the slipstream increased thrust, but as can be seen, the increase was less than for the cowling with air injection according to the present invention.
For the dynamic tests, the speed of the boat at various engine speeds was measured. The engine was taken through a range of engine speeds and the speed of the boat in the water was measured. The tests were conducted with the conventional propeller and with the propeller equipped with the thruster cowling both with and without an air stream. The results of the dynamic test are shown in FIG. 4. As can be seen, the thruster cowling-equipped propeller produced greater boat speeds throughout the range of engine speeds.
The foregoing has described the preferred principles, embodiments and modes of operation of the present invention; however, the invention should not be construed as limited to the particular embodiments discussed. Instead, the above-described embodiments should be regarded as illustrative rather than restrictive, and it should be appreciated that variations, changes and equivalents may be made by others without departing from the scope of the present invention as defined by the following claims.
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An air encircled marine thruster cowling includes a cowling that surrounds a propeller and provides an annular blanket of air around the slipstream from the propeller. The cowling includes an inner conical section around the propeller and an outer tubular section around the conical section to form an annular space around the conical section. A duct leads exhaust gas from the engine into the annular space, and an additional duct leads moving ambient air into the annular space, as when a boat is in motion.
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CROSS-REFERENCE TO RELATED U.S. APPLICATIONS
[0001] Not applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
NAMES OF PARTIES TO A JOINT RESEARCH AGREEMENT
[0003] Not applicable.
REFERENCE TO AN APPENDIX SUBMITTED ON COMPACT DISC
[0004] Not applicable.
BACKGROUND OF THE INVENTION
[0005] 1. Field of the Invention
[0006] The invention relates to the improvement provided to the rollers which are coated with elastic material, found in the drafting and guiding zone, and used in yarn production techniques, by apron cladding having shift structure and pre-tensioning mechanism.
[0007] 2. Description of Related Art Including Information Disclosed Under 37 CFR 1.97 and 37 CFR 1.98
[0008] Nowadays, in almost all of the yarn production techniques, rollers coated with elastic material are used either for drafting purposes or with the purpose of guiding the yarn to the next stage. The yarn, according to the place it is used either in fibre form or in its final form, contacts these rollers with a certain tension and it is exposed to drafting or guiding process via these rollers.
[0009] Material hardness of the rollers coated with elastic material is directly related with the quality of the yarn produced and its function, and the elastic material hardness of the top rollers at the drafting zone is especially important for the quality of the yarn. It is a known situation that the contact of the fibre or the yarn with the roller coated with elastic material has an abrasive effect. As the application point allows, the machine producers move the fibre or the yarn on the rollers on which they are guided or drafted in order to delay the abrasion of the elastic material and extend its operation period.
[0010] Compact ring yarn spinning technique is an important example in which the abrasion in the rollers coated with elastic material is intensive. In the compact spinning technology, yarns are positioned closer to each other by using a compacting zone just after the main drafting zone, and thus the spinning triangle is almost removed. In this way, the improvement of the properties of the yarn, for example increasing its strength, and reducing its hairiness is aimed.
[0011] One of the compact ring yarn production techniques is the mechanical compactor mechanism. In FIGS. 1 and 2 , the views of the prior mechanical compactor mechanism is given and the operating principle of this mechanism will be explained below by making references to the reference numbers found in the figures. In FIG. 1 , the side schematic view of the mechanical compactor mechanism used in the prior art for producing compact yarn is given. In FIG. 2 , the detail view showing the positions of the mechanical compactor and the rollers relative to each other is given. As it is seen in the figures, a Delivery drafting roller ( 1 ) initiated by the gearbox, supports the Top roller ( 9 ) and the Front roller ( 10 ) belonging to the compaction zone. The contact point of the compaction zone is between the points A and B shown in FIG. 2 . The mechanical compactor ( 12 ), which is a precision instrument, presses on the Delivery drafting roller ( 1 ) without any gaps. The mechanical compactor ( 12 ) forms a completely closed compaction room together with the Delivery drafting roller ( 1 ), and the Delivery drafting roller ( 1 ) surface moves together with the fibres synchronously in order to guide these fibres to the compactor ( 12 ) precisely. As it is seen in the detail view of the A-B compaction part, a compaction channel ( 12 . 1 ) is found at the inner part of the mechanical compactor ( 12 ), which has a funnel shaped structure narrowing downwardly. The fibres entering through the Delivery drafting roller ( 1 ) and the Top roller ( 9 ) are compacted while they go downwards through the compaction channel ( 12 . 1 ) which is found at the inner part of the mechanical compactor ( 12 ). When the compacted fibres go out of the channel ( 12 . 1 ), they are exposed to winding operation by passing through the Front roller ( 10 ) and the Delivery drafting roller ( 1 ) and they become high durability yarn.
[0012] As it is seen in FIG. 1 , mechanical compact yarn production mechanism according to the prior art comprises a Delivery drafting roller ( 1 ), which is made of metal based material and which makes rotational motion by being initiated by the gearbox and a Middle drafting roller ( 2 ), a roving guide ( 11 ) which operates as a guide for providing entrance of large numbers of fibre into the mechanism, a bottom apron ( 8 ) which is placed over a Middle drafting roller ( 2 ) and the Bottom apron guide bar ( 6 ), and a Top apron ( 7 ) which is placed over the Top apron roller ( 5 ) and the Apron cradle ( 4 ). Fibres entering from the roving guide ( 11 ) are compacted by passing through the top and the bottom apron ( 7 , 8 ). Fibres passing through the top and the bottom apron ( 7 , 8 ) reach between the Delivery drafting roller ( 1 ) and the Top roller ( 9 ). Via a pressure arm ( 3 ) of the mechanism, the Top roller ( 9 ) made of rubber material is pressed onto the Delivery drafting roller ( 1 ) with a certain force. The drafted and expanded fibres which passed through the Delivery drafting roller ( 1 ) and the Top roller ( 9 ) are guided to the mechanical compactor ( 12 ). Since the fibres pass through almost at the same place, abrasions occur at the rubber Top roller ( 9 ) surface and these deformations increase when the operation hours extend. Due to the deformations on the rubber surface, problems occur such as frequent grinding or renewal labour for the Top roller ( 9 ), loss of production, and quality differences between spindles. Yarn end brakes per average of 1000 spindles increase with the deformations at the surface, and problems occur due to the abundance of quality error cleaning in winding, which is the next operation, and therefore the expenses of maintenance increase. Moreover, in the prior mechanism, the fibres ( 20 ) which cannot enter the compactor ( 12 ) during spinning ( FIG. 6A ) generate fluffs, and these fluffs causes environment and machine pollution and/or it is added to the yarn structure at the spinning zone in an uncontrolled way. This situation makes negative impact on the yarn quality and operation conditions. Since the position of the clearer roller ( 18 ) shown in FIG. 6A is distant from the fibres ( 20 ) that can not enter the compactor, it is not effective in accumulating fibres on itself.
[0013] About the mechanical compact yarn production mechanism, the application with publication number WO 2006005207 is found as the closest document to the mechanism, which is the subject of the invention. However, when this patent document is examined, it can be seen that adequate solution suggestions are not provided in this document for eliminating the above said drawbacks and problems.
[0014] As a result, the inadequacy of the prior solutions have necessitated an improvement on the related field, which reduces the abrasion tendency at the rollers coated with elastic material for drafting and guiding purposes in the yarn production techniques, eliminates the said drawbacks and disadvantages in the mechanical ring compact spinning which is especially the basis of operation, improves the yarn parameters, and provides more efficient operation conditions.
[0015] Disadvantages of the Prior Art:
[0016] In the known status of the art, the abrasive impact on the elastic material and the coated surface as a result of the contact between the rollers coated with elastic material and the fibre or the yarn is inevitable after a certain period. Guiding of the fibre or the yarn to the rollers coated with elastic material by continuous moving, use of elastic material developed with different formulas, and choosing the roller dimensions in the smallest diameters and widths that can be used according to the application point are the applications for delaying this abrasion impact. Despite all these measures, in the spinning techniques in which the fibre or the yarn is guided to the roller coated with elastic material without moving to the left or to the right or with a very little moving distance;
[0017] 1. Maintenance labours due to abrasion in very short periods
[0018] 2. Quality problems due to rapid abrasion
[0019] 3. Great quality deviations between production units, and
[0020] 4. Negative operating conditions due to abrasion originating impacts such as breaks, laps etc. are observed.
[0021] Since the fibres pass through almost at the same place also in the prior mechanical compact ring spinning system, they rapidly cause abrasion at the place that they pass through on the Top roller ( 9 ). As a result of this, deformations occur in the yarn quality parameters and operating conditions. In order to prevent such an undesired condition, the Top roller ( 9 ) has to be grinded and renewed in very short periods. After each grinding, diameter of the Top roller ( 9 ) decreases and due to the decreased rubber amount, the hardness impact of the Top roller ( 9 ) increases. This situation ruins the fibre expanding property between the Top roller ( 9 ) and Delivery drafting roller ( 1 ).
[0022] Ineffective Removal of the Fluffs Occurring at the Compactor Zone:
[0023] In FIG. 6 a , fibres ( 20 ) that cannot go through the compactor ( 12 ) during the spinning operation in the present system are shown. Perspective view given in FIG. 6 b shows the distance of the clearer roller ( 18 ) to the fibres ( 20 ) coming out in between the top roller ( 9 ) and compactor ( 12 ) in the prior art. This distance is not sufficient for clearer roller ( 18 ) to collect the fibres ( 20 ) that cannot go through the compactor on itself.
[0024] The fibres ( 20 ) that can not enter the compactors generate fluffs, and these fluffs causes environment and machine pollution and/or it is added to the yarn structure at the spinning zone in an uncontrolled manner. This situation makes negative impact on the yarn quality and operation conditions.
BRIEF SUMMARY OF THE INVENTION
[0025] Purpose of the Invention
[0026] The main purpose of the invention is to develop a mechanical compact ring yarn production mechanism which eliminates the deficiencies found in the present mechanical compact yarn mechanism, improves the yarn parameters, and provides more efficient operating conditions.
[0027] The purpose of the invention is to provide application of a band called apron on the roller, in order to decrease the short term fibre or yarn originating abrasion impact on the roller made of material coated with elastic material, and comprise techniques which would extend the abrasion period.
[0028] In the mechanical compact yarn production mechanism, which is the subject of the invention, the technique of operating apron on the roller is used.
[0029] Patent applications are found which disclose various apron applications used in yarn production systems. The patents with publication numbers EP 0635590, WO2005038104 and WO2007101742 can be given as examples to these applications. However, in the invention, the improvements such as:
[0030] 1. Formation of the apron applied on the roller larger than the perimeter of the roller such that it would be as large as the other equipments allow, and thus the abrasion period can be extended,
[0031] 2. Obtaining different fibre or yarn path by shifting the apron on the roller by choosing the apron to be used in a narrow size than the roller width, and thus the abrasion period can be extended,
[0032] 3. Uniform winding of the apron to be used on the roller via a stretching mechanism mounted on the roller bearing component, are provided. In this way, advantages are obtained which can not be provided with the prior apron coating patents on the roller.
[0033] Again with the invention;
Winding of the apron over the roller coated with elastic material by stretching the apron via a stretching system, Formation of the apron with large perimeter as large as the space and mechanics at the application point allow (large operation surface, abrasion delay), Formation of the apron in a way that it is narrower than the roller coated with elastic material in order to be able to move the apron to the left or to the right on the roller coated with elastic material, Obtaining new yarn or fibre contact path by moving the apron to the left or to the right on the roller coated with elastic material (extension of the period of usage), Providing the operation of shifting the apron to the left or to the right on the roller coated with elastic material be made manually or automatically even during the progress of the production via the systems which will be developed according to the place of application, Formation of a bearing unit according to the present mechanics in order to provide the apron be mounted to its place of application, Formation of guide arms on this bearing unit, which will guide the apron in order to keep the apron on the roller coated with elastic material, In order to be able to coat the apron on the roller coated with elastic material with a certain tension, formation of a tension system between the bearing unit and the present mechanics (spiral or leaf spring, rubber chock etc), are provided.
[0042] With the application of narrow Top roller apron ( 17 ) and soft Top roller ( 9 ) under it, the pressure on the fibre is increased, and thus more effective fibre control is provided. Extension of the abrasion period due to the apron ( 17 ) used in the application being made of a material which is highly durable against abrasion regarding the present Top roller ( 9 ) and having less abrasion because of its structure, and also the perimeter of the apron ( 17 ) being larger than the present Top roller ( 9 ), is the most significant factor in reducing the yarn breaks. Application of narrow Top roller apron ( 17 ) and the effective point of the clearer roller ( 18 ) have also provided improvement in the next operations.
[0043] As a result of the above said benefits of the narrow Top roller apron ( 17 ), the defective zones determined in winding have decreased (especially A 1 zone in Classimat). Moreover, it has provided the advantages of reducing maintenance expenses, which are very important for business, reducing laps and yarn end breaks per hour, thus reducing the workload.
[0044] In order to achieve the above said purposes, the invention is a method, which comprises the phases of tensioning of the aprons ( 17 ) by application of tension via a tension component ( 22 ) and shifting of the bearing unit ( 15 ) carrying the aprons ( 17 ) in predetermined intervals while the fibre drafting operation continues in order to decrease the abrasion impacts on the said apron ( 17 ) caused just before the winding operation for production of compact yarns by the fibres moving over the aprons ( 17 ), which are covered over the bearing guide arms ( 15 . 2 ) connected to a bearing body ( 15 . 1 ) on a bearing unit ( 15 ) placed on the pressure arm ( 3 ) and the Top rollers ( 9 ) in a way that it would cover these ( 9 , 15 . 2 ) together, and thus since the Top roller ( 9 ) and apron ( 17 ) surfaces are abraded in a longer period, the usage and operation periods are extended.
[0045] Again the invention is a fibre drafting mechanism, in which just before the winding operation for the production of compact yarn, the aprons ( 17 ), which are covered over the bearing guide arms ( 15 . 2 ) connected to a bearing body ( 15 . 1 ) on a bearing unit ( 15 ) placed on the pressure arm ( 3 ) and the Top rollers ( 9 ) and can be shifted in horizontal plane if desired, in a way that it would cover these ( 9 , 15 . 2 ) together, and which are stretched by application of a tension.
[0046] The structural and characteristic features of the invention and all advantages will be understood better in detailed descriptions with the figures given below and with reference to the figures, and therefore, the assessment should be made taking into account the said figures and detailed explanations.
BRIEF DESCRIPTION OF THE DRAWINGS
[0047] FIG. 1 is the side schematic view of the mechanical compactor mechanism used in the prior art for producing compact yarn.
[0048] FIG. 2 is the detail view showing the positions of the mechanical compactor and the rollers relative to each other.
[0049] FIG. 3 a is the side schematic view of the alternative mechanical compactor mechanism, which is the subject of the invention.
[0050] FIG. 3 b is the perspective view of and alternative embodiment of the invention.
[0051] FIG. 4 a is the detail view showing the crush of the Top roller in the mechanical compact mechanism of an alternative embodiment of the invention.
[0052] FIG. 4 b is the detail view showing the crush of the Top roller in the mechanical compact mechanism of the prior art.
[0053] FIG. 5 a is the front view of the bearing body according to the alternative embodiment.
[0054] FIG. 5 b is the upper view of the bearing body according to the alternative embodiment.
[0055] FIG. 5 c is the side view of the bearing body according to the alternative embodiment.
[0056] FIG. 6 a is the representative drawing showing the positions of the fibres that do not enter the compactor and the clearer roller in the prior art.
[0057] FIG. 6 b is the perspective drawing showing the position of the clearer roller in the prior art.
[0058] FIG. 6 c is the representative drawing showing the layout of the clearer roller, which is the subject of the invention and effective removal of the fibres that do not enter the compactor from the environment via the clearer roller.
[0059] FIG. 7 is the side mounted view of the bearing unit found in the mechanical compact mechanism, which is the subject of the invention.
[0060] FIG. 8 a is the perspective mounted view of the bearing unit in the shift mechanical compact mechanism, which is the subject of the invention.
[0061] FIG. 8 b is the demounted perspective view of the bearing unit in the mechanical compact mechanism, which is the subject of the invention.
[0062] FIG. 8 c is the view of an alternative embodiment of the bearing unit in the mechanical compact mechanism, which is the subject of the invention.
[0063] FIG. 8 d is the front schematic view showing the application of the subject of the invention to the pressure arm and Front roller group of the ring spinning system.
[0064] FIG. 8 e is the front view of an alternative embodiment of the invention.
[0065] FIG. 9 a is the perspective view showing the contact between the Top roller and the Delivery drafting roller in the prior art.
[0066] FIG. 9 b is the schematic view showing the fibre pinch distance and the contact width between the Top roller and the Delivery drafting roller in the prior art.
[0067] FIG. 10 a is the perspective view showing the contact between the Top roller apron and the Delivery drafting roller, which is the subject of the invention.
[0068] FIG. 10 b is the schematic view showing the fibre pinch distance and the contact width between the Top roller and the Delivery drafting roller, which is the subject of the invention.
[0069] FIG. 11 a is the yarn quality error versus time graph according to the prior art.
[0070] FIG. 11 b is the yarn quality error versus time graph after the application according to the subject of the invention.
REFERENCE NUMBERS
[0000]
1 . Delivery drafting roller
2 . Middle drafting roller
3 . Pressure arm
4 . Apron cradle
5 . Top apron roller
6 . Bottom apron guide bar
7 . Top apron
8 . Bottom apron
9 . Top roller
10 . Front roller
11 . Roving guide
12 . Mechanical compactor
12 . 1 Compaction channel
13 . Front roller cage
14 . Compactor centralizer
15 Bearing unit
15 . 1 Bearing body
15 . 2 Guide arms
15 . 2 . 1 Roller bearing
15 . 2 . 2 Limiter
15 . 2 . 3 1st grade cavity
15 . 2 . 4 2nd grade cavity
15 . 3 Housing
15 . 4 Bar housing
15 . 5 Additional roller bearings
15 . 6 Housing base
16 . Clearer roller bearing component
17 . Top roller apron
18 . Clearer roller
19 Fixing component
19 . 1 Adjustment component
19 . 2 Pressure adjustment pin
19 . 3 Retaining ring
20 . Fibre that can not enter the compactor
21 . Front roller pressure spring
22 Tension component
23 Shift components
DETAILED DESCRIPTION OF THE INVENTION
[0108] The invention relates to a mechanical compactor fibre yarn production mechanism used in producing compact yarn.
[0109] In the yarn production techniques, the rollers coated with elastic material are commonly used at the points where the fibre or the yarn are drafted or at the parts where they are guided to the next step. As examples for the yarn spinning systems, ring spinning, rotor spinning, air jet spinning systems etc. can be given. In all these spinning techniques, the roller coated with elastic material systems with drafting or guiding purposes are used.
[0110] In mechanical compact ring spinning yarn production, the required explanations are made regarding the operation of the mechanism and the deficiencies of the known status of the art. In such yarn spinning systems, for modelling the elimination of the deficiencies of the known status of the art, a study is made on the Top roller ( 9 ) coated with elastic material in the mechanical compact ring spinning system and the details of this study are given below.
[0111] If the subjects which are the basis of the invention are considered under main headings;
[0112] Improvement Obtained by Application of Apron ( 17 ) Over the Top Roller ( 9 ):
[0113] The deformations in the yarn quality parameters and the operating conditions by rapid abrasion of the Top roller ( 9 ) in the prior art have been disclosed in the above technical part. In the improvement made, an apron ( 17 ) is placed on the Top roller ( 9 ), which is in narrower dimensions than the Top roller ( 9 ), but which is made of a material having higher abrasion resistance and which has larger perimeter than the Top roller ( 9 ). This apron ( 17 ) is stretched via a bearing unit ( 15 ) mounted on the pressure arm ( 3 ) and a bearing body ( 15 . 1 ) which is connected to this unit ( 15 ), and thus its movement together with the Top roller ( 9 ) over the Delivery drafting roller ( 1 ) is provided.
[0114] By choosing the Top roller ( 9 ) as soft as possible and by choosing the apron ( 17 ) as narrow as possible than the Top roller ( 9 ), a higher pressure is applied on the fibre with the present pressure force. In this case, better fibre control and thus improvement in the yarn quality parameters are obtained. The apron ( 17 ) materials being resistant against abrasion and its perimeter being larger than the Top roller ( 9 ), long-lasting usage with constant values are provided. The perimeter of the apron ( 17 ) being larger than the perimeter of the Top roller ( 9 ) is the factor which also increases its expected life.
[0115] In FIG. 3 a , the side schematic view of the mechanical compactor mechanism, which is the subject of the invention, and in FIG. 3 b the perspective view of the mechanical compactor mechanism, which is the subject of the invention are given. Mechanical compactor yarn production mechanism; comprises a Delivery drafting roller ( 1 ), which is made of metal based material and which makes rotational motion by being initiated by the gearbox and a Middle drafting roller ( 2 ), a roving guide ( 11 ) which operates as a guide for providing entrance of large numbers of fibre into the mechanism, a bottom apron ( 8 ) which is placed over a Middle drafting roller ( 2 ) and the Bottom apron guide bar ( 6 ), and a Top apron ( 7 ) which is placed over the Top apron roller ( 5 ) and the Apron cradle ( 4 ). Fibres entering from the roving guide ( 11 ) are compacted by passing through the top and the bottom apron ( 7 , 8 ). Fibres passing through the top and the bottom apron ( 7 , 8 ) are compacted by passing through the Delivery drafting roller ( 1 ) and the Top roller ( 9 ) and through the compaction channel ( 12 . 1 ) (See FIG. 2 A-B detail) at the inner part of the mechanical compactor ( 12 ), and finally they are made into yarns after the winding operation made at the outlet of the Front roller ( 10 ) and the Delivery drafting roller ( 1 ), and they are wound on the bobbins found on spindles.
[0116] Via a pressure arm ( 3 ) of the mechanical compactor mechanism, the Top roller ( 9 ) made of rubber material is pressed on the Delivery drafting roller ( 1 ) with a certain force. The fibres passing through the Delivery drafting roller ( 1 ) and the Top roller ( 9 ) are expanded and guided to the mechanical compactor ( 12 ).
[0117] As it is seen in FIG. 2 , a Delivery drafting roller ( 1 ) initiated by the gearbox belonging to the mechanical compact yarn production mechanism, supports the Top roller ( 9 ) and the Front roller ( 10 ) belonging to the compaction zone. The contact point of the compaction zone is from the point A to point B. The mechanical compactor ( 12 ), which is a precision instrument, presses on the Delivery drafting roller ( 1 ) without any gaps. The mechanical compactor ( 12 ) forms a completely closed compaction room together with the Delivery drafting roller ( 1 ), and the Delivery drafting roller ( 1 ) surface moves together with the fibres synchronously in order to guide these fibres to the compactor ( 12 ) precisely. As it is seen in the detail view of the A-B compaction part, a compaction channel ( 12 . 1 ) is found at the inner part of the mechanical compactor ( 12 ), which has a funnel shaped structure narrowing downwardly. The fibres entering through the Delivery drafting roller ( 1 ) and the Top roller ( 9 ) are compacted while they proceed downwards through the compaction channel ( 12 . 1 ) which is found at the inner part of the mechanical compactor ( 12 ) and when the compacted fibres come out of the channel ( 12 . 1 ), they are exposed to winding operation by passing through the Front roller ( 10 ) and the Delivery drafting roller ( 1 ) and they become high durability yarn.
[0118] However, since the fibres pass through almost at the same place between the Delivery drafting roller ( 1 ) and the Top roller ( 9 ), abrasions occur in a short while at the rubber Top roller ( 9 ) surface. The Top rollers ( 9 ) grinded after short periods of usage are removed and grinded or they are replaced with a new Top roller ( 9 ). In both situations, very high labour force losses and additional processing (grinding etc.) and material costs occur.
[0119] As it is also said above, in order to prevent the abrasion formed on the Top roller ( 9 ) made of rubber material, different from the mechanical compact yarn mechanisms of the prior art, apron ( 17 ) application is made on the Top roller ( 9 ). The Top roller apron ( 17 ) operates on the Top roller ( 9 ) on which the abrasions occur and guides the fibres to the mechanical compactor ( 12 ). Moreover, since the width of the apron ( 17 ) used is narrower than the Top roller ( 9 ) width the force impact formed on the fibre by the pressure arm ( 3 ) increases and thus better fibre control is provided. With the application of narrow Top roller apron ( 17 ) and soft Top roller ( 9 ) under it, the pressure on the fibre is increased, and thus more effective fibre control is provided. Extension of the abrasion period due to the apron ( 17 ) used in the application being made of a material which is highly durable against abrasion regarding the present Top roller ( 9 ) and having less abrasion because of its structure, and also the perimeter of the apron ( 17 ) being larger than the present Top roller ( 9 ) provided extending the abrasion period. This situation is one of the most significant factors in reducing the yarn breaks.
[0120] In FIGS. 2 and 3 a , the exit drafting zone in the ring spinning system is given as side view. The fibres guided from the rear part are drafted through the Top roller ( 9 ) coated with elastic material mounted on the pressure arm ( 3 ) and the Delivery drafting roller ( 1 ) found below it, and they are guided to the spinning system at the outlet of the rollers ( 1 , 9 ).
[0121] During guidance of the fibres, the Top roller ( 9 ) coated with elastic material is abraded with time. On the Top roller ( 9 ) coated with elastic material on which abrasion occurs, it is essential to clad an apron ( 17 ) under tension in a narrower dimension and larger diameter than the Top roller ( 9 ) coated with elastic material, which would be shifted to the left or to the right when required. In order to provide bearing of the apron ( 17 ), a bearing unit ( 15 ) is mounted on the pressure arm ( 3 ). The guide arms ( 15 . 2 ) fitted on the bearing unit ( 15 ) is used in order to provide the bearing of the apron ( 17 ) to be able to rotate with the initiation of the Delivery drafting roller ( 1 ) on the Top roller ( 9 ) coated with elastic material.
[0122] In FIGS. 5 a , 5 b and 5 c , a bearing body ( 15 . 1 ) belonging to the said alternative embodiment is shown. As it is seen in FIG. 5 , the bearing unit ( 15 ) mounted on the pressure arm ( 3 ); comprises a bearing body ( 15 . 1 ) having a convenient cavity with the form of the pressure arm ( 3 ) in a way that the pressure arm ( 3 ) would be mounted on it, preferably two guide arms ( 15 . 2 ) formed integrally at the side parts of the bearing body ( 15 . 1 ), and roller bearings ( 15 . 2 . 1 ) formed on the guide arms ( 15 . 2 ) in order to provide the apron ( 17 ) fully fit. The roller bearings ( 15 . 2 . 1 ) allow the apron ( 17 ) make rotating motion together with the Top roller ( 9 ) on the guide arms ( 15 . 2 ) without shifting to the left or to the right. As an alternative to the guide arms ( 15 . 2 ) having fixed structure, the pulleys and couplings having rotating structure which allow rotating motion of the apron ( 17 ) can also be used as the bearing component.
[0123] In FIG. 3 b , the perspective view of and alternative embodiment of the invention is given. According to the figure, the Top roller apron ( 17 ) makes rotational motion in a way that, on one hand while it is in contact with the Top roller ( 9 ) surface, on the other hand it is in contact with the roller bearing ( 15 . 2 . 1 ) surface formed on the guide arms ( 15 . 2 ) belonging to the bearing body ( 15 . 1 ) mounted on the pressure arm ( 3 ).
[0124] Again as it is clearly seen in FIG. 5 a , 5 b , 5 c , a housing is formed at the upper surface of the bearing body ( 15 . 1 ). The bearing body ( 15 . 1 ) is mounted on the pressure arm ( 3 ) via a fixing component ( 19 ) passing through the housing ( 15 . 3 ). By providing mounting of the bearing unit ( 15 ) and the bearing body ( 15 . 1 ) on the pressure arm ( 3 ) via the housing ( 15 . 3 ), the distance setting between the guide arm ( 15 . 2 ) and the Top roller ( 9 ) and therefore the tension of the apron ( 17 ) can be adjusted.
[0125] In order to provide bearing of the apron ( 17 ), a bearing unit ( 15 ) is mounted on the pressure arm ( 3 ). The guide arms ( 15 . 2 ) fitted on the bearing unit ( 15 ) is used in order to provide the apron ( 17 ) with the bearing that it would rotate on the Top roller ( 9 ) coated with elastic material with the initiation of the Delivery drafting roller ( 1 ). The tension component ( 22 ) between the pressure arm ( 3 ) and the bearing unit ( 15 ) provides the apron ( 17 ) to be wound over the Top roller ( 9 ) coated with elastic material with a certain tension. Tension component ( 22 ) can be formed in various different forms, such as leaf spring, spiral spring, bending chock etc.
[0126] Again as it is seen in FIG. 3 a , 3 b (alternative) and in FIG. 8 a , the tension adjustment of the bearing unit ( 15 ) and the bearing body ( 15 . 1 ) pushed upwards via a tension component ( 22 ) is provided with the help of a fixing component ( 19 ), which preferably a screw. Moreover, in order to make distance adjustment between the said bearing unit ( 15 ) and the bearing body ( 15 . 1 ) and the pressure arm ( 3 ), an adjustment component ( 19 . 1 ) is placed on the bearing body ( 15 . 1 ). In the said placement operation, the adjustment component ( 19 . 1 ) is fixed on the pressure arm ( 3 ) found below in a vertical form, from the hole/housing opened on the bearing body ( 15 . 1 ). The adjustment component ( 19 . 1 ) is preferably in a screw form and it keeps the bearing unit ( 15 ) and the bearing body ( 15 . 1 ) and the pressure arm ( 3 ) in a certain distance if adjustment is not made. At the same time, it also limits the tension component. This component ( 19 . 1 ), by being rotated to the left or right, provides an adjustment operation by increasing or decreasing the distance between the bearing unit ( 15 ) and the bearing body ( 15 . 1 ) and the pressure arm ( 3 ).
[0127] Via the said tension component ( 22 ), rotation of the Top roller apron ( 17 ) is provided with a tension, or in other words, its free rotation is prevented. When a little pressure is applied from above on the said bearing unit ( 15 ) and the bearing body ( 15 . 1 ), the bearing unit ( 15 ) and the roller bearings ( 15 . 2 . 1 ) which are mounted together with the guide arms ( 15 . 2 ) integrally shown in FIG. 3 a , 3 b (alternative) and FIG. 8 a , move downwards and the Top roller aprons ( 17 ) can have a more free form.
[0128] Moreover, an adjustment component ( 19 . 1 ) is used between the said pressure arm ( 3 ) and the bearing unit ( 15 ) in order to determine the tension limit point. The fixing component ( 19 ) is used for fitting the tension component ( 22 ) to the bearing unit ( 15 ). Again, in order to provide the said bearing unit ( 15 ) be fit to the pressure arm ( 3 ) in a way that it would be able to move, pin ( 19 . 2 ) is used. The pin ( 19 . 2 ) connects the pressure arm ( 3 ) and the bearing unit ( 15 ) via retaining rings in a way that it would not prevent upwards and downwards motion of the bearing unit ( 15 ). In this way, the bearing unit ( 15 ) mounted on the pressure arm ( 3 ) via the pin ( 19 . 2 ) stretches the apron ( 17 ) rotating between the Top roller ( 9 ) coated with elastic material and the guide arms ( 15 . 2 ) as much as the adjustment component ( 19 . 1 ) allows via the tension component ( 22 ) fitted into its inner part.
[0129] In order to adjust the pressure distribution of the said Top rollers ( 9 ) the pin ( 19 . 2 ) is placed on the pressure arm ( 3 ). While the structural function of the said pin ( 19 . 2 ) remains same, bearing of the pin ( 19 . 2 ) is provided by addition of retaining rings ( 19 . 3 ) to the bearing body ( 15 . 1 ). Mounting of the tension component ( 22 ) to the bearing body ( 15 . 1 ) is provided via the fixing component ( 19 ) and the holes which are projections of the housings ( 15 . 3 ) formed on the bearing body ( 15 . 1 ). While the said tension component ( 22 ) is mounted on the bearing unit ( 15 ) and the bearing body ( 15 . 1 ) to be adjusted by the fixing component ( 19 ), it is also in contact with the pressure arm ( 3 ) in order to bend and make pressure on the pressure arm ( 3 ). In this way, a bend between the pressure arm ( 3 ) and the bearing unit ( 15 ) and the bearing body ( 15 . 1 ) is provided. Therefore, with this bend provided by the pressure arm ( 3 ), a tension load is provided on the guide arms ( 15 . 2 ) connected to the bearing body ( 15 . 1 ) seen in the FIG. 3 a , 3 b (alternative) and the FIG. 8 a , and the aprons ( 17 ) in bearing position on the roller bearings ( 15 . 2 . 1 ).
[0130] In the said invention; the guide arms ( 15 . 2 ) can be fitted on the guide arm (bar) housing ( 15 . 4 ) on the bearing unit ( 15 ) via the grade cavities ( 15 . 2 . 3 , 15 . 2 . 4 ) in a way that it is shifted to the left or right. As an alternative to this embodiment, the guide arms ( 15 . 2 ) can be mounted to the pressure arm ( 3 ) as a screw. Guide arms ( 15 . 2 ) can be shifted to the left or right on the pressure arm ( 3 ) with a screw motion.
[0131] In both embodiments or in all shifting techniques which can be alternative, the purpose is to provide the guide arms ( 15 . 2 ) be shiftable to the right or left on the bearing unit ( 15 ). Thus, the apron ( 17 ) which is narrower than the width of the Top roller ( 9 ) coated with elastic material can be shifted on the Top roller ( 9 ) coated with elastic material. The purpose is to obtain a new operating surface on the apron ( 17 ), which is not abraded by the fibre or yarn coming from the systems at the backside. Thanks to this operation, the expected life of the apron ( 17 ) increases twice or more.
[0132] In FIG. 7 , the side mounted view of the mechanical compactor mechanism, which is the subject of the invention is given. According to the figure, the bearing unit ( 15 ) and the bearing body ( 15 . 1 ) are seen which are placed on the said pressure arm ( 3 ) in contact with each other via the tension component ( 22 ) and the adjustment component ( 19 . 1 ). At the front part of the bearing unit ( 15 ), a guide arm ( 15 . 2 ) is placed. The said guide arm ( 15 . 2 ) is in a modular structure and it provides bearing of the apron ( 17 ). The apron ( 17 ) seen in the figure can have a longer perimeter through the guide arms ( 15 . 2 ) which would be added on the bearing unit ( 15 ). This can be made until the most available apron ( 17 ) perimeter is obtained at all places that the application will be made. The purpose is to obtain the largest apron ( 17 ) perimeter which can be applied according to the perimeter of the perimeter of the Top roller ( 9 ) coated with elastic material, and thus extend the abrasion period said in the known status of the art.
[0133] In FIG. 9 a , the perspective view showing the contact between the Top roller ( 9 ) and the Delivery drafting roller ( 1 ) in the prior art is given. In FIG. 10 a , the perspective view showing the contact between the Top roller apron ( 17 ) and the Delivery drafting roller ( 1 ), which is the subject of the invention, is given. The width of the Top roller apron ( 17 ) used is preferably the half of the width of the Top roller ( 9 ) width.
[0134] In FIG. 9 b , the fibre pinch distance (A 1 ) and the contact width (B 1 ) between the Top roller ( 9 ) and the Delivery drafting roller ( 1 ) in the prior art is given.
[0135] In FIG. 10 b , the fibre pinch distance (A 2 ) and the contact width (B 2 ) between the Top roller apron ( 17 ) and the Delivery drafting roller ( 1 ), which is the subject of the invention, is given. A 1 and A 2 pinch distances are given in the side views in the FIGS. 4 a and 4 b.
[0136] As it is again seen in FIG. 7 , while the said apron ( 17 ) can be wound only between the Top roller ( 9 ) and the guide arms ( 15 . 2 ), it can also make ring over the additional roller bearings ( 15 . 5 ) which are formed on the bearing unit ( 15 ) and/or the bearing body ( 15 . 1 ).
[0137] In FIG. 8 a , the mounted perspective view of the bearing unit ( 15 ) in the mechanical compact mechanism, which is the subject of the invention, is given. As it is seen in the figure, the said guide arm ( 15 . 2 ) is placed at the lower part of the bearing body ( 15 . 1 ). At the lower part of the bearing unit ( 15 ), which has a demounted perspective view in FIG. 8 b , a bar housing ( 15 . 4 ) is formed for placement of the said guide arm ( 15 . 2 ). Again as it is seen in FIG. 8 b , grade cavities ( 15 . 2 . 3 , 15 . 2 . 4 ) are formed at the lower part of the bar ( 23 ). Via these grade cavities ( 15 . 2 . 3 , 15 . 2 . 4 ) the guide arm ( 15 . 2 ) can be fixed on the bar housing ( 15 . 4 ) by fitting on it. In the fitting operation the 1st grade cavities ( 15 . 2 . 3 ) or the 2nd grade cavities ( 15 . 2 . 4 ) are arbitrarily fitted on the housing base ( 15 . 6 ) in the bar housing ( 15 . 4 ).
[0138] For example, the guide arm ( 15 . 2 ), which is fitted on the 1st grade cavity ( 15 . 2 . 3 ) in the first usage, would form an abrasion zone by the yarn on the apron ( 17 ) which makes rings in a bearing form. After a certain time, when the abrasion increases, the said guide arm ( 15 . 2 ) is lifted upwards by being hold through the apron limiters ( 15 . 2 . 2 ) and thus it is removed from the bearing body ( 15 . 1 ). Afterwards, the guide arm ( 15 . 2 ) is shifted in the “−x axis” and the said guide arm ( 15 . 2 ) is again fixed on the bearing body ( 15 . 1 ) in a way that it would fit on the 2nd grade cavity ( 15 . 2 . 4 ) housing base ( 15 . 6 ) belonging to the guide arm ( 15 . 2 ). After this operation, the yarn will pass through another zone on the apron ( 17 ) which is not abraded. This operation is the method of usage of the un-abraded other surface of the apron ( 17 ), on which the used zone is abraded after usage. In this way, profitable usage of the apron ( 17 ) surface is provided. The adjustment operations said here are made without stopping the machine. This is a very important property. Because, stopping the machine for each adjustment operation causes serious losses in production. All the adjustments in the prior are made by stopping the machine. The known status of the art is exceeded by using the apron ( 17 ) in a profitable manner without stopping the production, and far exceeding the grinding or renewal life of the Top roller ( 9 ) used in the prior art.
[0139] As it is seen in the figures, via the Top roller apron ( 17 ), which is the subject of the invention, the contact width (B 2 ) decreases and the fibre pinch distance (A 2 ) increases regarding the prior art. Thanks to the increasing fibre pinch distance (A 2 ), the fibres are caught better and their compaction is provided under higher pressure. In this way, control of fibre is provided in a much easier manner and the quality of the yarn increases.
[0140] For the mathematical explanation of the FIGS. 9 b and 10 b , the below given conditions have to be met:
[0141] a) F 1 =F 2 ,
[0142] b) The materials of the Top roller ( 9 ) in FIG. 9 a and the Top roller ( 9 ) in FIG. 10 a would have elastic properties and their hardness would be equal,
[0143] c) The Top roller apron ( 17 ) width (B 2 ) would be smaller than the prior Top roller ( 9 ) width (B 1 ), In this case;
[0000] A 2> A 1
[0000] would be obtained. Since the F 1 and F 2 forces found in the figures have impact on a circular surface;
[0000] B 1/ B 2> A 2/ A 1
[0000] is obtained. In this case, the inequality could be expressed as;
[0000] A 1× B 1> A 2× B 2
[0144] According to these data the P 1 pressure impacting on the fibres in the prior art in FIG. 9 a is;
[0000] P 1=( F 1/2)/( A 1× B 1)
[0145] Whereas, the P 2 pressure impacting on the fibres in the mechanism, which is the subject of the invention is;
[0000] P 2=( F 2/2)/( A 2× B 2)
[0146] According to the above given information, since F 1 =F 2 and A 1 ×B 1 >A 2 ×B 2 ;
[0000] P 2> P 1
[0000] is obtained. In other words, under a constant F force, the pressure force applied on the fibre on a unit area is increased via the Top roller apron ( 17 ) used in the mechanism, which is the subject of the invention. In this way, the fibre is caught better, its control is provided in a better manner, and the quality of the yarn increases.
[0147] Effective Cleaning Obtained with the New Position of the Clearer Roller ( 18 ):
[0148] Since the clearer roller ( 18 ), with its new position, effectively catches the fibres ( 20 ) that cannot enter the mechanical compactor ( 12 ), and accumulates these on itself, their entrance into the yarn structure is prevented and the working environment is kept cleaner.
[0149] As it is seen in FIGS. 6 a and 6 b , in the prior art, the clearer roller ( 18 ) in cylindrical structure is far away from the zone where the fibres ( 20 ) that cannot enter the mechanical compactor ( 12 ) generate fluffs, its cleaning effect is quite small. As it is seen in FIGS. 5 and 6 c , the clearer roller ( 18 ) is placed at a zone much nearer to these fibres generating fluffs via the clearer roller bearing component ( 16 ), which is the subject of the invention. In this way, the fluffs formed between the Top roller apron ( 17 ) and the mechanical compactor ( 12 ) is effectively taken onto the clearer roller ( 18 ). The clearer roller ( 18 ) is in contact with the Top roller apron ( 17 ) and makes rotating motion via the motion it takes from the apron ( 17 ), and thus gathers the fibre fluffs on itself and increases the yarn quality by preventing these fly be added into the yarn structure.
[0150] The length of the apron ( 17 ) used in FIG. 8 a is longer than the one in FIG. 3 b . In this way, the expected life of the apron ( 17 ) is longer. The said guide arm ( 15 . 2 ) seen in this structure can be gradually shifted to the right and to the left on the “x” plane. In this way, two different yarn paths can be obtained on the apron ( 17 ), which provides the increase of the expected of the apron ( 17 ) twice.
[0151] Whereas in FIG. 7 , the length of the apron ( 17 ) is increased much more, which is used by forming additional roller bearings ( 15 . 5 ) on the said bearing body ( 15 . 1 ) (the apron ( 17 ) shown in dotted form in FIG. 7 ). In this way, the expected life of the apron ( 17 ) increased much more because of its increased length and also the guide arm ( 15 . 2 ) being gradually shiftable on the “x” plane.
[0152] FIG. 8 c is the view of another alternative embodiment of the bearing unit in the mechanical compact mechanism. For profitable use of the said apron ( 17 ), other alternative embodiments can also be formed in which the apron ( 17 ) is moved. In another alternative embodiment, the said guide arm ( 15 . 2 ) is again placed on the bearing body ( 15 . 1 ), whereas it makes its movement to the left or right not in a gradual manner, and in infinite screw etc. embodiments by being a shifting component ( 23 ). In FIGS. 8 d and 8 e , an alternative embodiment is seen. In the figures, an alternative embodiment is seen, in which the guide arms ( 15 . 2 ) are separate from the bearing body ( 15 . 1 ). In this structure, at the parts where the guide arms ( 15 . 2 ) would be connected to the bearing body ( 15 . 1 ), screw paths/gears are formed. In this way, the shifting of the guide arms ( 15 . 2 ) on the bearing unit ( 15 ) by being moved back and forth via the geared form and their re-positioning and profitable usage of the apron ( 17 ) by making the guide arm ( 15 . 2 ) and apron ( 17 ) left-right movement is provided. In this context, all the structures comprising the shifting of the apron ( 17 ) with the guide arm ( 15 . 2 ) on which it is carried are within the context of this invention, and thus, they would not comprise novelty.
[0153] As a result of all of these improvements, the expected grinding or renewal life of the Top rollers ( 9 ) in the prior art are far exceeded and thus the known status of the art is exceeded. In this way the inventive step criterion is exceeded.
[0154] The above provided improvement is not only used in ring spinning systems, but also it can be used in all other yarn production techniques. Therefore, the invention cannot be limited to the representative applications given in this section. In the light of the basic elements and methods stated in the claims, any alternative embodiment which can be developed by the people skilled in the related art would mean violation of the invention.
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The purpose of the invention is to reduce the abrasive impact of the fibre or the yarn on the rollers coated with elastic material, which are used for drafting and guiding purposes in yarn production techniques, and thus keep the operating conditions and yarn quality parameters constant. The fibre on the top rollers coated with elastic material especially in the mechanical ring compact yarn production among the yarn production techniques, is an apron cladding method, over the top roller and the bearing guide arms connected to a bearing body found on the bearing unit placed on the pressure arm, in a way that it would cover these together. The method includes the operation steps of stretching the aprons by application of tension via a tension component and, while the fibre drafting operation continues, the bearing unit carrying the aprons being shifted in the horizontal plane in certain intervals.
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RELATED APPLICATIONS
This application claims priority to “Byte Slice Based DDR Timing Closure”, Provisional Application for U.S. Patent, Ser. No. 60/495,585, filed Aug. 15, 2003, which is incorporated herein by reference in its entirety for all purposes.
FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[Not Applicable]
MICROFICHE/COPYRIGHT REFERENCE
[Not Applicable]
BACKGROUND OF THE INVENTION
A dual data rate (DDR) memory is characterized by a data signal that provides bits of information during the rising edge of a clock signal as well as the falling edge of the DQS signal. Accordingly, 2 bits/cycle are possible. The data signal is to be sampled at 90 and 270 degrees phase shift from the DQS signal.
As the clock signal increases, such as from 100 MHz to 200 MHz, the time period shrinks from 10 ns to 5 ns. Skews that may be permissible for slower clocks become unacceptable for faster clocks.
Integrated circuits are generally designed using synthesis tools. The timing for data pins in a DDR memory are carefully measured and adjusted. However, as the number of data pins increases, the effort is also repeated. This leads to increased prefabrication period.
Further limitations and disadvantages of conventional and traditional systems will become apparent to one of skill in the art through comparison of such systems with the invention as set forth in the remainder of the present application with reference to the drawings.
BRIEF SUMMARY OF THE INVENTION
presented herein is a system and method for byte slice based DDR timing closure.
In one embodiment, there is presented a method for synthesizing/laying out a dual data rate memory, said method comprising synthesizing/laying out a portion of the dual data rate memory; replicating the portion; and placing the synthesized/laid out portion and the replicated portions in proximity to a corresponding plurality of pads.
In another embodiment, the portion comprises a plurality of input/outputs.
In another embodiment, the plurality of input/outputs comprises a byte lane.
In another embodiment, synthesizing/laying out the portion further comprises generating a macro, said macro synthesizing/laying out the portion.
In another embodiment, the macro comprises a plurality of cells, each of said cells corresponding to a particular one of the plurality of input/outputs.
In another embodiment, there is presented a computer readable media for synthesizing a dual data rate memory controller. The computer readable media stores a plurality of instructions. The plurality of instructions comprises receiving a macro representing a portion of the dual data rate memory controller; replicating the macro; and placing the macro and the replicated macros in proximity to a corresponding plurality of pads.
In another embodiment, the portion comprises a plurality of input/outputs.
These and other advantageous and novel features as well as details of illustrated embodiments will be more fully understood from the following description and drawings.
BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 is a block diagram of an exemplary dual data rate memory controller interface;
FIG. 2 is a flow diagram for synthesizing the dual data rate memory controller in accordance with an embodiment of the present invention;
FIG. 3 is a block diagram of a synthesized dual data rate memory controller portion in accordance with an embodiment of the present invention; and
FIG. 4 is a block diagram of an exemplary computer system in accordance with an embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to FIG. 1 , there is illustrated a block diagram describing an exemplary 64-bit dual data rate memory. The dual data rate memory controller is an integrated circuit comprising of say 64 data pins D( 0 ). . . D( 63 ), eight data strobe signal pins DQS( 0 ). . . DQS( 7 ), and eight data mask signals DQM( 0 ). . . DQM( 7 ). Each eight of the data pins, e.g., D( 0 ). . . D( 7 ), is associated with a particular one of the data strobe signal pins, e.g., DQS( 0 ), and a particular one of the data mask signals, e.g., DQM( 0 ). The eight data pins D( 0 ). . . D( 7 ), the associated data strobe signal DQS( 0 ), and the data mask signal DQM( 0 ), are collectively referred to as a byte lane.
The data signal pins D provide or receive data signals. The data signals are synchronized with a clock, such that the data signal pins D provide/receive a bit of information during both a high cycle and low cycle of the clock signal. Accordingly, during each clock cycle, each data pin D can either provide or receive two bits per clock cycle.
During a memory write, a memory controller provides the data signals to the data pins D; along with data strobe signals DQS. The data strobe signals DQS are shifted 90 degrees with respect to the data signals. The DDR memory latches the data signals at both the rising edge and the following edge of the DQS signal.
During a memory read, the DDR memory provides the DQS signals, DQS( 0 ). . . DQS( 7 ), along with the data signals D( 0 ). . . D( 63 ). The DQS signals are aligned with the data signals.
As the clock signal for the DDR memory becomes faster, timing skews that are acceptable for slower clocks signals become unacceptable for faster clocks signals. Thus, minimal timing skews between the data pins D are permissible.
Integrated circuits, such as DDR memory controllers are generally converted from RTL to gates/layout using synthesis/layout tools. During the design, the timing of data paths associated with the data pins D are carefully measured and adjusted. However, as in the present illustration, with 64 pins, the efforts increase.
Referring now to FIG. 2 , there is illustrated a flow diagram for synthesizing a dual data rate memory controller in accordance with an embodiment of the present invention. At 205 , a portion of the dual data rate memory controller is synthesized. According to certain aspects of the invention, the portion can comprises, for example, a byte lane. The portion is synthesized and laid out such that the timing is measured and appropriate.
Additionally, according to certain aspects of the present invention, the portion of the dual data rate memory controller can be represented by what is known as a macro. The macro comprises a plurality of cells, each of which corresponds to a particular one of the data pins D. At 210 , the portions are replicated as needed. At 215 , each of the synthesized portion and the replication portions are placed in proximity to a corresponding plurality of pads.
Referring now to FIG. 3 , there is illustrated a block diagram describing an exemplary synthesized DDR memory controller in accordance with an embodiment of the present invention. Each of the byte lanes is associated with a particular one of a plurality of macros 305 . Each of the macros is placed in proximity with pads 310 .
Referring now to FIG. 4 , a representative hardware environment for practicing the present invention is depicted and illustrates a typical hardware configuration of a computer information handling system 58 in accordance with the subject invention, having at least one central processing unit (CpU) 60 . CpU 60 is interconnected via system bus 12 to random access memory (RAM) 64 , read only memory (ROM) 66 , and input/output (I/O) adapter 68 for connecting peripheral devices such as disc units 70 and tape drives 90 to bus 62 , user interface adapter 72 for connecting keyboard 74 , mouse 76 having button 67 , speaker 78 , microphone 82 , and/or other user interfaced devices such as a touch screen device (not shown) to bus 62 , communication adapter 84 for connecting the information handling system to a data processing network 92 , and display adapter 86 for connecting bus 62 to display device 88 .
Although the invention has been described with a certain degree of particularity, it should be recognized that elements thereof may be altered by persons skilled in the art without departing from the spirit and scope of the invention. One of the embodiments of the invention can be implemented as sets of instructions resident in the random access memory 64 of one or more computer systems configured generally as described in FIG. 4 . Until required by the computer system, the set of instructions may be stored in another computer readable memory, for example in a hard disk drive, or in a removable memory such as an optical disk for eventual use in a CD-ROM drive or a floppy disk for eventual use in a floppy disk drive. Further, the set of instructions can be stored in the memory of another computer and transmitted over a local area network or a wide area network, such as the Internet, when desired by the user. One skilled in the art would appreciate that the physical storage of the sets of instructions physically changes the medium upon which it is stored electrically, magnetically, or chemically so that the medium carries computer readable information. The invention is limited only by the following claims and their equivalents.
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Presented herein is a system and method for byte slice based DDR timing closure. In one embodiment, there is presented a method for synthesizing/laying out a dual data rate memory, said method comprising synthesizing/laying out a portion of the dual data rate memory; replicating the portion; and placing the synthesized/laid out portion and the replicated portions in proximity to a corresponding plurality of pads.
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This application is a continuation of Ser. No. 071/365, filed Jul. 9,1987, now U.S. Pat. No. 4,796,388, issued Jan. 10, 1989.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to an apparatus and method for the removal of flashing from elastomeric elements after they have been molded. More particularly, it is directed to a refrigerating and tumbling device for achieving deflashing of such elements.
2. Description of the Prior Art
The manufacture of molded elements from elastomeric materials, such as, synthetic and organic rubbers, as well as silicone rubbers, is well known. In the manufacture of such materials, a thin extraneous membrane (called "flashing") of the elastomer forms about the edges of the main body of the molded part. In the finishing of the molded part, it is necessary that the flashing be removed.
In the past, flashing was removed by manual methods which, of course, proved to be extremely slow and economically unfeasible. Cryogenic deflashing methods have been developed which utilize the principle that the very thin flashing membranes freeze much more quickly than the body of the molded element, when frozen, the flashing becomes extremely brittle, and when impacted with other molded parts or appropriate media, e.g., sand or other particulate material, the frozen, brittle flashing membrane breaks cleanly at the edge of the molded element. This results in a smooth surface, free from the undesirable flashing membrane.
The devices and methods used heretofore for cryogenic deflashing of such elements have relied on quick freezing of the elements using extremely cold temperatures, i.e., temperatures in the range from -32° C. to -150° F. For this purpose, the art has used solid or liquefied carbon dioxide or liquid nitrogen. Typically, the molded parts to be deflashed are immersed in the solid or liquid carbon dioxide or liquid nitrogen in a vessel which contains, if desired, an appropriate deflashing media. The vessel is rotated or vibrated so as to cause impact between the parts and/or media. The flashing membrane freezes to brittleness and easily breaks away upon impact.
Because of the nature of the cryogenic materials, e.g., liquid nitrogen, liquid carbon dioxide, and solid carbon dioxide, the devices for use with such materials are necessarily relatively complicated and expensive. Because such materials are or become gaseous, they generally result in pressure build-ups so that the apparatuses must be sufficiently structurally strong to withstand the higher pressures resulting from these materials. In addition, substantial insulating must be used with the devices because of the "quick freeze" aspect of the cryogenic materials.
Because of the extremely low temperatures accompanying their use as well as the pressure build-up, there is also a safety problem and the devices must be equipped with appropriate safety mechanisms to avoid accidents. Also, of course, appropriate storage tanks must be provided with such devices to provide for holding the cryogenic materials during their use.
All of this contributes to the increased complexity and costs of these prior art devices. In addition, the use of the cryogenic materials, in and of itself, provides a storage and handling problem for the user. Normally, smaller elastomer finishing operations do not have or cannot afford to maintain the expensive facilities needed to store significant amounts of the cryogenic materials on site. As a result, the cryogenic materials must be delivered shortly before their use. This can cause supply problems if the cryogenic materials cannot be provided at the time necessary for their use in the deflashing apparatus. Of course, the cryogenic materials themselves are relatively expensive.
An additional problem with the prior devices is that their use is accompanied by an extremely high noise level, particularly, when a number of the machines are being used at the same time. Usually, workers in the area are required to wear ear protection because of the intensity of the noise. In addition, these machines generate a substantial amount of dust. Each of these disadvantages results in the machines normally being kept in a separate room in order to isolate both the noise and the dust from other areas of the workplace.
Also, because of the relative complexity of the machines and the necessity for having a source of liquid nitrogen close at hand, as well as the pressures which are generated in the devices, the machines are normally fixed in place. Thus, they are not easily movable from one area to another.
SUMMARY OF THE INVENTION
I have discovered a device for the removal of the thin flashing membrane resulting from the molding of elastomeric elements which avoids the costly apparatus, operations and dangers of the prior art cryogenic devices. It further avoids the need to have a constant supply of liquid nitrogen or liquid or solid carbon dioxide near at hand and is superbly suited for the smaller molder. Moreover, the device of the present invention represents a substantial cost saving as compared to the complicated cryogenic devices presently used.
In particular, the apparatus of the present invention comprises a tumbling barrel which has a closable opening so that molded elastomeric elements and, if desired, deflashing media, can be introduced to the barrel. The device further comprises a refrigeration chamber which is larger than the barrel so that the barrel can be placed therein. The refrigeration chamber has an appropriate cooling means for lowering the temperature of the interior of the chamber and further has means for imparting an impacting movement to elements to be deflashed which are placed within the barrel. As used herein, the expression "impacting movement" means motion which is sufficient to cause the elements which are to be deflashed to collide with each other and/or with media within the barrel with sufficient force to effect deflashing.
This "impacting movement" may be achieved by having means for rotatably mounting the tumbling barrel within the chamber with appropriate drive means for rotating the barrel when it is so mounted. Alternatively, the apparatus can have means for vibrating the barrel while it is in the chamber or rotating the barrel through reciprocal rotation cycles wherein the barrel is rotated in any given cycle less than 360 degrees.
The present invention also comprises a method for deflashing elastomeric elements by introducing the elastomeric elements into a tumbling barrel, movably mounting the tumbling barrel within a refrigeration chamber, the interior of which has been cooled to the desired deflashing temperature, and moving the barrel within said chamber to impart an impacting movement to the contents of the barrel.
With the present invention, when the refrigeration chamber is insulated, substantial reduction in the noise produced when operating the apparatus is affected. In addition, because of the fact that the tumbling barrel is within an enclosed chamber, namely, the refrigeration chamber, there is a substantial reduction in the dust production in the room in which the operation is being carried out.
Finally, because of the apparatus of the present invention need only be plugged into an appropriate electrical outlet and does not need accompanying piping and/or pressurized connections to gas sources, the apparatus is easily movable from one location to another within a working site. This greatly enhances the flexibility of the apparatus as compared to prior art devices.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a perspective view of an apparatus in accordance with the present invention.
FIG. 2 is a partial perspective of a detail of the apparatus of FIG. 1.
FIG. 3 is an exploded perspective view of another embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows an apparatus in accordance with the present invention, designated generally as 10, comprises a first chamber 12, having refrigeration means for cooling the interior of the chamber. In the drawing, the refrigeration means are shown as cooling coils 14 within the walls constituting the chamber. Such refrigeration systems are known and normally comprise refrigeration coils connected to an appropriate compressor/motor arrangement (not shown) and a refrigerant gas system, e.g., freon, and the like. The walls 16 forming chamber 12 contain insulation sufficient to assist in temperature control in the interior of the chamber and for noise abatement.
Chamber 12, as shown in the drawing, also has two apertures 18 and 20 with appropriate closures 22 and 24. These closures 22 and 24 are doors which would have appropriate locking means (not shown) and are attached in a conventional manner by hinges. The openings allow access to the interior of the refrigeration chamber. Two openings may be provided for convenience, although, of course, a single opening would be sufficient. The doors are also appropriately insulated in order to maintain the desired low temperature of the interior of the chamber.
If desired, a circulating means may be provided for the interior of the chamber shown as fan 26 for purposes of circulating the cooled atmosphere within the chamber to assist in uniform cooling. The refrigerating means should be capable of reducing the interior of chamber 12 to a temperature sufficiently low to effect freezing of the flashing membrane so that it will be removed during the operation. The desirable deflashing temperature depends on the particular elastomer being treated. A preferred temperature range is from about -32° to -180° F., most preferably, about -32° to about -150° F. Moreover, the refrigerating mechanism desirably possesses control means, conventional in the art, so as to be able to maintain the temperature within ±10° F. of the desired temperature for a given deflashing operation. Thus, depending upon the particular elastomeric material being deflashed, a temperature within the above-specified range with the variation of ±10° F. would normally be used. One of the distinct advantages of the present system utilizing conventional refrigeration means is the improved temperature control that can be attained, as compared to, for example, liquid nitrogen systems.
Mounted in the interior of chamber 12 is a tumbling barrel 28. The tumbling barrel shown is hexagonal in shape, although other conventional shapes may be used. Typically, such a tumbling barrel may have a length of approximately 30 inches with each side being approximately 14 inches wide. Of course, larger or smaller tumbling barrels may be utilized depending upon the amount of elastomeric elements to be treated as well as the amount of deflashing media to be used. One of the sides 30 of barrel 28 constitutes a door with hinges (not shown) to provide access to the interior of barrel 28. This side may be opened for introducing elastomeric components and media to the interior of barrel 28 and then secured in the shut position for the tumbling operation.
Barrel 28 has extending therefrom a shaft 32 which is securely mounted to the side of barrel 28 via bolted plate 34. Shaft 32 is attached to the barrel at its axis of rotation and extends therefrom through circular aperture 36 in the side wall of refrigerating chamber 12. Shaft 32 and aperture 36 are in an insulatingly sealed relationship to avoid interference with the maintenance of the decreased temperature within chamber 12. Also, however, shaft 32 is able to rotate in aperture 36.
Shaft 32 is supported exterior of chamber 12 by supporting bearings 38 as shown. In the drawing, the bearings are attached to a supporting chassis indicated generally at 40. The entire combination of supporting bearings 38 and shaft 32 are sufficiently strong such as to support in a rotatable manner, tumbling barrel 28 within the interior of chamber 12.
Shown generally at 42 is a drive means composed of a motor 44 having a belt or drive chain 48 attached to the motor drive shaft which is, in turn, connected to a rotary gear 46, mounted on shaft 32. Drive means 42 has appropriate control means, conventional in the art for activating the motor as well as controlling the speed of rotation of tumbling barrel 28. Preferably, drive means 42 is sufficient to rotate tumbling barrel 28 at speeds of up to about 200 rpm. The desired speed of rotation will necessarily depend on the particular elements which are being deflashed.
Alternatively, the drive means can be such so that tumbling barrel does not rotate through a full 360 degree cycle. Thus, drive means 42 can be adapted to effect reciprocal rotary movement of the tumbling barrel through rotations of less than 360 degrees. In essence, this means that the barrel would rotate a given number of degrees in one direction and then rotate back through that same number of degrees in the opposite direction.
The time period for tumbling depends on the particular elements to be deflashed. Normally, the tumbling will be carried out for a period from about 15 minutes to 4 hours.
Tumbling barrel 28 may also, if desired, have apertures 50 in the side walls thereof providing access of the cooled atmosphere within chamber 12 into the interior of the tumbling barrel. These apertures would be suitably screened so as to prevent loss of any tumbling media or the elements during operation of the apparatus. This aids in cooling of the interior of the tumbling barrel. As is clear, however, no special gas or atmosphere is maintained within the barrel or chamber. Thus, only atmospheric air is present. Consequently, there is no need for the chamber walls, tumbling barrel or other elements of the invention (except, of course, for the internal aspects of the sealed refrigeration system) to be especially designed or structured so as to withstand pressure other than normal atmospheric pressure. In this manner, the cooling mechanism of the present invention is indirect in that the actual refrigerant does not directly contact the elastomer elements.
As shown in FIG. 1, the drive means 42 as well as the shaft 32 are placed exterior of refrigeration chamber 12. It is possible, of course, to locate the entire drive means including the shaft supports 38 within chamber 12. However, the embodiment shown is desirable from the standpoint that the drive mechanism does not interfere with the refrigeration of the interior of chamber 12.
In operation, the elements to be deflashed and any deflashing media therefor are introduced into tumbling drum 28 which is rotatably mounted within chamber 12. It should be noted that tumbling barrel 28 can be removably mounted in chamber 12 so that tumbling barrels of different sizes and/or shapes may be used as desired.
A variety of mechanisms may be used for removably mounting tumbling barrel 28 within chamber 12. For example, a mounting plate could be secured to the side of tumbling barrel 28 and shaft 32 can have a flange corresponding to the mounting plate attached to its end. The mounting plate and mounting flange are simply bolted to one another to secure the tumbling barrel to the shaft. To replace the tumbling barrel with another, the bolts are simply undone and a new tumbling barrel having its own mounting plate secured thereto can be introduced to and secured in the chamber. The mounting plate on the barrel is shown in greater detail in FIG. 2. Plate 31 is secured to the side of barrel 30 by means not shown. Extending from plate 31 are bolts 33 which can be threaded. Plate 34 (FIG. 1) which is securing the end of shaft 32 can have holes therein in registration with bolts 33. When the two plates 31 and 34 are married, they can be secured to one another through nuts. (not shown).
The removability of tumbling barrel 28 is advantageous since additional tumbling barrels can be maintained in a refrigerated state exterior of chamber 12, i.e., in a separate conventional refrigeration unit. Also, the deflashing media can be kept in a refrigerated state. In use, a precooled tumbling barrel with its precooled ingredients can then be introduced to chamber 12, thus reducing the amount of time to bring the contents of the tumbling barrel down to the desired temperature. This procedure is advantageous in reducing the overall deflashing time, so that while one barrel is being utilized within apparatus 10, other tumbling barrels with their ingredients are being cooled.
FIG. 3 shows yet another embodiment of the present invention wherein rather than imparting rotary movement to the tumbling barrel, it is made to vibrate so as to place the contents of the barrel into motion. As shown in FIG. 3, this can be accomplished by having the apparatus generally shown at 110 with tumbling barrel 112 attached to vibrating means shown generally at 114. Vibrating means 114 is composed of a mechanical or electromagnetic vibrator 116 which supports a pair of plates 118 secured to each other by springs and sandwiched therebetween. Mounted on the top plate of plates 118 is a shaft 120 which protrudes through the bottom of refrigeration chamber 122. Shaft 120 is secured, preferably in a removable manner by flange 124 to the bottom of tumbling barrel 112. Insulating boot 128 is provided to cover the area where shaft 120 protrudes through the bottom wall of refrigeration chamber 122. Also shown exterior of the refrigeration chamber is the cooling means indicated as being a compressor refrigerant.
In use, the elements to be deflashed and/or media are introduced to the tumbling barrel 112, the contents cooled within the refrigeration chamber and set into motion with the vibrating means. In this connection, it is noted that it is not necessary for media to be used in every instance. Thus, depending on the nature and size of the elastomeric elements, it is possible to effect deflashing without the presence of media.
An alternative procedure is to place the media into the barrel and cool the barrel and its contents to the desired deflashing temperature. The elements are then placed into the barrel with the precooled media and subjected to impacting movement by rotation, vibration, etc., until they are completely deflashed. The elements are then removed from the barrel and the next batch of elements is subjected to the same treatment. In this manner, the media is continuously maintained at the desired temperature and the newly introduced elements cool quickly to the deflashing temperature. This procedure greatly reduces the time for deflashing.
The following example illustrates the present invention.
Using a tumbling device as shown in FIG. 1 hereof, tumbling media composed of 1/4 inch thick triangular shaped stones having a side surface of approximately 3/8 inch in length was placed into a tumbling barrel and the media in the tumbling barrel was cooled to -100° F. This took from about 6 to 8 hours. As of this point, the tumbling unit will maintain the barrel and media temperature.
1000 pieces of a molded neoprene washer having a 1 inch outside diameter, a 1/4 inch inside diameter and a thickness of 3/4 inches were placed into the tumbling barrel. With the barrel closed and refrigerating chamber closed, the barrel was rotated at a speed of approximately 60 rpm for a period of from 30 to 45 minutes. The neoprene washers were then removed from the tumbler and all flashing thereon had been removed.
As shown, the apparatus of the present invention is highly advantageous in that it completely avoids the need for the refrigeration chamber to be sufficiently strong so that it can withstand the build-up of pressure within its interior. This, in turn, avoids the dangers of utilizing cryogenic materials, such as, liquid nitrogen and dry ice. The present apparatus provides both economic as well as safety advantages over prior art devices.
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An apparatus for deflashing of elastomeric elements comprising: a) a tumbling barrel having a closable opening for introducing and withdrawal of elastomeric elements and deflashing media to the interior of the barrel; b) a refrigeration chamber sized for receiving the barrel therein, having an access opening for providing access to a barrel located therein, having means for mounting the barrel therein, and having means for lowering the temperature of the interior of the chamber; and c) means for imparting motion to the barrel mounted within the chamber to achieve impacting movement to the barrel contents. The apparatus avoids the high costs and dangers of the complicated prior art cryogenic devices and is excellently suited for smaller molders.
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CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] None.
BACKGROUND OF THE INVENTION—FIELD OF THE INVENTION
[0002] The dry ice delivery method of the current invention gives one an effective alternative when using dry ice as a temperature lowering means in a portable cooler or other cooling compartment and it eliminates problems associated with the use of gel packs or wet ice as the cooling vehicle when trying to maintain a consistently low temperature in a cooling compartment. By arranging various insulating and breathable materials, each separately or in conjunction with the other, and the dry ice or cooler contents, one can effectively regulate the temperature of a cooling compartment by controlling the rate at which dry ice sublimates. Due to the wide range of temperature regulation that can be achieved when using dry ice, one has greater flexibility when preserving the contents stored in a portable cooler or other cooling compartment; from above freezing (greater then 32° F.), down to sub-zero temperatures, and other temperatures in between. Further, an anti-freeze bag made out of breathable material can assist in regulating the temperature of a cooling compartment in several ways. For example, different liquids freeze at varying temperatures and when a cooling compartment is kept just below 32° F., water tends to freeze first. Water bottles can be encapsulated in the anti-freeze bag allowing them to remain liquid, while other drinks that are also in the cooler's storage area, remain in the liquid state as well. Preferred embodiments of this invention also include a vented module that houses dry ice while it is encapsulated in insulating and breathable materials, or a combination of materials, allowing for the temperature of a cooling compartment to be regulated within a temperature range targeted for the cooler's contents while also allowing individuals to safely touch the dry ice module without getting injured. Dry ice is made of CO 2 (carbon dioxide gas) the sublimation of which is the cooling vehicle in this present invention. Further, because of its molecular make-up CO 2 is heavier than atmospheric air and it falls to the lowest point possible. Therefore, the dry ice module of the present invention should be placed somewhere near the top of a cooler or other cooling compartment in which it is used so the CO 2 gas will fall downward and spread throughout the cooling compartment. When the insulating and breathable materials that make-up the dry ice module are assembled in a manner to achieve a desirable temperature, the build up of pressure from the CO 2 gas accumulated within the cooling compartment is typically inconsequential, even when the lid is not opened for an extended period of time.
BACKGROUND OF THE INVENTION—DESCRIPTION OF THE RELATED ART
[0003] Portable devices are commonly used for cooling food, beverages, medications, and other items in and around the home, as well as away from home. In addition, commercial applications of portable coolers include, but not limited to, the shipment of perishable items, the transport of temperature sensitive medicines, samples to laboratories and the transport of donor organs to medical facilities. Many coolers used for such purposes are non-electric and configured to use wet ice as the primary means of temperature regulation. However, to store items longer than a day and ensure adequate temperature regulation for the cooler's contents, one must repeatedly drain from the cooler a large majority of the surplus water created from the melted ice and add a fresh supply of wet ice. This process is time consuming, messy, does not provide a uniform temperature for the cooler contents over an extended period of time, has the potential to soak and ruin inadequately protected items in the cooler that are adversely affected by water, and requires a renewable source of wet ice. Although wet ice is widely available in gas stations, motels, convenience stores, restaurants, and similar commercial establishments, when temperatures surrounding the cooler are significantly elevated, the refilling of such coolers with fresh supplies of wet ice may be needed more than once a day to maintain the temperature of their contents below a desired level for option consumption and/or spoilage prevention. In the alternative, gel packs and other refreezable pre-packaged products are available for use in coolers instead of wet ice, or in combination therewith. However, to be reused, they have the disadvantage of requiring refreezing in an independent cooling chamber, such as a household freezer, which is not typically available during travel away from home. The amount of cooling time provided depends upon their size and they are rigid which takes up cooler space that otherwise could be devoted to stored items requiring cooling. Further, although the gel packs and other refreezable pre-packaged products are commonly available and eliminate the messiness associated with wet ice, they are not typically large enough to provide temperature regulation for periods longer than are possible with wet ice. It would therefore be useful to have a method of temperature regulation for portable coolers and other portable and non-portable cooling compartments that can maintain lowered temperatures for the contents in the cooling compartments during extended periods of time without refurbishment, maintain a temperature range to protect the contents within a cooling compartment from spoilage, and provide temperature regulation without the mess associated with wet ice and other liquid media, while also providing the ability to cool or freeze contents at a level far below conventional cooling means.
BRIEF SUMMARY OF THE INVENTION
[0004] It is the primary objective of the present invention to provide a system of temperature regulation for portable coolers and other portable and non-portable cooling compartments that can maintain lowered temperatures for the contents therein during extended periods of time without the mess associated with wet ice and other liquid media. It is also an objective of the present invention is to provide a system of temperature regulation for cooling compartments that can be used to maintain the temperatures of contents that are frozen or at temperatures just above freezing. A further objective of the present invention to provide a system of temperature regulation for cooling compartments that maintains a narrow range of temperature during the entire time of its use to protect the contents therein from spoilage. It is also an objective of the present invention is to provide a system of temperature regulation for cooling compartments that is user friendly, environmentally friendly, and requires little monitoring or refurbishment during use. It is a further objective of the present invention to provide a system of temperature regulation for cooling compartments that is made from durable materials and intended for repeated long term use. A further objective of the present invention to provide a system of temperature regulation for cooling compartments that can be employed with reusable and disposable coolers and containers. It is also an objective of the present invention is to provide a system of temperature regulation for cooling compartments that can be permanently built into new cooling compartments or easily retrofit to existing cooling compartments.
[0005] The current invention provides a system of temperature regulation for portable coolers and other portable and non-portable cooling compartments that allows them to be used for prolonging the useful life of perishable items such as but not limited to food, donor organs, and/or medical supplies stored therein by achieving and maintaining a pre-selected and narrowly targeted temperature range. In the alternative, the present invention can be used to maintain the temperatures of different beverages each at its individual optimal drinking temperature, even though such optimal temperatures are not the same. It comprises at least one dry ice module containing a quantity of dry ice, with vents incorporated into the dry ice module and venting means between the dry ice module and the cooling compartment or compartments where items needing temperature regulation are stored. When multiple cooling compartments are available in the same cooler, each can be maintained at independent temperatures, if needed. With the proper combination of rigid or flexible insulation and single or multiple layers of breathable materials, the sublimation of dry ice is slow and the temperature within the cooling compartments with which it is used is maintained in a narrow range. In the alternative, a neighboring cooling compartment can be used for a similar purpose as long as it is also insulated to prevent injury to any skin inadvertently touching its outside surface. The outside surface of the dry ice module, and cooling compartments used in the present invention will always be safe for a user to touch. It is also contemplated for the present invention to be configured to maintain the frozen state of frozen contents placed within the cooling compartments, as well as maintain contents above freezing, as needed. Use of an anti-freeze bag made from breathable material is one contemplated means of preventing the freezing of selected items and/or maintaining them within a targeted temperature range in a cooling compartment chilled to point where other items in the same cooling compartment are maintained in a frozen state or are otherwise maintained below 32° F. for optimum flavor or other purpose even though they do not attain a frozen state at such temperature. Therefore, bags made from breathable material can have different uses in the present invention when different contents are placed inside. When items such as but not limited to food, beverages, medicines, and other storage items are placed inside an anti-freeze bag, it can be used inside another cooling compartment. However, when a soft-sided cooler bag is used for item storage, it would not be made from breathable material. Although it is primarily intended for the present invention to be portable, size is not a limiting factor. Also, any form of dry ice can be used with the present invention, such as but not limited to block, pellets, cryo and/or any new form of dry ice that may be needed for a particular application. It is contemplated for the present invention to be configured for retro-fit to existing coolers, and also be configured for incorporation into new coolers. Also, venting of the sublimated gas into a cooling compartment occurs through vents incorporated into the dry ice module. As another option, the venting means incorporated in the dry ice module can be placed in association with a cooling compartment lid. One contemplated application in motorized vehicles, including boats and airplanes, involves the use of a designated recess in the trunk or a rear storage area, where the present invention is permanently mounted for the temporary storage of food, beverages, and other items, as needed. In the alternative, the present invention may be removably mounted in the designated recess.
[0006] The description herein provides preferred embodiments and should not be construed as limiting the scope of the present invention device. For example, variations in the size, configuration, and location of dry ice module, the size and material construction of any liners or dry ice module used; the type of dry ice used; and the number of dry ice modules and cooling compartments or storage areas used; other than those shown and described herein may be incorporated into the present invention.
[0007] Thus the scope of the present invention should be determined by the appended claims and their legal equivalents, rather than being limited to the examples given.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0008] FIG. 1 is a top perspective view of a first preferred embodiment of the present invention having two cooling compartments or storage areas, and one vented dry ice module attached to the lid for each of the storage areas.
[0009] FIG. 2 is a top perspective view of a second preferred embodiment of the present invention having three adjacent cooling storage areas and one vented dry ice module attached to the lid for each of the storage areas.
[0010] FIG. 3 is a top perspective view of a third preferred embodiment of the present invention having a single cooling storage area and a vented dry ice module built into a two-part cooler lid, with the dry ice module attached to the lid top and venting through the lid bottom.
[0011] FIG. 4A is a front perspective view of one preferred vented dry ice module of the present invention.
[0012] FIG. 4B is a rear perspective view of the dry ice module in FIG. 4A with male couplings.
[0013] FIG. 4C is a cross-sectional view of the dry ice module in FIG. 4A showing its different layers of insulation and breathable material and a detachable lid
COMPONENT NUMBERS USED IN THE DRAWINGS
[0014] 1 . Dry Ice Module (made of insulating and breathable materials, each separately or in conjunction with the other, that houses the dry ice)
[0015] 2 . Insulating Material
[0016] 3 . Breathable Insulating Material
[0017] 4 . Non-Woven Breathable Material, Insulating or Not
[0018] 5 . Vent Holes
[0019] 6 . Detachable Dry Ice Module Lid
[0020] 7 . Dry Ice
[0021] 8 . Male Coupling
[0022] 9 . Female Portal
[0023] 10 . Cooling Compartment
[0024] 11 . One-Piece Cooling Compartment Lid
[0025] 12 . Cooling Compartment Lid Top
[0026] 13 . Cooling Compartment Lid Bottom
[0027] 14 . Anti-Freeze Bag
[0028] 15 . Cooling Compartment Stowage Area
DETAILED DESCRIPTION OF THE INVENTION
[0029] FIG. 1-4 show four preferred embodiments of the present invention having a cooling compartment 10 for items/contents (not shown) requiring storage at temperatures below ambient temperature, and a dry ice module 1 that can be integral with cooling compartment 10 and which is made from or lined with an insulating material 2 that encloses the dry ice 7 primarily to slow down the rate of its sublimation, but which also prevents the outside of the dry ice module 1 from becoming hazardous to touch. Insulating material 2 or materials may comprise a combination of rigid insulating board or lightweight flexible insulating material, but is not limited thereto. Dry ice module 1 also has a lid or flap 6 that can be opened for introduction of a new supply of dry ice 7 when the previously used supply of dry ice 7 becomes spent. Dry ice module 1 can be positioned external to or within cooling compartment 10 . Dry ice module 1 is made from any insulating material 2 or combination of materials (such as the materials 2 , 3 , and 4 that are shown in FIG. 4C ) that allow dry ice 7 to sublimate at a sufficiently slow rate for the regulation of the ambient temperature within cooling compartment 10 at a desired temperature or within a specified temperature range. The venting of sublimated gas should be conducted in such a manner as to allow it to enter the cooling compartment 10 at or near the top thereof. Because CO 2 from sublimated dry ice is heavier than air, it will fall to the bottom of the cooling compartment 10 . By using different wrapping and insulating materials 2 , 3 , 4 , or other (not shown), both alone or in combination, it is possible to slow the sublimation of dry ice 7 to the point that surrounding items inside of cooling compartment 10 can exist in a temperature regulated environment that ranges from sub-zero to above freezing and can be easily changed to meet application requirements. This allows for the maximum use of dry ice 7 as a cooling medium without worrying about freezing a container's contents unless one is trying to make or keep things frozen. In addition to controlling the sublimation process, by layering or wrapping the contents of cooling compartment 10 , one can further control the temperature of the contents therein. For example, an “anti-freeze” bag (marked with the number 14 in FIG. 4C ) made out of a breathable material, such as breathable material 4 in FIG. 4C , can ensure that water bottles (not shown) do not freeze if the temperature of cooling compartment 10 is maintained just below freezing.
[0030] The first preferred embodiment shown in FIG. 1 has a dry ice module 1 configured with insulating material or materials 2 to control the sublimation rate of dry ice 7 and to prevent outer surface of dry ice module 1 from injuring human skin that comes into direct contact with it. The dry ice module 1 is attached to the underside surface of a one-piece lid 11 and configured for transferring sublimated gas from dry ice module 1 into the cooling stowage area 15 below it. It is contemplated for the dry ice module 1 to be removable or permanent and a part of newly manufactured cooling compartment 10 or retrofitted to an existing cooling compartment 10 having a rigid outer surface construction or a resilient outer surface construction. In addition, although not shown in FIGS. 1-4 herein, any of the preferred embodiments of the present invention can have more than one area of vent holes 5 in the dry ice module 1 or through one or more walls of cooling compartment 10 for movement of the sublimated dry ice into cooling stowage area 15 . Different adaptation and variations can be used in the present invention for reducing the temperature in the cooler compartment 10 , including variation in the dry ice module's 1 insulating materials 2 , insulating/breathable materials 3 , breathable materials 4 , and other breathable materials (not shown) which directly encapsulate the dry ice 7 . Optionally, although not limited thereto, in addition to dry ice module 1 , one can use a multi-layer soft-sided bag made from breathable material that contains dry ice 7 and is placed directly within cooler stowage area 15 . In the alternative, such a multi-layer bag may be used alone in a cooler stowage area 15 , without any dry ice module 1 or other cooling means, due to the ever-evolving technological advances of the breathable materials, such as breathable material 4 . When a multi-layer bag is used, depending upon the accuracy needed for the temperature control in cooler stowage area 15 and what other cooling means is used therein, if any, the multi-layer bag used may include one or more layers of an outer insulating material, like the insulating materials 2 and 3 used to construct the dry ice module 1 shown in FIG. 4C . Therefore, for the cooling of sodas, water, and bottled fruit juices that are pasteurized and not readily prone to spoilage during an evening meal, a multi-layer bag may provide sufficient cooling without any need for maintenance or refurbishment. For daytime cooling purposes relating to pre-packaged beverages and food that does not readily spoil, a dry ice module 1 with outer insulating material 2 and single or multiple layers of breathable material 4 and/or breathable/insulating material 3 can be used. However, for medical applications relating to the transport of medications, test samples, blood supplies, and/or donor organs, a properly insulated dry ice module 1 configured with the appropriate outer insulating material 2 and single or multiple breathable/insulating material 3 and other breathable materials 4 would be required to maintain a narrow range of temperature within a cooler stowage area 15 for maximizing the usable life of stored contents. The transport of poultry and other perishable meats would also benefit from the aforementioned dry ice module 1 configuration of the present invention. As mentioned before, in any preferred embodiment of the present invention, dry ice 7 can be in any form and include, one or more large blocks, small chips, irregularly shaped broken pieces, small cubes, pellets, or any form that will easily fit within the targeted dry ice module 1 . “Anti-freeze” bags 14 can also be used within cooler stowage area 15 to assist in controlling the temperature of contents with a propensity toward freezing at temperatures below 32° degrees. Further, the preferred embodiments of the present invention can include dry ice module 1 that are permanently installed in new cooling compartments 10 or retrofitted for existing portable or non portable cooling compartments 10 wherein the dry ice module 1 is either permanently or temporarily added thereto. When multiple cooling compartments 10 are regulated by the present invention, a user can employ one such cooling compartment 10 for drinks and separate cooling compartments 10 for other contents such as but not limited to sandwiches or frozen treats. When the insulating and breathable materials 2 , 3 , 4 , and/or other similar materials (not shown) that make-up dry ice module 1 are assembled in a manner to achieve a desirable temperature within cooling compartment 10 , the build up of pressure from the CO 2 gas accumulated within cooling compartment 10 is typically inconsequential, even when lid 11 is not opened for an extended period of time. The rectangular configuration of cooling compartments 10 and dry ice modules 1 shown in FIGS. 14 are not critical, and it is contemplated for other configurations to be used, such as but not limited to cylindrical, spherical, and the like. Further, the outer surface construction of cooling compartments 10 may be rigid or resilient. Also, the location of dry ice modules 1 relative to cooling compartment one-piece lids 11 and two-piece lids 12 / 13 is not limited to the central positioning shown in FIGS. 1-3 . Further, since no liquid is involved, no drain hole is shown or needed in any of the cooling compartments used in or with the present invention dry ice module 1 . Also, while the cooling stowage areas 15 shown in FIG. 2 are substantially uniform in size, such an arrangement is not limiting and cooling stowage areas 15 of differing size and configuration are also contemplated as being within the scope of the present invention. In addition, the two-part construction of cooling compartment lid (designated by the numbers 12 and 13 in FIG. 3 , with 12 representing the lid top and 13 representing the lid bottom) has an advantage of being able to renew the supply of dry ice 7 without disturbing cooling stowage area 15 , thus avoiding unnecessary temperature fluctuation within cooling stowage areas 15 . Also, although it is contemplated for dry ice module 1 to be secured in an elevated position to the underside surface of the cooler lid 11 , the positioning and orientation of dry ice module is not limited to that shown in FIG. 1 . Further, although not shown, the number and configuration of ventilation holes 5 and male couplings 8 may be different from that shown in FIGS. 4A and 4B , and in the alternative dry ice module lid 6 may be detachable, hinged, snap-fit, threaded, or have other attachment means to dry ice module 1 . One factor in the selection of the size, number, and configuration of venting holes 5 and location of dry ice module 1 is the size of the dry ice module 1 in relation to the size of the cooling compartment 10 . In summary, dry ice modules 1 may, be a permanent part of cooling compartment 10 , be a non-permanent part of cooling compartment 10 , removable from cooling compartment 10 , be temporarily attached to the underside of a cooling compartment lid 11 , be permanently attached to the underside of a cooling compartment lid 11 , be a part of cooling compartment 10 , be adapted for achieving temperatures below freezing in cooling compartment 10 , be made from rigid insulating materials 2 , be made from non-rigid/flexible insulating materials 2 , be made from a combination of rigid and non-rigid insulating materials 2 , be made at least in part from breathable single or multiple layered materials 3 or 4 , be mounted inside cooling compartment 10 , be integral with cooling compartment 10 , be retrofitted to existing cooling compartments 10 , and be adapted for achieving and maintaining a predetermined temperature within cooling compartment 10 for extended periods of time. The present invention configuration and non-liquid function makes it suited for use in motorized vehicles, including but not limited to automobiles, sport-utility vehicles, vans, boats, and airplanes, where it may be permanently or temporarily secured in a designated recess in the trunk, a rear storage area, or any other suitable space.
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A cooler/container with a dry ice sublimation regulating system having an insulated dry ice module that encloses dry ice so that the module's outside surface is not hazardous to touch. Insulation, breathable material, or a combination of insulating and breathable materials, allows dry ice sublimation at a sufficiently slow rate within the attached dry ice module to control the ambient temperature in the cooler/container. Dry ice module attachment is done in a location that maximizes dry ice cooling properties, typically at or near the top of the cooler/container or its lid. Since sublimated dry ice is carbon dioxide and heavier than normal air, it falls to the bottom of the cooler and builds up. The venting placement in the dry ice module is based upon the make up of the dry ice module and the breathable materials inside of it.
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CROSS-REFERENCE TO RELATED APPLICATION
This application is a divisional of application Ser. No. 13/161,694 filed Jun. 16, 2011, which claims the benefit of U.S. Ser. No. 61/355,353, filed Jun. 16, 2010.
FIELD OF THE INVENTION
The subject matter disclosed herein relates generally to monitoring stray electrical energy, such as stray voltage and leakage currents, and in particular, to a method of monitoring and recording stray electrical energy over a large region to identify and mitigate the stray electrical energy.
BACKGROUND AND SUMMARY OF THE INVENTION
Stray electrical energy is often identified as “stray voltage.” Stray voltages describe voltages that exist between two objects that should not have a voltage difference between them. Stray voltages may be produced, for example, by improper grounding of electrical equipment, unbalanced multi-phase electrical equipment such as motors, generators, and transformers, or defective equipment. Electrical devices typically include a ground wire which is often connected to a metal rod, water pipe, or other conductive member extending into the ground. Ideally, the ground conductor remains at a zero voltage potential. However, if any of the above-mentioned conditions exist, there is the possibility of a voltage potential existing on the ground conductor and being passed into the ground.
Stray electrical energy may also be identified as “leakage current.” Leakage currents exist, for example, when current unexpectedly flows along an unintended conductive path. Deterioration or failure of an electrical device may create the unintended conduction. Alternately, electromagnetic coupling of radiated energy may establish current flow in electrical conductors. Unintended conduction also occurs, for example, due to non-ideal behavior of electrical components such as diodes, transistors, and capacitors.
The modern farm presents one environment in which stray electrical energy is of interest. Farms typically require a significant amount of electrical equipment, such as ventilation fans, water pumps, and specialized equipment, for example, milking machines on dairy farms. The electrical equipment may be spread out across several buildings and is often present in a dirty and wet environment. The harsh environment has the potential for excessive wear, corrosion, and/or failure of the electrical equipment. Prior to failure of electrical equipment, the equipment may operate in a state which introduces stray voltage and/or leakage currents onto ground conductors.
Although the stray electrical energy is typically imperceptible to humans or animals, it is possible that stray electrical energy of sufficient amplitude may exist to be felt by or cause irritation to humans or to the animals. Stray electrical energy may travel between buildings and aggregate from multiple buildings to create a potentially unsafe or unpleasant environment. For example, animal water tanks are often metallic. Further, the water tanks may be fed by water pumped from a central source or from a well and carried through metal pipes. Stray electrical energy may be conducted through the water, pumps, pipes, water tanks, or a combination thereof into the animals. The effects of the stray electrical energy on animals have been reported to range from a minor irritation to causing sickness or death of an animal. Accurate measuring and recording of stray electrical energy can help in mitigating this energy.
Typically, stray electrical energy is monitored by measuring stray voltage. Stray voltages on farms have typically been measured at specific points using a voltmeter with a 500 ohm resistor in parallel to the leads from the voltmeter. A first lead is then connected to, or inserted into, the ground and a second lead is connected to the point at which the stray voltage is to be measured, such as a water tank, metal pipe, or metal structural element. The 500 ohm resistance is selected as it is believed to simulate the resistance through a cow's body.
However, measuring stray voltage in this manner is not without its drawbacks. Readings of stray voltage are typically taken at a single point. The reading may be affected by many variables, including loading of the electrical system or humidity. Further, the single reading captures the stray voltage at only a single instant and fails to capture trends or peak values of the stray voltage. Additionally, measurements of leakage current may provide more relevant information about the level of stray electrical energy present than measurements of stray voltage. A high level of voltage with a low current, may present little danger, while a relatively low level of voltage with a high current may present a significant danger.
Therefore, it is a primary object and feature of the present invention to provide an improved method of measuring and recording stray electrical energy, especially over a significant geographical region, to identify areas of interest having higher levels of stray voltage and/or leakage current and to minimize the level of stray electrical energy in the identified areas.
In accordance with the present invention, a system for reducing stray electrical energy over a geographical region includes a plurality of sensing devices positioned within the geographical region, a data acquisition device, and at least one stray electrical energy mitigation device. Each sensing device includes a sensor generating a signal corresponding to the amplitude of stray electrical energy present at a location of the sensing device, and a communication port transmitting the signal. The data acquisition device includes at least one input configured to receive the signals from the sensing devices, and at least one memory device configured to store the signals from the sensing devices. A processor is configured to execute a stored program to compile the signals over the geographical region for a preselected time period, which may be 6 months or longer, and to identify at least one pattern of emission of the stray electrical energy over the period of time. At least one stray electrical energy mitigation device is positioned within the geographical region as a function of the pattern of emission of the stray electrical energy. The at least one stray electrical energy mitigation device may be selected from a dual holding tank system connected in series with a supply line, a multi-layer, electrically isolated supply line, a pump connected in series with the supply line to modify water flow between a water supply and a water tank, and an electrical insulator positioned between the water tank and a surface on which the tank is placed.
In accordance with another aspect of the present invention, at least one of the signals corresponding to the amplitude of stray electrical energy measures the amplitude of a leakage current at a resolution finer than 30 milliamps. Optionally, the resolution is selected between 50 microamps and 1 milliamp.
In accordance with yet another aspect of the present invention, multiple sensing devices positioned within the geographical region generate signals corresponding to an environmental condition within the geographical region, and the data acquisition device stores each of the plurality of signals corresponding to the environmental condition in the memory device over the period of time. The processor is further configured to execute the stored program to correlate the pattern of the emission of stray electrical energy to the signals corresponding to the environmental condition.
In accordance with another embodiment of the present invention, an animal watering system with improved electrical isolation includes a water supply, a supply line in fluid communication with the water supply, a water tank configured to deliver water to at least one animal and in fluid communication with the supply line, and at least one electrical isolation means operatively located proximate to one of the water supply, the supply line, and the water tank to mitigate stray electrical energy. The electrical isolation means may further include a fill valve having an input in fluid communication with the supply line and an output in fluid communication with a first holding tank. The first holding tank is operatively connected to the output of the fill valve, and the fill valve selectively establishes fluid communication between the supply line and the first holding tank. A coupling valve has an input operatively connected to the first holding tank and an output operatively connected to a second holding tank. The coupling valve selectively establishes fluid communication between the first holding tank and the second holding tank. An exit valve has an input operatively connected to the second holding tank and an output in fluid communication with the water tank. The exit valve selectively establishes fluid communication between the second holding tank and the water tank. The animal watering system may further include a first gasket positioned between the coupling valve and either the first holding tank and the second holding tank. The animal watering system may similarly include a second gasket positioned between the coupling valve and the other holding tank. Each of the gaskets is made of a non-conductive material.
In accordance with another aspect of the invention, the animal watering system also includes a data acquisition device and multiple sensing devices positioned within the geographical region. The data acquisition device includes at least one memory device configured to receive a plurality of signals corresponding to an amplitude of stray electrical energy and a processor configured to execute a stored program. Each sensing device includes a sensor generating one of the signals corresponding to the amplitude of stray electrical energy present at a location of the sensing device and a communication port transmitting the signal to the data acquisition device. The processor executes to compile the signals over the geographical region for a preselected time period, and the electrical isolation means is selected as a function of the compiled signals
In accordance with still another aspect of the invention, the electrical isolation means may be a supply line with multilayer construction. The multilayer construction includes an internal pipe having an inner periphery and an outer periphery, an electrically conductive layer adjacent to the outer periphery of the internal pipe, and an external layer substantially covering the electrically conductive layer. The electrical isolation means may also include a pump connected in series with the supply line to periodically interrupt the water flow and inject an air pocket in the supply line. Optionally, the electrical isolation means may further include a nozzle operatively connected between an output of the supply line and the water tank.
In accordance with yet another embodiment of the present invention, a method of monitoring stray electrical energy over a plurality of locations obtains signals corresponding to an amplitude of stray electrical energy at a plurality of locations with a sensing device. The signals are transmitted from each of the plurality of locations to a data acquisition device, and analyzed to identify at least one pattern of stray electrical energy. The stray electrical energy is mitigated as a function of the pattern of stray electrical energy.
These and other objects, advantages, and features of the invention will become apparent to those skilled in the art from the detailed description and the accompanying drawings. It should be understood, however, that the detailed description and accompanying drawings, while indicating preferred embodiments of the present invention, are given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the present invention without departing from the spirit thereof, and the invention includes all such modifications.
BRIEF DESCRIPTION OF THE DRAWINGS
The drawings furnished herewith illustrate a preferred construction of the present invention in which the above advantages and features are clearly disclosed as well as others which will be readily understood from the following description of the illustrated embodiment.
In the drawings:
FIG. 1 is an exemplary environmental view illustrating electrical conduction paths of leakage current from a water pipe through a water tank and to an animal;
FIG. 2 is an exemplary environmental view illustrating isolation of a water tank from ground;
FIG. 3 is a cross-sectional view of a water pipe which may be electrically isolated for use in an exemplary animal watering system according to the present invention;
FIG. 4 is a block diagram representation of an exemplary animal watering system according to the present invention;
FIG. 5 is a block diagram representation of an exemplary system to measure and identify stray voltages according to the present invention;
FIG. 6 is a block diagram representation of a sensing device according to FIG. 5 ; and
FIG. 7 is a block diagram representation of a data acquisition device according to FIG. 5 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The various features and advantageous details of the subject matter disclosed herein are explained more fully with reference to the non-limiting embodiments described in detail in the following description.
Referring to FIG. 1 , an exemplary environmental view illustrates electrical conduction paths 100 a - 100 c of leakage current from a water pipe 105 through a water tank 110 and to an animal 115 . Typically, the water pipe 105 and water tank 110 are made of metal and are, therefore, electrically conductive. Water 120 is also electrically conductive. Consequently, if water 120 is flowing from the water pipe 105 into the water tank 110 a conduction path 100 a is established from the water pipe 105 into the water tank 110 . If an animal 115 drinks from the water tank 110 as water 120 is flowing from, the water pipe 105 , another conduction path 100 c is established from the water tank 110 through the animal 115 to ground 125 . Additionally, the water tank 110 is commonly resting directly on the ground 125 . Therefore, still another conduction path 100 b may exist from the water 120 through the tank 110 and into the ground 125 . When an animal 115 drinks from the water tank 110 a complete circuit is formed by the conduction path 100 c returning current to the ground 125 . Thus, an animal 115 drinking from a water tank 110 in an environment which includes stray voltages and/or leakage currents, may be susceptible to creating a conduction path through the animal's 115 body when drinking from the water tank 110 .
Referring to FIG. 2 , an improved watering system may employ one or more options for isolating the water tank 110 from the ground 125 to prevent the electrical conduction paths 100 of FIG. 1 . As a first option, a pump 103 may be operatively connected to the water pipe 105 to periodically inject an air pocket into the water 120 flowing through the water pipe 105 . This air pocket creates a discontinuity in the water flow, electrically separating segments of the water flow from each other to prevent the water 120 from conducting stray electrical energy to the water tank 110 . As another option, a nozzle 107 may be operatively connected to the output of the water pipe 105 to increase the electrical impedance of the water flow, thereby reducing the magnitude of leakage current in the conduction path 100 a . As still another option, an insulator 123 may be positioned between the water tank 110 and the ground 125 preventing a conduction path 100 b from being established between the water tank 110 and the ground 125 . It is contemplated that one or more of these options may be implemented to reduce conduction of stray electrical energy according to the application requirements.
Referring next to FIG. 4 , capacitive coupling is one method by which the stray electrical energy enters the animal watering system 130 . Capacitive coupling may be reduced by electrically isolating one or more of the water pipes, 105 or 135 . Referring also to FIG. 3 , the water pipe may be constructed with multiple layers. The internal pipe 170 may be of traditional construction including, but not limited to, copper or polyvinyl chloride (PVC). The internal pipe 170 has an inner periphery 172 through which the water flows and an outer periphery 174 . An intermediate layer 175 is, for example, wound around or slid on the outer periphery 174 of the internal pipe 170 . The intermediate layer 175 is preferably electrically conductive and may be copper pipe or mesh. An electrical connection to the intermediate layer 175 may be made based on the nature of stray electrical energy present in the system and on site requirements. The electrical connection is preferably made to provide the smallest leakage current. The connection to the intermediate layer 175 may be, but is not limited to, connection to an appropriate neutral, ground, or other point in the animal watering system 130 , either directly or via an appropriate resistive, inductive, or capacitive element. An external layer 180 protects the intermediate layer 175 and may be any suitable material, including another pipe or an insulating layer.
Referring again to FIG. 4 , one embodiment of an improved animal watering system 130 is illustrated. The animal watering system 130 has a dual-tank construction to prevent electrical conduction from a water supply 133 , such as a well or a municipal water supply, to the water tank 110 . A pump 137 draws water from the water supply 133 and creates a flow path via a supply line 135 to a first holding tank 145 . A fill valve 140 is connected between the supply line 135 and the first holding tank 145 . The fill valve 140 preferably has a first position, closing the flow path between the water supply 133 and the first holding tank 145 , and a second position, establishing the flow path between the water supply 133 and the first holding tank 145 . Alternately, the fill valve 140 may be a variable position valve to continuously vary the flow rate of water between the water supply 133 and the first holding tank 145 from the off position to a fully on position.
A coupling valve 150 connects the first holding tank 145 to the second holding tank 155 . The coupling valve 150 preferably has a first position, closing the flow path between the first holding tank 145 and the second holding tank 155 , and a second position, establishing the flow path between the first holding tank 145 and the second holding tank 155 . Alternately, the coupling valve 150 may be a variable position valve to continuously vary the flow rate of water between the first holding tank 145 and the second holding tank 155 from the of position to a fully on position. Preferably, a gasket or sealing member 147 is positioned between the coupling valve 150 and either one or both of the first and second holding tanks, 145 and 155 respectively. The gasket 147 may aid in sealing the connection between the coupling valve 150 and each holding tank, 145 and 155 . In addition, the gasket 147 is preferably made of a non-conductive material such as rubber or nylon to prevent electrical conduction between the first holding tank 145 and the second holding tank 155 . Alternately, a gasket 147 may be integrally formed in the coupling valve 150 or the coupling valve 150 may be constructed of a non-conductive material.
The first holding tank 145 and the second holding tank 155 are preferably positioned as near each other as possible while minimizing the capacitive coupling between the two tanks, which is capable of conducting leakage currents. Consequently, the coupling valve 150 preferably directly connects the first holding tank 145 and the second holding tank 155 . Optionally, one or more segments of pipe (not shown) may be included between the first holding tank 145 and the coupling valve 150 or between the second holding tank 155 and the coupling valve 150 to facilitate coupling the first and second holding tanks, 145 and 155 , respectively.
An exit valve 160 connects the second holding tank 155 to the water pipe 105 . The exit valve 160 preferably has a first position, closing the flow path between the second holding tank 155 and the water pipe 105 , and a second position, establishing the flow path between the second holding tank 155 and the water pipe 105 . Alternately, the exit valve 160 may be a variable position valve to continuously vary the flow rate of water between the second holding tank 155 and the water pipe 105 from the off position to a fully on position. The water pipe 105 delivers the water 120 to the water tank 110 .
In operation, the improved animal watering system 130 , as illustrated in FIG. 4 , is operated to maintain separation between the water supply 133 and the water in the water tank 110 . The fill valve 140 , coupling valve 150 , and the exit valve 160 are preferably controlled such that at least one of the valves is always in the closed position. Water may enter the first holding tank 145 by opening the fill valve 140 . Water is then transferred from the first holding tank 145 to the second holding tank 155 by opening the coupling valve 150 . Prior to opening the exit valve 160 , either the fill valve 140 or the coupling valve 150 is closed. For example, the fill valve 140 may close, permitting water to flow from the first holding tank 145 to the second holding tank 155 as well as from the second holding tank 155 to the water tank 110 . Alternately, the coupling valve 150 may be closed, permitting the first holding tank 145 to be filled from the water supply while the water tank 110 is filled from the second holding tank 155 . Keeping one of the valves in a closed position prevents an electrical conduction path from being established through the water flowing from the water supply 133 to the water 120 in the water tank 110 .
In order to identify the stray voltage and/or leakage currents, an improved data acquisition system 5 is disclosed. Referring to FIGS. 5-7 , the data acquisition system 5 includes at least one monitoring location 10 which preferably includes a data acquisition device 12 connecting to at least one sensing device 14 . The data acquisition device 12 may be, but is not limited to, a computer having a data acquisition board 70 mounted to one of the slots of the motherboard. The data acquisition board 70 may be configured to receive signals directly via wired or wireless communications. For example, one or more data ports may be mounted on the data acquisition board 70 and connected to each sensing device 14 , for example, by an appropriate electrical conductor 16 or using wireless communications. Optionally, the data acquisition board 70 may be configured to receive these signals via any other network interface card (NIC) 68 incorporated within the data acquisition device 12 . According to one embodiment of the invention, the data acquisition device 12 includes a user interface 66 , such as a mouse, keyboard, or touch screen, for receiving input from an operator and a display 64 for displaying data to the operator. According to another embodiment of the invention, the data acquisition device 12 may include a wireless interface for communication to a remote device, not shown. An operator may then interface with the remote device to either provide input to or view data from the data acquisition device 12 . The remote device may include, but is not limited to, a dedicated receiver, a portable electronic device, such as a personal digital assistant, a smart phone, or a tablet computer, or another electronic, device, such as a desktop computer or central server housed within a local or a remote building. The data acquisition device 12 also includes a memory device 62 and a processor 60 in communication with the memory device 62 . The processor 60 is configured to execute a program stored in the memory device 62 and stores the signals received from the sensing devices in the memory device 62 . It is contemplated that one or more of the processor 60 , memory device 62 , data acquisition board 70 , and network interface card 68 may be incorporated onto a single application specific integrated circuit (ASIC) or field programmable gate array (FPGA). Similarly, portions of each of the processor 60 , memory device 62 , data acquisition board 70 , and network interface card 68 may be separated and executed independently or in a coordinated manner on multiple devices as would be known in the art.
Each sensing device 14 may be, but is not limited to, a probe 48 , which includes a pair of leads, 50 and 52 , connected in parallel to measure voltage or in series to measure current. For example, a first lead 50 may be connected to or embedded into the ground at a first point and a second lead 52 connected to a conductive surface at a second point remote from the first point. The pair of leads, 50 and 52 , measures the amplitude of the desired voltage or current and transmits the signal via an analog to digital convener 46 to a processor 42 within the sensing device 14 . The processor 42 on the sensing device 14 may temporarily store the signal in the memory device 44 or directly transfer the signal to a communication port 54 for transmission to the data acquisition device 12 . The communication port 54 may be connected by a suitable electrical conductor 16 or by an antenna 56 to wirelessly transmit the signals to the data acquisition device 12 . It is contemplated that one or more of the processor 42 , memory device 44 , analog to digital converter 46 , and communication port 54 may be incorporated onto a single application specific integrated circuit (ASIC) or field programmable gate array (FPGA). Similarly, portions of each of the processor 42 , memory device 44 , analog to digital converter 46 , and communication port 54 may be separated and executed independently or in a coordinated manner on multiple devices as would be known in the art.
Similarly, a first lead 50 may be connected at a first point within a conduction path and a second lead 52 connected at a second point within a conduction path such that the pair of leads, 50 and 52 , is connected in series with the conduction path. The conduction path may be configured to include a conducting material and the current flowing through the conducting material is thereby measured. Alternately, the conduction path may be a coil positioned about a conducting material and the field induced in the coil by the current flowing through the conducting material is measured. For example, a Rogowski coil may be positioned about a water pipe to measure currents flowing through the water pipe. A Rogowski coil is an electrical device for measuring alternating current, including a helical coil with the lead from one end returning through the center of the coil such that both leads are at one end of the coil. Optionally, a current sensor using flux gate technology may be employed. It is contemplated that other suitable sensing devices 14 as would be known in the art may be used to measure stray voltages and/or leakage currents at varying points within the monitoring location 10 .
The sensing devices 14 are configured to precisely measure signals having small amplitudes as is consistent with stray voltages and leakage currents. Although typical ground fault detectors have a threshold of 30 milliamps, leakage currents as small as 1 milliamp may cause irritation to an animal 115 . Thus, a current sensing device preferably measures leakage currents with a resolution of 50 microamperes or better. Because stray electrical energy may be introduced into the sensor via an electrical power connection to the utility grid, the sensing device 14 may be remotely powered, for example, by a battery or a photovoltaic cell connected to the sensing device 14 . Similarly, an electrical conductor 16 providing the measured signal to the data acquisition device 12 may receive and conduct stray electrical energy. Thus, transmission of the signal via wireless communication may further improve precision of the sensing device 14 .
The data acquisition device 12 is configured to collect the incoming signals from the sensing devices 14 . The data acquisition device 12 may be configured to measure voltage, current, or selectively measure either voltage or current. The data acquisition device 12 measures a range of frequencies for the incoming signals. The incoming signals may include components at one or more frequencies, such as a direct current (DC) component at zero Hertz (0 Hz), a utility voltage or current component at sixty Hertz (60 Hz), a higher frequency component such as a one kilohertz (1 kHz) signal, or components at other frequencies within the sweep range of the data acquisition device 12 . The data acquisition device 12 may be configured to process, either digitally or by analog components, the incoming signals to obtain data across a desired frequency band. Each signal may be acquired at a predetermined periodic interval or, optionally, the data acquisition device 12 may be configured to read each signal if the signal reaches or exceeds a predetermined threshold. It is further contemplated that additional signals may be measured by suitable sensing devices 14 , including, but not limited to, electric field strength, temperature, wind speed, humidity, rain fall amounts, or other environmental variables that may affect the levels of stray voltage and leakage currents.
The sensing devices 14 may be positioned to measure signals at loads distributed about the monitoring location 10 , at the connection to the utility grid, or a combination thereof. If the monitoring location 10 is, for example, a farm, the loads distributed about the monitoring location may include, but are not limited to, fans, pumps, or specialized farm processing equipment requiring either single or multi-phase power. Signals measured at the connection to the utility grid may include, but are not limited to, the voltages and/or currents in one or more of the phases of electrical power entering the farm.
The data acquisition device 12 stores the digital signals on the memory device 62 . The digital signals are preferably stored on the memory device 62 in data files suitable for importation into a spreadsheet or other graphing applications. The memory device 62 is sized to store signals over a long period of time, for example months or years. Optionally, the data acquisition device 12 may be configured to periodically transmit stored data to a central processing device 30 or to copy the stored data to a removable storage medium 72 such as a CD-ROM, DVD-ROM, USB storage device, or other such storage device. Once stored data has been. transmitted or copied, the memory device 62 may be cleared to accept new data.
The data acquisition system 5 is also configured to process the incoming signals from the sensing devices 14 . Processing of the incoming signals may occur either at the data acquisition device 12 , at a central processing device 30 , or at a combination thereof. The central processing device 30 is preferably connected to the data acquisition device 12 at each monitoring location 10 by a network 20 , such as the Internet, and network connections 25 , which may utilize, any suitable wired or wireless network infrastructure. Data from multiple monitoring locations 10 may be compiled at a central processing device 30 for analysis.
In operation, the data acquisition system 5 is configured to record and evaluate stray voltages and/or leakage currents over an extended period of time and over a broad geographical region. A significant number of factors, many varying over time, may influence stray voltage and leakage currents. Thus, it is desirable to record and analyze stray voltages and leakage currents over time rather than recording individual readings at a single instant in time.
The measurements made at the connection to the utility grid may be used to identify faults in the transmission lines, such as ground faults, or if the electrical phases of the incoming power are unbalanced. It is possible for an imbalance or a ground fault in the utility grid supplying power to the monitoring location 10 to produce additional stray voltages or leakage currents. In addition, the measurements at the connection to the utility grid may further be used to monitor energy consumption.
The data acquisition system 5 is configured to analyze the recorded data. The data acquisition device 12 preferably operates continuously, measuring signals at predefined intervals or if a signal exceeds a predefined threshold. Sensing devices 14 preferably measure electrical signals at varying points as well as environmental variables within the monitoring location 10 . The data acquisition system preferably also has knowledge of the electrical equipment or electrical loads that are active within the monitoring location 10 . Thus, levels of the stray voltages or leakage currents may be analyzed to identify trends related to operation of specific equipment. Further, interactions between different equipment or varying power requirements may also be identified.
The central processing device 30 is further configured to analyze data from individual monitoring locations 10 or a combination of monitoring locations 10 . The central processing device 30 may request data to be transmitted over the network 20 from a specific monitoring location 10 or each monitoring location 10 may be configured to periodically transmit data to the central processing device 30 . By analyzing multiple monitoring locations 10 , the central processing device 30 identifies trends in stray voltage or leakage current over a broad geographical region. Further, interactions between the levels of stray voltage or leakage current and the power requirements of different monitoring locations may be identified. It is also contemplated that the central processing device 30 may access topographical data, for example from a local file or database or from an online service, such as GOOGLE® map, to identify topographical features, including, but not limited to, roads, rivers, hills, trees, fields, and structures. Using the topographical features, the central processing device 30 may identify patterns in stray voltage or leakage current that correspond to different topographical features.
The central processing device 30 may be also be configured to trend stray voltage or leakage current over extended periods of time. Because the data acquisition device 12 preferably operates continuously, data may be analyzed, for example, daily, weekly, over a given season, annually, or over any other desired time interval to identify patterns in stray voltage or leakage current during the specified period of time. As still another aspect of the invention, the central processing device 30 may filter the data signals to identify, for example, DC signals, AC signals, or harmonic components of AC signals.
Having analyzed the stray voltages or leakage currents from the monitoring locations 10 , it is desirable to minimize these stray voltages and leakage currents. An improved animal watering system 130 , as described above, may be used to reduce stray voltages present in an animal watering tank. Optionally, a conductive material may be positioned for example in a ring around equipment that creates an increased level of stray voltage or leakage current or around equipment that may be sensitive to increased levels of stray voltage or leakage current. Similarly, analysis of the recorded data may identify conduction paths or interactions between equipment that may be disrupted by appropriate grounding and/or guarding. The conductive material may be positioned for example in a ring along the earth's surface to surround a specific transmission line, building, or other conductive path.
It should be understood that the invention is not limited in its application to the details of construction and arrangements of the components set forth herein. The invention is capable of other embodiments and of being practiced or carried out in various ways. Variations and modifications of the foregoing are within the scope of the present invention. It also being understood that the invention disclosed and defined herein extends to all alternative combinations of two or more of the individual features mentioned or evident from the text and/or drawings. All of these different combinations constitute various alternative aspects of the present invention. The embodiments described herein explain the best modes known for practicing the invention and will enable others skilled in the art to utilize the invention.
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A system and method for monitoring and mitigating leakage currents is disclosed. The data acquisition system records data from multiple monitoring locations over extended periods of time to identify stray voltage and/or leakage currents present at the monitoring location. The data is processed to identify trends in the stray voltage and/or leakage currents and to suggest methods for mitigating the same.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to downhole cutting tools and clean-out methods and more particularly, but not by way of limitation, it relates to a downhole rotary cutting tool that has both a grinding and a liquid jetting capability.
2. Description of the Prior Art
The prior art has seen a number of different downhole tools of the rotary type that may be used for cutting casing, underreaming, notching formations and other downhole operations. However, Applicant is not aware of any type of rotary tool that has the capability for both an abrading rotary action and a lateral high pressure jet action such as that provided by the present invention. Such a tool is particularly useful in downhole operations where it is desired to remove a section of casing, e.g., a twenty or so foot casing section, while simultaneously removing surrounding cement or earthen formation by means of liquid jet pressure. Such a subterranean configuration is useful in adapting an existing cased borehole for accommodation of a horizontal drill string extension and continued horizontal drilling. The invention is an improvement on the downhole tool teachings of U.S. Pat. Nos. 5,201,817 and 5,242,017.
SUMMARY OF THE INVENTION
The present invention relates to improvements in downhole cutting tools which utilize an expansible cutter blade that has both (1) a hardened, abrading or cutting surface and (2) opposed liquid jets for releasing high pressure fluid from the internally channeled fluid conduits. The cutter blade actuation is effected by upward and/or downward piston force within the cutting tool, and the cutting blades have both cutting and abrading surfaces and water jet release points. Thus, the actual cutting tool is highly similar to the tool disclosed and claimed in U.S. Pat. No. 5,201,817; however, the cutting/jetting combination blades constitute another point of novelty. In addition, the internally applied actuation fluid, downcoming through the axial bore of the rotary tool and support string, is provided with yet another axial bore through the upper piston whereby the high pressure fluid is introduced into the interior channels of each of the cutting blades for subsequent release as lateral jets of cutting fluid. The cutting blades also are dressed with suitable hardened surfaces positioned for a rotary abrading or cutting motion such that the tool with combination rotary cutter is capable of cutting and milling an extended section of casing while simultaneously jet cutting the surrounding formations.
Therefore, it is an object of the present invention to provide a downhole cutting tool having a dual cutting mode.
It is also an object of the invention to provide a cutting tool that is capable of milling casing while directing jet cutters toward the surrounding matter.
It is yet further an object of the present invention to provide a rotary cutting tool that is compatible for use with various horizontal drilling configurations.
Finally, it is an object of the present invention to provide a milling and clean-out tool that is capable of more rapid operation during certain horizontal drilling practices.
Other objects and advantages of the invention will be evident from the following detailed description when read in conjunction with the accompanying drawings which illustrate the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is view in vertical section of a cutter tool with the cutter blades in the withdrawn position;
FIG. 2 is a view in vertical section of the tool of FIG. 1 with the cutter blades extended to operative position;
FIG. 3 is a top plan view of the cutter blades of FIG. 2 when in the expanded position;
FIG. 4 is a view in vertical elevation of the cutter blades of FIG. 2;
FIG. 5 is a section taken along lines 5--5 of FIG. 4;
FIG. 6 is a section taken along lines 6--6 of FIG. 4; and
FIG. 7 is a view in vertical cross section of the lower portion of a single cutter blade.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1, the cutting tool 10 consists of an elongated, cylindrical body member 12 which houses the cutter blades 14 and 16 and all actuating components along an axial bore formed therein. Cutting blades 14 and 16 are pivotally retained by means of a pivot pin 18 that is threadedly engaged across body member 12. A bottom cap 20 or other sub unit may be threadedly affixed to the lower end of body member 12 as pressurized drilling fluid is able to circulate down through the entire mechanism.
A plurality of equi-spaced stabilizer elements (not shown) may be secured around the outer circumference of cutter tool 10 to maintain centering of the tool 10 within the surround of casing or the like. The cutter tool 10 is joined at the upper end by a threaded subassembly in the form of a rotational motor sub 24, a selected motor suitable for small diameter drilling systems. Such motors are available from SlimDril, Inc. of Houston, Texas. The small diameter SLIMDRIL® motors are capable of generating bit speeds from 740-1230 RPM for 1 11/16 outside diameter and in a range of 400-800 RPM at an outside diameter of 31/2.
As shown also in FIG. 2, the body member 12 is secured on the motor sub 24 by means of threads 26. Threads 26 are standard drill string type continually engaged in response to right turning of the string. The motor sub 24 includes a central bore 28 for delivering drilling fluid 29 under pressure down to the cutting tool 10. The upper end of cutting tool 10 includes an axial bore 30 extending downward into an annular shoulder 32 which then extends into a central cavity 34 that houses the pivotally affixed cutter blades 14 and 16. A transversely extending slot 36 is formed by opposite side, vertically elongated slot ways 38 and 40 as the slot intersects with central cavity 34. The cavity 34 is formed in one dimension to accommodate the double thickness of cutter blades 14 and 16 as retained by a pivot pin 18, and in the other dimension to have sufficient width to enable cutter blades 14 and 16 to be expanded completely outboard through slotways 38 and 40 into operational configuration as shown in FIG. 2.
The lower end of body member 12 is formed with a first axial bore 42 in communication with central cavity 34 and expanding outward into a lower bore 44 that extends downward and is funneled into drilling fluid passage 46. A volume 47 constitutes a lower cylinder that houses a lower piston assembly, as will be further described below.
A first actuating assembly consists of an upper piston 48 having a rod end 50 disposed for reciprocation within the axial cylinder bore 30. The rod end 50 includes a circular foot end 52 which functions to engage and depress the cutter blades 14 and 16 during actuation, as shown in FIG. 2. An upper annular groove 54 is formed around bore 30 in communication with a plurality of ports 56 which lead to by-pass ports 58 that extend downward around the cutter mechanism. The number of by-pass ports 58 utilized may vary with design considerations for cutting tool 10.
As illustrated in FIG. 1, the inoperative or deactivated position, the upper surface of piston 48 rests adjacent the lower wall of annular groove 54 so that there is normally open fluid flow from the bore 28 downward through annular groove 54 and ports 56 to by-pass ports 58 and on to the lower volume 47 and outlet fluid passage 46. A second annular groove 60 is formed around axial bore 30 at a position where it is normally blocked by the sidewalls of piston 48, and further sealing is provided by a seated elastomer O-ring 62. The annular groove 60 also communicates via ports 64 and by-pass ports 66 down to the lower volume 47 and outlet fluid passage 46. Noting also FIG. 2, it is apparent that sufficient fluid pressure 29 in bore 28 forces piston 48 downward and beneath the position of second annular groove 60 thereby allowing additional pressurized fluid flow through the respective ports 64 and by-pass ports 66. Also, the downward movement of piston 48 places rod end 50 and foot pad 52 in activating contact with respective upper angle ends 68 and 70 of cutter blades 14 and 16 thereby to expand the blades outboard through respective slot ways 38 and 40 and into operational position, as shown in FIG. 2.
Simultaneous with downward actuation of upper piston 48, the fluid pressure build-up in lower bore volume 47 via by-pass ports 58 and 66 will cause actuation of a lower piston 72 sliding upward within cylinder bore 44 thereby to extend an elongated rod end 74 having angled pad end 76 upward against the bias of a coil spring 78. Thus, the elongated rod end 74 is moved upward through narrower bore 42 such that pad end 76 engages the lower edges 80 and 82 of respective cutter blades 14 and 16 thereby to force the cutter blades open as well as to continually brace the cutter blades against any opposing force.
The cutter blades 14 and 16 constitute a pair of blades in combination wherein each has an abrading as well as a jet cutting capability. The respective cutter blades 14 and 16 have lower edges 80 and 82 as well as respective upper angle ends 68 and 70. Referring to FIGS. 3-7, each of cutter blades 14 and 16 includes, respectively, the lower acute angle edges 80 and 82 as well as the opposite outer edges 84 and 86 which secure a foot pad 88 and 90 therebetween, respectively. The foot pads 88 and 90 may be preformed from a selected hardened steel alloy and inset with rows of natural diamond 92 and 94 as foot pads 88 and 90 are secured as by welding into abrading position on the bottom of respective blades 14 and 16. Alternatives to the diamond inlay cutting configurations may be used, e.g., tungsten carbide surfaces such as KUTRITE® inserts and/or thermally stable polycrystalline diamond materials as held within suitable matrices.
Each of blades 14 and 16 has an upper corner block 96 and 98, respectively, which are formed for locking abutment against respective upper blade corners 100 and 102 that are formed as extensions of respective outer edges 84 and 86. Pivot holes 104 are formed generally centrally through the upper portion of each of cutter blades 14 and 16 as they are pivotally supported on pivot pin 18 (see FIG. 1). Lower stop blocks 106 and 108, respectively, are also formed on the cutter blades 14 and 16 both to broaden the support surface for receiving respective foot pads 88 and 90 and to provide a stop engagement at the upper portions against respective diagonal edges 110 and 112.
Referring particularly to FIGS. 3 and 4, the cutter blades 14 and 16 are shaped for scissors-like coaction as they pivot about pivot pin 18 (FIG. 1). They are each constituted of a continuous half thickness throughout the area of the respective cutter blades 14 and 16 with only upper corner blocks 96, 98 and lower corner blocks 106, 108 constituting the remaining half thickness. Thus, the continuous half thickness portions of cutter blades 14 and 16 are formed to include respective upper orifices 114 and 116 which lead into respective downward bores 118 and 120 which communicate for fluid input with the axial bore 121 of the piston 48 and rod end 50 (see FIGS. 1 and 2). The lower end of respective bores 118 and 120 then communicate internally with respective conical bores 122 and 124. Thus, high pressure fluid 29 flowing downward communicates through axial bore 121 of piston 48 and rod end 50 when the blades 14 and 16 are in operational position as in FIG. 2. The high pressure fluid 29 is then able to flow via cutter blade upper orifices 114 and 116 (see FIGS. 3 and 4) and respective ports 118 and 120 to provide a lateral jet stream from each of orifices 126 and 128.
FIG. 5 illustrates the manner in which the vertical bores 118 and 120 are formed down through the continuous half thicknesses of the respective cutter blades 14 and 16. FIG. 6 shows a continuation in progression of the downwardly directed bores 118 and 120, and FIG. 7 illustrates in vertical section for the cutter blade 16 (cutter blade 14 being formed identically) the manner in which vertical bore 118 is directed into a laterally directed conical bore 122 which then emits a high pressure jet stream from the orifice 126. It should be noted too, that as a practical matter, an alternative structure for the orifice 126 may be preferred. That is, a generally lateral bore 130 may be formed in communication with the vertical bore 118; thereafter, a nozzle insert 132 formed from a hardened steel alloy may be secured therein to provide the conical bore and orifice that is more free from jet wear and more secure in long term usage.
In operation, the cutting tool 10 with the jet/abrading cutter blades 14 and 16 are particularly useful in applications where it is desired to provide a lateral bend in a drill string for purposes of longitudinal drilling. Thus, the cutter tool 10 may be run down an existing or newly drilled borehole to the desired depth whereupon operation requires that a number of feet, e.g., 20 to 30 feet, of the casing be removed and that lateral space be widened to permit proper longitudinal drill string orientation. Cutting tool 10 can then be made operational with outboard locking of cutter blades 14 and 16 to cut through the existing casing surrounding cutter tool 10. After cutting through the casing, the cutter tool 10 is spread as in FIG. 2 so that downward pressure can be exerted on the cutter foot pads 90 and 92 and the rotation acts to grind down the casing. During the process of grinding down the casing, which may continue until 20 or 30 feet of casing is removed, the drilling fluid 29 is applied through the respective ports 120 and 118 of cutter blades 14 and 16 to emit the fluid jets 134 and 136. The drilling jets 134 and 136 are directed at sharp focus and very high pressure into the surrounding cement and/or earthen formation to remove material and form a concentric cavity around the vacant portion of the casing. The cavity is formed long enough and having sufficient diameter to enable right angle bending of the drilling tool string thereby to commence horizontal drill progression.
The foregoing discloses a novel cutter blade combination for use in rotary cutting tools that are employed in preparing a vertical borehole to enable lateral orientation of a horizontal drilling tool. The cutter blades employ both an abrading cutter surface for separating casing and grinding away casing while also including a high pressure jet fluid drilling element for removing any surrounding cement and/or earthen formation to a predetermined diameter surrounding the casing. The cutter tool and combination cutter blades of the present invention provide a rotary element that enables certain horizontal drilling preparation with much increased speed and greater control by the surface operator.
Changes may be made in the combination and arrangement of elements as heretofore set forth in the specification and shown in the drawings; it being understood that changes may be made in the embodiments disclosed without departing from the spirit and scope of the invention as defined in the following claims.
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A downhole rotary cutting tool having an elongated cylindrical body with radially expanded cutting blades that are controlled by application of selected fluid as controlled from a surface source. The cutting blades have a combined abrading/jetting capability as hardened cutting surfaces are disposed at critical points of each blade and each cutting blade is ported to provide lateral jet emissions for entry into the surrounding earth medium.
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FIELD OF INVENTION
[0001] The instant application relates to a device, and a method for extending a distal end of an anatomic tube.
BACKGROUND OF THE INVENTION
[0002] Congenital abnormalities may cause serious threats to the well-being of individuals with such abnormalities. Congenital abnormalities, i.e. birth defects, include a wide range of malformations that occur during the fetal development. For example, esophageal atersia is a congenital abnormality where the esophagus fails to connect to the stomach. As a result, the esophagus ends in a pouch, and nothing the baby swallows gets into the stomach.
[0003] In the case of a baby with esophageal atersia, a surgery is generally required to connect the esophagus to the stomach. In general, a residual esophagus is expanded via a bladder thereby facilitating the connection between the esophagus and the stomach via surgery. Residual esophagus, as used herein, may be a tubular extension of the stomach; or in the alternative, it may be an incomplete esophagus that fails to connect to the stomach. However, the expansion of the residual esophagus via the current methods causes expansion of the residual esophagus both circumferentially and longitudinally. Although the longitudinal expansion of the residual esophagus facilitates the connection to the stomach and the esophagus; thus a desired outcome, the circumferential expansion of the residual esophagus is an undesired by-product, which must be corrected via surgery.
[0004] Accordingly, there is a need for a device to facilitate the extension of the distal end of an anatomic tube, e.g. a residual esophagus, along its longitudinal axis while minimizing any circumferential expansion.
SUMMARY OF THE INVENTION
[0005] The instant application relates to a device, and a method for extending a distal end of an anatomic tube. This device includes an accordion pleated bladder, which includes a proximal end and a distal end. The method includes the steps of (1) providing a device for extending a distal end of an anatomic tube including an accordion pleated bladder, wherein said bladder has a proximal end and a distal end; (2) placing the device for extending a distal end of an anatomic tube in the anatomic tube; (3) connecting the device to a pressure generator; (4) increasing the internal pressure of the device thereby extending the bladder along its longitudinal axis; and (5) thereby extending the anatomic tube along its longitudinal axis.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] For the purpose of illustrating the invention, there is shown in the drawings a form that is presently preferred; it being understood, however, that this invention is not limited to the precise arrangements and instrumentalities shown.
[0007] FIG. 1 is a first embodiment of the instant invention in a compressed state; and
[0008] FIG. 2 is the first embodiment of the instant invention in an extended state.
DETAILED DESCRIPTION OF THE INVENTION
[0009] Referring to the drawings wherein like numerals indicate like elements, there is shown, in FIGS. 1-2 , a first embodiment of device 10 for extending a distal end of an anatomic tube such as a residual esophagus. Device 10 includes an accordion pleated bladder 12 . The bladder 12 has a proximal end 14 and a distal end 16 .
[0010] The instant invention, for convenience, has been described in terms of a device for extending the distal end of a residual esophagus; however, the instant invention is not so limited, and it may be employed to extend the distal end of any anatomic tube, e.g. the distal end of an intestine in the case of bowl removal. Residual esophagus, as used herein, may be a tubular extension of the stomach; or in the alternative, it may be an incomplete esophagus that fails to connect to the stomach.
[0011] Bladder 12 may be made of any biocompatible elastomeric material. For example, bladder 12 may be made of a biocompatible elastomeric material selected from the group consisting of silicone rubber, natural rubber, styrene-butadiene copolymer, polychloroprene, nitrile rubber, butyl rubber, polysulfide rubbercis-i,4-polyisoprene, ethylene-propylene terpolymers (EPDM rubber), certain metallocene grades of elasticated polyolefins such as elasticated polypropylene or elasticated polyethylene, and polyurethane rubber. Bladder 12 may have any shape adapted to facilitate the longitudinal extension of any anatomic tube such as a residual esophagus. Bladder 12 may, for example, have a tubular shape. Bladder 12 may further include different physical configurations; for example, bladder 12 may have a compressed state or an extended state, as shown in FIGS. 1 and 2 respectively.
[0012] Bladder 12 is pleated. Bladder 12 may have any number of pleats 18 . For example, bladder 12 may have a single pleat 18 ; or it may have a plurality of pleats 18 . Pleats 18 may be any type of pleats; for example, pleats 18 may be annular pleats. Pleats 18 may have any shape; for example, pleats 18 may have a discoid shape.
[0013] Bladder 12 may further include a small diameter rib 24 or a large diameter rib 26 . Bladder 12 may include any number of small diameter ribs 24 or any number of large diameter ribs 26 . Bladder 12 may, for example, include one or a plurality of either of small diameter ribs 24 or large diameter ribs 26 .
[0014] Small diameter rib 24 may have any shape adapted to minimize the uncontrolled circumferential expansion of bladder 18 ; for example, small diameter rib 24 may have an annular shape. Small diameter rib 24 may be made of any biocompatible elastomeric material. Small diameter rib 24 , for example, may be a biocompatible elastomeric material selected from the group consisting of silicone rubber, natural rubber, styrene-butadiene copolymer, polychloroprene, nitrile rubber, butyl rubber, polysulfide rubbercis-i,4-polyisoprene, ethylene-propylene terpolymers (EPDM rubber), certain metallocene grades of elasticated polyolefins such as elasticated polypropylene or elasticated polyethylene, and polyurethane rubber. Small diameter rib 24 may be an integrated component of bladder 12 , or in the alternative, it may be a separate component secured thereto bladder 12 .
[0015] Large diameter rib 26 may have any adapted to minimize the uncontrolled circumferential expansion of bladder 12 ; for example, large diameter rib 26 may have an annular shape. Large diameter rib 26 may be made of any biocompatible elastomeric material. Large diameter rib 26 may, for example, may be a biocompatible elastomeric material selected from the group consisting of silicone rubber, natural rubber, styrene-butadiene copolymer, polychloroprene, nitrile rubber, butyl rubber, polysulfide rubbercis-i,4-polyisoprene, ethylene-propylene terpolymers (EPDM rubber), certain metallocene grades of elasticated polyolefins such as elasticated polypropylene or elasticated polyethylene, and polyurethane rubber. Large diameter rib 26 may be an integrated component of bladder 12 , or in the alternative, it may be a separate component secured thereto bladder 12 .
[0016] Proximal end 14 is a non-pleated proximal portion of bladder 12 , and it may have a sealable opening 32 . Proximal end 14 may include alternative means for securing bladder 12 to the proximal end of an anatomic tube such as a residual esophagus. Proximal end 14 may have any shape adapted to facilitate the extension of the distal end of an anatomic tube such a residual esophagus. For example, proximal end 14 may have a cylindrical shape adapted for securing bladder 12 to the proximal end of an anatomic tube such as a residual esophagus. Proximal end 14 may be adapted to expand circumferentially in a range of about 1% to about 30% thereby securing bladder 12 to the proximal end of an anatomic tube such as a residual esophagus. Proximal end 14 may further include first anchors (not shown) to secure the bladder 12 to the proximal end of an anatomic tube such as a residual esophagus. Proximal end 14 may further include the means for connecting bladder 12 to a pressure generator (not shown). Means for connecting bladder 12 to a pressure generator includes, but is not limited to, quick-connect fittings, threads, or other detachable coupling means such as clamps or fasteners.
[0017] Distal end 16 is a non-pleated distal portion of bladder 12 , and it is sealed. Distal end 16 may include alternative means for securing bladder 12 to the distal end of an anatomic tube such as a residual esophagus. Distal end 16 may have any shape adapted to facilitate the extension of the distal end of an anatomic tube such a residual esophagus. For example, distal end 16 may have a cylindrical shape adapted for securing bladder 12 to the distal end of an anatomic tube such as a residual esophagus. Distal end 16 may be adapted to expand circumferentially in a range of about 1% to about 30% thereby securing bladder 12 to the distal end of an anatomic tube such as a residual esophagus. Distal end 16 may further include second anchors (not shown) to secure the bladder 12 to the distal end of an anatomic tube such as a residual esophagus.
[0018] In operation, device 10 is disposed in a residual esophagus, employing conventional methods known in the medical field. Device 10 is connected to a pressure generator (not shown) via a pressure pipe coupled with the proximal end 14 . Pressure generator, for example, may generate pressure by pumping a fluid into device 10 thereby facilitating the expansion of bladder 12 . Fluid, as used herein, refers to any liquid, e.g. saline solution, or any gas, e.g. CO 2 . As the fluid is pumped into device 10 , the internal pressure of device 10 increases thereby inducing bladder 12 to expand both circumferentially and longitudinally. However, the small diameter ribs 24 and the large diameter ribs 26 prevent the uncontrolled circumferential expansion of bladder 12 thereby facilitating the extension of the bladder 12 along its longitudinal axis. The controlled circumferential expansion of bladder 12 facilitates securing the proximal end 14 of the bladder 12 to the proximal end of the residual esophagus; and, it further facilitates securing the distal end 16 of bladder 18 to the distal end of the residual esophagus. The longitudinal extension of bladder 12 facilitates the extension of the distal end of the residual esophagus along its longitudinal axis. The extended residual esophagus may be maintained in an extended state until its extension along its longitudinal axis becomes permanent. For example, the extended residual esophagus may be maintained in an extended state for a period of about 1 month to about 6 months. During this period of extended state, as the residual esophagus gradually extends further, the internal pressure of device 10 declines; therefore, supplemental fluid is pumped into device 10 in order to increase the internal pressure of device 10 thereby inducing bladder 12 to further extend along its longitudinal axis. The longitudinal extension of bladder 12 facilitates further extension of the distal end of the previously extended residual esophagus. The addition of the supplemental fluid to facilitate further extension of the distal end of residual esophagus may be repeated as many times as necessary until an optimum extension of the distal end of the residual esophagus is achieved. In the alternative, the residual esophagus may be extended along its longitudinal axis as many times as necessary to induce a permanent extension along its longitudinal axis. For example the internal pressure of device 10 may, repeatedly, be reduced, and then, increased in order to induce a permanent extension along the longitudinal axis of the residual esophagus.
[0019] In an alternative operation, device 10 is disposed in residual esophagus, employing conventional methods known in the medical field. Device 10 is connected to a pressure generator (not Shown) via a pressure pipe coupled with the proximal end 14 . Pressure generator, for example, may generate pressure by pumping a fluid into device 10 thereby facilitating the expansion of bladder 12 . Fluid, as used herein, refers to any liquid, e.g. saline solution, or any gas, e.g. CO 2 . The proximal end 14 of the bladder 12 is secured to the proximal end of the residual esophagus via first anchors, and the distal end 16 of the bladder 12 is secured to the distal end of the residual esophagus via second anchors. As the fluid is pumped into device 10 , the internal pressure of device 10 increases, and the bladder 12 begins to expand both circumferentially and longitudinally. However, the small diameter ribs 24 and the large diameter ribs 26 prevent the uncontrolled circumferential expansion of bladder 12 thereby facilitating the extension of the bladder 12 along its longitudinal axis. The longitudinal extension of bladder 12 facilitates the extension of the distal end of the residual esophagus along its longitudinal axis. The extended residual esophagus may be maintained in an extended state until its extension along its longitudinal axis becomes permanent. For example, the extended residual esophagus may be maintained in an extended state for a period of about 1 month to about 6 months. During this period of extended state, as the residual esophagus gradually extends further, the internal pressure of device 10 declines; therefore, supplemental fluid is pumped into device 10 in order to increase the internal pressure of device 10 thereby inducing bladder 12 to further extend along its longitudinal axis. The longitudinal extension of bladder 12 facilitates further extension of the distal end of the previously extended residual esophagus. The addition of the supplemental fluid to facilitate further extension of the distal end of residual esophagus may be repeated as many times as necessary until an optimum extension of the distal end of the residual esophagus is achieved. In the alternative, the residual esophagus may be extended along its longitudinal axis as many times as necessary to induce a permanent extension along its longitudinal axis. For example the internal pressure of device 10 may, repeatedly, be reduced, and then, increased in order to induce a permanent extension along the longitudinal axis of the residual esophagus.
[0020] The present invention may be embodied in other forms without departing from the spirit and the essential attributes thereof, and, accordingly, reference should be made to the appended claims, rather than to the foregoing specification, as indicated the scope of the invention.
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The instant application relates to a device, and a method for extending a distal end of an anatomic tube. This device includes an accordion pleated bladder, which includes a proximal end and a distal end. The method includes the steps of (1) providing a device for extending a distal end of an anatomic tube including an accordion pleated bladder, wherein said bladder has a proximal end and a distal end; (2) placing the device for extending a distal end of an anatomic tube in the anatomic tube; (3) connecting the device to a pressure generator; (4) increasing the internal pressure of the device thereby extending the bladder along its longitudinal axis; and (5) thereby extending the anatomic tube along its longitudinal axis.
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RELATED APPLICATIONS
[0001] This application: claims the benefit of co-pending U.S. Provisional Patent Application Ser. No. 61/579,596, filed on Dec. 22, 2011; which is hereby incorporated by reference.
BACKGROUND
[0002] 1. The Field of the Invention
[0003] This invention relates to sound speakers and, more particularly, to novel systems and methods for earbud-style, miniature or personal audio system speakers.
[0004] 2. The Background Art
[0005] Music, podcasts, and other audio materials are now available to listeners. With the advent of the ipod™ and other MP3 audio players, individuals can carry with them gigabytes of data representing audio files for their listening desires. Personal audio devices have given rise to a plethora of speaker systems requiring very low power and fitted to a user. Such systems include headsets, earbuds, and the like. These speaker systems are very light weight, require very low power, and require very little space in most circumstances.
[0006] Pedestrians on the street, drivers in vehicles, and individuals at their work stations may often be found listening to their choice of music or other audio materials. This has become a traffic and safety issue in certain circumstances. For example, a pedestrian walking on a street needs to be aware of certain sounds in the environment. Public transportation agencies spend tremendous amounts of advertising dollars educating the public as to safety around mass-transit rail systems. An individual who cannot hear a coming commuter train, particularly quiet light-rail types of systems, may step into the path of a train, approach too close to the tracks, or otherwise be endangered because the speaker systems of an audio player block out other sounds.
[0007] Typically, a speaker system based on earbud technology includes a speaker that transmits sound directly into the outer ear channel of a user. Typically, a plug surrounds the central sound channel. Thus, not only is the sound directed immediately into the outer ear channel, other sounds are blocked out. Thus, the earbuds act not only as speakers but also as earplugs to cut out surrounding sound.
[0008] Thus, an individual who is listening to music or other audio materials not only has the volume of the sound obscuring any environmental sound sources but also has the effect of an ear plug blocking out any sounds other than those emanating from the speaker.
[0009] It would be an advance in the art to develop a speaker that is safer, by permitting bypass of certain sounds in order to allow a user to still detect environmental sounds affecting safety.
BRIEF SUMMARY OF THE INVENTION
[0010] In view of the foregoing, in accordance with the invention as embodied and broadly described herein, a method and apparatus are disclosed in one embodiment of the present invention as including an apparatus having flutes that fit within the outer channel of an ear of a user, having apertures between the flutes. A sound channel is typically directed along the center of the apparatus, with the flutes extending away therefrom in order to support the apparatus in the outer ear channel of a user.
[0011] Apertures are sized to provide passage of sounds having a wavelength suitable for safety. Thus, apertures may have one dimension of about ⅛ inch or less, and another dimension of over a ¼ of an inch to about ½ inch. Typically, the apparatus will be provided with a sleeve surrounding the sound channel. The sleeve fits over the housing of a speaker system. The speaker system may include a housing around a speaker itself, as well as a stem that transitions the electrical connections with electronics and eventually connects to a cord.
[0012] In certain embodiments, the housing may provide a shank adapted to secure into the sleeve. The speaker may contain electrically active elements operated in response to electrical signals passed through a cord into the speaker. The shank and the sleeve each surround the channel or lumen that carries sound from the speaker directly into the ear channel of a user. In some embodiments, the flutes may be supported and maintained a distance away from the sleeve in order to provide pressure against the inside surface of an outer ear channel of a user in order to maintain the apparatus firmly positioned.
[0013] In certain embodiments of apparatus and methods in accordance with the invention, a speaker may be provided having an interface specifically fitted to hold or secure a shank on the speaker. Deforming and resilience help interface between the comparatively harder plastic of a speaker and the comparatively softer and more sensitive tissue in an outer ear canal of a user. The shank includes a hollow center channel (lumen) that propagates sound waves into the interface. The interface may be thought of as a fitting that surrounds the speaker and provides the interface between a user and the speaker. Accordingly, the interface may typically be formed of a comparatively soft and flexible elastomeric polymer material. The speaker will typically be contained in a housing of comparatively harder and more rigid material, such as a metal, hard plastic, or the like.
[0014] In one contemplated embodiment, the interface (i.e. fitting) may include a sleeve configured as a cylindrical element having fins radiating outward therefrom and extending along at least a portion of the length of the sleeve. Each of the fins will typically terminate at its outermost radius by becoming, or terminating in, a flute.
[0015] By flute here is meant a broader based portion of material having a comparatively larger area in contact with an outer ear canal of a user. The flutes thus remediate the pressure that might otherwise be exerted by the comparatively narrower or thinner ribs. Thus, whereas a rib might exert a comparatively larger pressure over a smaller area, that same force will generate a comparatively smaller pressure over a larger area when passed through a flute to the skin lining the outer ear canal of a user.
[0016] The length of a fin along the sleeve, as well as the thickness circumferentially of the fin in a circumferential direction around the sleeve may be designed according to the size of the canal expected to be fitted by the fitting, and the pressure expected to be suitable for comfort for a user.
[0017] For example, the ribs may be formed of an expanded polymeric foam, such as an expanded elastomeric polymer material. Thus, the ribs may be comparatively softer and more flexible than the housing, instead approximating the tissue of the ear of a user. Moreover, the ribs may be comparatively thinner in the circumferential direction, and sized in thickness in an aspect ratio with radial height selected to initiate column buckling.
[0018] For example, a comparatively thinner rib will deflect by buckling, yet the flute, having a larger area in contact with an outer ear canal of a user may still remain oriented thereagainst. Accordingly, column buckling of the rib provides relief in the backing force urging each flute against the wall of the outer ear canal.
[0019] In certain embodiments, the polymer from which the interface is formed may be molded. For example, injection molding has been found suitable and various elastomeric materials have proven suitable. Elastomeric materials of those which maintain a certain resilience and deflect elastically, completely recovering upon removal of an applied stress. Polyurethane, silicone, and other synthetic elastomeric polymers have been found suitable.
[0020] The path of sound waves emanating from the speaker passes through the central canal of the shank and into the central canal of the interface. Thus, the interface directs sound waves directly into the outer ear canal of a user, toward the eardrum. Meanwhile, parallel paths are formed to propagate environmental sounds through channels formed by each pair of adjacent fins and the intervening portion of the sleeve. The outer wall in such a channel may be a combination of the flutes and the wall of the outer ear canal of a user.
[0021] In the contemplated embodiments, the dimensions for the thickness, length along the sleeve, and radial height from the sleeve to the flute for each rib may be selected to be identical to all others. In an alternative embodiment, these may vary. Nevertheless, in one currently contemplated embodiment, the interface may be made point symmetric having a plurality of ribs and their corresponding flutes, radially opposite one another about a circumference of the interface.
[0022] Accordingly, the characteristic length may include each dimension across or along a channel between the ribs. Characteristic lengths may relate to the frequency and wavelength of sound propagated. Thus, the channels may tend to filter out longer wavelengths that do not match the characteristic lengths (e.g., circumferential width, radial height, and axial length) of the bypass channels along the outside of the sleeve.
[0023] In certain embodiments, the flutes may be spaced apart to provide more or less distance therebetween. Meanwhile, the flutes may be sized in thickness to provide more or less distance therebetween. Nevertheless, it has been found effective to provide about twenty five percent of the circumferential distance in open space between flutes. This permits the flutes to move toward one another, closer together and the ribs to deflect to accommodate that deflection or movement by the flutes. Accordingly, the flutes maintain open the channels defined by the adjacent ribs and intervening sleeve in each case.
[0024] In some embodiments, the ribs may actually deflect circumferentially and tip over. To the extent, that a rib does so deflect, it may leave behind a channel nevertheless. Thus, the channels need not all be identical in shape or size about the entire circumference of the fitting.
[0025] In some embodiments, it has been found suitable to provide a rim interconnecting the flutes at their front end (insertion end) near the outlet of the sound channel of the sleeve, at the rear (speaker end) of the fitting, or both. In certain embodiments, it has been found that the deflection suitable for comfortable fitting of the interfacing fitting with the outer ear canal of a user is best served without a rim, or with rimless flutes that are free to move with the deflection of the ribs in multiple dimensions. In this way, no rim need remain to enforce the spacing between flutes. Accordingly, the flutes may move closer together with circumferential deflection of the ribs, thus providing stabilization, a comfortable fit, and channel maintenance. This buckling or distortion of ribs minimizes the force applied by the resilient ribs and flutes against the wall of the outer ear canal of user.
[0026] The fitting thus provides two parallel paths for sound. While orienting the shank (e.g., outlet channel) of the speaker to propagate sound waves directly into the outer ear channel of a user, the interface also establishes, defines, and provides outer channels. Environmental sound passes around the sleeve and speaker, through channels defined by adjacent ribs and their intervening sleeve portion. Sound waves propagate directly into the outer ear channel of a user.
[0027] It has been found that two significant properties affect the sound quality perceived by a user of the ear bud or personal earphone type of speakers. First, is providing a direct line of sound propagation from a speaker into an outer ear channel of a user. Second is occlusion or blocking of environmental sounds. However, in certain environments, environmental sound is critical to safety. Thus, by providing the environmental sound channels around the outside surface of the sleeve, and the propagated sound from speakers from the inside channel along the interior of the sleeve, both environmental and propagated audio sound are provided to a user.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] The foregoing features of the present invention will become more fully apparent from the following description and appended claims, taken in conjunction with the accompanying drawings. Understanding that these drawings depict only typical embodiments of the invention and are, therefore, not to be considered limiting of its scope, the invention will be described with additional specificity and detail through use of the accompanying drawings in which:
[0029] FIG. 1 is a frontal perspective view of one embodiment of an apparatus in accordance with the invention;
[0030] FIG. 2 is a rear perspective view thereof;
[0031] FIG. 3 is front elevation view thereof;
[0032] FIG. 4 is a rear elevation view thereof;
[0033] FIG. 5 is a top plan view thereof;
[0034] FIG. 6 is a bottom plan view thereof;
[0035] FIG. 7 is a right side elevation view thereof;
[0036] FIG. 8 is a left side elevation view thereof;
[0037] FIG. 9 is a front perspective view thereof one embodiment of speaker housing system;
[0038] FIG. 10 is a rear perspective view thereof suitable for securing a fitting such as the audio-bypass safety earbud fitting;
[0039] FIG. 11 is a rear perspective view of an alternative embodiment of a sleeve of a fitting in accordance with the invention.
[0040] FIG. 12 is a frontal perspective view of a fitting having discrete apertures distributed over the outer wall of the fitting;
[0041] FIG. 13 is a front perspective view of an alternative embodiment of a fitting in accordance with the invention;
[0042] FIG. 14 is a rear perspective view thereof;
[0043] FIG. 15 is a front perspective view of an alternative embodiment for a fitting in accordance with the invention;
[0044] FIG. 16 is an alternative embodiment thereof, using a serrated or undulating edge on selected flutes thereof;
[0045] FIG. 17 is a perspective view of a one embodiment of a fitting in accordance with the invention;
[0046] FIG. 18 is a frontal perspective view of an alternative embodiment of a fitting in accordance with the invention;
[0047] FIG. 19 is an alternative embodiment of a fitting having flutes without a surrounding rim;
[0048] FIG. 20 is a front elevation view thereof;
[0049] FIG. 21 is a front elevation view of the apparatus of FIG. 18 , showing distortion that may typically occur when positioned in place
[0050] FIG. 22 is a frontal perspective view of one embodiment of an apparatus in accordance with the invention;
[0051] FIG. 23 is a rear perspective view thereof;
[0052] FIG. 24 is front elevation view thereof;
[0053] FIG. 25 is a rear elevation view thereof;
[0054] FIG. 26 is a top plan view thereof, the bottom plan view being the same; and
[0055] FIG. 27 is a right side elevation view thereof, the left side elevation view being a minor image thereof about any vertical plane extending into the page to the left or right of the image.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0056] It will be readily understood that the components of the present invention, as generally described and illustrated in the drawings herein, could be arranged and designed in a wide variety of different configurations. Thus, the following more detailed description of the embodiments of the system and method of the present invention, as represented in the drawings, is not intended to limit the scope of the invention, as claimed, but is merely representative of various embodiments of the invention. The illustrated embodiments of the invention will be best understood by reference to the drawings, wherein like parts are designated by like numerals throughout.
[0057] Referring to FIGS. 1-8 , while referring generally to FIG. 1-27 , an apparatus 10 may include a speaker system having a fitting 11 adapting the speaker system 10 to fit within an outer ear channel of a user. In the illustrated embodiment, the fitting 11 may be formed to have flutes 12 acting to apply a force to a wall of the outer ear channel of a user or wearer of the apparatus 10 .
[0058] In the illustrated embodiments, the flutes 12 of the fitting 11 may include apertures 14 formed in the flutes 12 of the fitting 11 or positioned between adjacent flutes 12 . The apertures 14 provide a bypass region 14 in order that sound may pass through the fitting 11 , past the apparatus 10 , and into the ear of a listener. The apertures 14 thus provide a sound channel 14 for environmental sounds to bypass the apparatus 10 , and reach a user. The apertures 14 thus do tend to pass filtered background sounds a means to bypass the fitting 11 , thus rendering the fitting 11 no longer an ear plug as a sound deadening device.
[0059] An apparatus 10 provided with a fitting 11 presenting flutes 12 that are formed of a resilient material, such as a rubber, synthetic polymer, or other elastomeric material, provides a compressible fit within the outer ear of a user. Thus, the flutes 12 secure the apparatus 10 , in place, by virtue of the compressibility of the flutes 12 of the fixture 11 . Meanwhile, apertures 14 provided among the flutes 12 provide a bypass channel 14 in order to pass sound through the fitting 11 and apparatus 10 to the outer ear channel of a wearer or user.
[0060] A channel 16 is formed within a sleeve 18 . The sleeve 18 is typically centrally located from the outer surface of the fitting 11 . Typically, the outer surface of the fitting 11 is the outer surface of the flutes 12 themselves.
[0061] However, the flutes 12 may be formed in a variety of configurations in order to accomplish their functions. In some embodiments the flutes 12 may actually be constituted by a surface. In other embodiments, the flutes 12 may be narrower or wider and may be rib-like in their shape. Accordingly, such flutes 12 may fold, compress, or the like in order to deflect to fit within the outer ear channel of a wearer.
[0062] Meanwhile, the sound channel 16 is formed in the sleeve 18 , and the sleeve 18 forms the central element connecting between the speaker 20 of the apparatus 10 and the outer ear channel of a user.
[0063] For example, the speaker 20 may be enclosed in a housing 22 . The housing may typically be formed of a comparatively rigid or stiff polymeric material, such as a hard plastic. The housing 22 thus provides a degree of protection to the overall speaker system 20 or speaker 20 .
[0064] By the same token, a stem 24 may form a transition member 24 between the housing 22 , and a cord 26 carrying the electronic signals to the speaker 20 . After conversion by the speaker 20 into audio waves or sound waves, the music or other material can be heard by a user after transmission through the channel 16 into the outer ear channel of the user.
[0065] The apertures 14 may be sized to have a width and a length of characteristic acoustic distances. The wavelengths that pass through openings are controlled by the dimensions of the openings that will permit those wavelengths to pass. Thus, an aperture 14 operates to a certain degree as a filter for sound. Sound waves that will be passed through air through the apertures 14 must have a wavelength less than the characteristic length defined by an aperture 14 .
[0066] In operation, each fitting 11 fits into an outer ear channel of a user, and thus may be partially closed. Nevertheless, the clearance or relief provided between the flutes 12 and the sleeve 18 , is bounded. The boundary is defined by the outer ear channel or the wall of the outer ear channel of a user. The flutes and ear wall define the passage opening the apertures 14 provide or enforce.
[0067] Referring to FIGS. 7-10 , while continuing to refer generally to FIGS. 1-27 , the sleeve 18 may fit around a portion of the housing 22 that houses the speaker 20 . A housing 22 may have a shank portion 28 , or a mount 28 , that extends away from the larger portion of the housing 22 in which an actual speaker 20 is contained in the speaker system 20 . Typically, the shank 28 is slightly larger than the internal diameter of the sleeve 18 . Thus, the sleeve 18 may form a friction fit around the shank 28 . This maintains the sleeve 18 and the resulting fitting 11 of the apparatus 10 firmly secured to the shank 28 . In certain embodiments, a relief, detent, or other interference on the shank 28 may interact with a corresponding portion in the side the sleeve 18 . This provides an affirmative grip or securement of the sleeve 18 on the shank 28 .
[0068] In general, the directions 30 of FIG. 2 , defining the apparatus 10 and its use with respect to a wearer, may be defined as an axial direction 30 a that effectively runs parallel to the channel 16 and down the center of the sleeve 18 as well as the center of the shank 28 . This forms the axis along which the audio waves are transmitted from the speaker 20 into the ear of a wearer.
[0069] Likewise, a lateral direction 30 b may be thought of as a horizontal direction, nominally, while a transverse direction 30 c may be thought of as a nominal vertical direction. Nevertheless, both the lateral direction 30 b and the transverse direction 30 c are actual radial directions 30 d. A radial direction 30 d is orthogonal to the axial direction 30 a but may go in any direction around a full 360 degrees in a plane, any plane, perpendicular to the axial direction 30 a.
[0070] Accordingly, ribs 32 formed behind the flutes 12 , or as a supporting portion of a flute 12 , or in some embodiments as the structure of the flute 12 , maintain an outer surface against the inner surface of the outer ear channel of a user.
[0071] For example, in the embodiments of FIGS. 1-8 and 17 - 27 , the ribs 32 may serve as spacers or supports for the flutes 12 . Thus, the ribs 32 extend between the sleeve 18 and the flutes 12 . Thus, the ribs 12 each provide a column 32 that may apply a force to the flutes 12 , thus urging the flutes 12 to fit snugly against the inside surface of the wall of an outer ear channel of a user.
[0072] The ribs 32 may be formed of a suitable material, and typically will be homogeneously molded with the sleeve 18 and flutes 12 as a monolithic, integrated, and homogeneous construction. Nevertheless, the apparatus 10 may be assembled, and even the fitting 11 may be assembled. It may be productively manufactured in a molding process as a single integrated piece 11 .
[0073] Referring to FIGS. 11-27 , while continuing to refer generally to FIGS. 1-27 , various alternative embodiments for a fitting 11 of an apparatus 10 may include variations in the size, shape, orientations, positions, and the like of the flutes 12 and their intermediate apertures 14 .
[0074] Referring to FIG. 11 , various mechanisms for securement may be provided. In this embodiment of a fitting 11 , a sleeve 18 is centered within the fixture 11 . The flute 12 is shown as an entirely enclosed surface. Nevertheless, the embodiment of FIG. 11 illustrates a shaping of the interior channel 16 of the sleeve 18 in order to provide easier deflection, and yet a gripping by the sleeve 18 against the shank 28 of a housing 22 . The outer surface or material of the fitting 11 may be perforated with apertures 14 according to any or all of the suitable embodiments illustrated, for example, that of FIG. 12 .
[0075] Referring to FIG. 12 , in one embodiment of an apparatus 10 in accordance with the invention, the flutes 12 are actually simply the material of the fitting 11 . The fitting 11 is, provided with apertures, discretely positioned and separated from one another. Thus, the sleeve 18 and the sound channel 16 through the fitting 11 operate in accordance with the other embodiments illustrated herein.
[0076] Referring to FIGS. 13-14 , the flutes 12 may be spaced a substantial distance apart. For example, the illustrated embodiments of FIGS. 13-14 show alternative mechanisms for supporting the flutes 12 spaced away from the sleeve 18 . In the embodiment of FIG. 13 , no ribs 32 are shown.
[0077] However, in the embodiment of FIG. 14 , ribs 32 space the flutes 12 a distance away from the sleeve 18 . The ribs 32 each form a support member 32 that may flexibly urge each of the corresponding flutes 12 into contact against the surface of an outer ear channel of a wearer.
[0078] Referring to FIGS. 15-16 , flutes 12 may be separated from one another, and each may emanate, by extending in a radial direction 30 d , away from the center sleeve 18 . In the illustrated embodiment, the convergence of the individual flutes 12 actually forms the central sleeve 18 . The sleeve 18 then may or may not be discretely identifiable separate from the flutes 12 , as the sleeve 18 defines the sound channel 16 .
[0079] Referring to FIG. 16 , the flutes 12 in one embodiment may be serrated along their edges in order to provide a more gripping surface. For example, by having a serrated edge on one or more of the flutes 12 , areas of higher and lower pressure alternate. Thus, the tendency is for a greater resistence to sliding. That is, each area of higher compression corresponds to an area of a higher tooth on the serrated edge of a flute 12 . In this manner, the tooth has a larger incursion in depressing the outer ear channel wall against which it fits, leaving less depression in the areas or valleys between the teeth (or crests) of the serrations. Thus, greater support against axial movement may be achieved.
[0080] Referring to FIG. 17 , the embodiment of FIG. 17 may or may not include ribs 32 as illustrated in FIGS. 1-8 . In this embodiment, as in the embodiment of FIG. 13 , a stiffer material may not benefit as much from the presence of ribs 32 . Likewise, manufacturing may be somewhat simpler. Nevertheless, a substantially softer material, even a foamed elastomeric material, may be used to mold many of the embodiments of fittings 11 , thereby providing sufficient flexibility for comfort. Meanwhile, ribs 32 may act as stiffeners. A rib 32 provides additional radial force. Ribs 32 act as supports, stabilizers, or the like in order to maintain the distance, spacing, or he like. Ribs 32 enforce, under pressure, the original tendency of flutes to stay spaced apart from the sleeve 18 and from the other flutes 12 .
[0081] Referring to FIGS. 18-27 , while continuing to refer generally to FIGS. 1-27 , a fitting 11 may take on various configurations suitable to the material selected and the comfort of a user. For example, radial supports, such as ribs 32 , may apply force in a radially outward direction against a flute 12 , on the outside. They may apply corresponding force against the sleeve 18 located on the inside thereof Likewise, circumferential support may be provided by and actually may deflect the flutes.
[0082] Referring to FIG. 18 , for example, the flutes 12 extend circumferentially around the sleeve 18 , spaced away from the sleeve 18 by the ribs 32 . Meanwhile, the flutes 12 have a convoluted shape that varies in diameter and radius as the flutes progress along the axial direction 30 a. Thus, one or more ribs 32 , which may or may not be continual in the axial direction, space the sleeve 18 from the flutes 12 , and represent a somewhat convoluted outer surface. Thus, in this embodiment, as in the embodiment of FIG. 16 , alternating areas of higher pressure and lower pressure tend to provide additional gripping against axial dislodgement of the apparatus 10 .
[0083] Referring to FIG. 19 , an embodiment having no outer rim for the flutes 12 , but simply the flutes 12 themselves, are effectively like ribs 32 . They extend from the sleeve 18 and contact directly the surface of the outer ear channel of the wearer. In this embodiment, the edge of each flute 12 itself may fit against the ear channel of a user, and maintain the sleeve 18 against dislodgement. In this embodiment, a stiffer material may be needed than in certain of the other embodiments, where more surface area, more material, and more contact area are provided.
[0084] However, in this embodiment, the aperture region 14 is substantial, and effectually is most of the projected area of the entire fitting 11 . That is, for example, proceeding in an axial direction 30 a , the majority of the cross-sectional area circumscribed by the envelope around the fitting 11 is the aperture region 14 itself. Only the four flutes 12 , which could be three flutes 12 in certain embodiments, or another number, actually represent spacing and structure between the sleeve 18 and the wall of the outer ear channel.
[0085] Referring to FIG. 20 , in one embodiment, as illustrated in FIG. 19 , the flutes 12 may compress, deflect, or otherwise change shape in order to fit within the ear channel of a user. In the illustrated embodiment, two of the flutes 12 maintain substantially their shape, while two others are deflected or distorted in order to fit in the ear channel of the wearer.
[0086] Referring to FIG. 21 , similarly, the embodiment of FIG. 18 shows the flutes 12 that basically rely on the rim 34 around the ribs 32 . All may deflect selectively in order to fit within the outer ear channel of a user. Thus, a rim 34 may be desirable to maintain a certain amount of stability between the ribs 32 that together with the rim 34 actually form the flutes 12 or the structure 12 that axial flutes 12 would otherwise provide.
[0087] Referring to FIGS. 22-27 , while continuing to refer generally to FIGS. 1-27 , a speaker system 10 may be provided with a fitting 11 (i.e., interface) suitable for interfacing between an outer ear canal of a user and the speaker system 20 of an audio device. In the illustrated embodiment, the rim 34 is noticeably absent between the adjacent ribs 32 and flutes 12 . In this embodiment, it has been found effective to provide a fitting 11 having flutes 12 surrounding the sleeve 18 . Each flute 12 is supported by a rib 32 extending radially between the sleeve 18 and the corresponding flute 12 .
[0088] The material of which the fitting 11 is molded or cast may be any suitable material, but an elastomeric polymer material has been found most suitable. For example, silicone compounds have been found suitable, and sufficiently durable. Meanwhile, they have sufficient softness (e.g., by durometer test value) and flexibility (e.g., by mechanical stiffness and deflection underload) to match mechanical properties of, fit well into, the outer ear canal of a user in the dimensions illustrated.
[0089] In other embodiments in which a rim 34 interconnects the ribs 32 or flutes 12 of the fitting 11 , a conservation-of-mass principle as well as the mechanical stiffness of the rim 34 and rib 32 combination tends to stabilize the flutes 12 more than necessary. Inasmuch as the shape of the flutes 12 is fitted to contact the surface of the skin lining the outer ear canal of a user, the flutes 12 tend to stabilize within the ear channel.
[0090] Meanwhile, deflections as required may occur in the flutes 12 . Of particular note, the ribs 32 are made to have a thickness and height (height measured radially from the sleeve 18 ) to be sufficiently flexible to engage in column buckling. To the extent that the fitting 11 needs to deform or deflect to fit inside the outer ear canal, that deflection may be provided by buckling of one or more of the ribs 32 . By buckling, the ribs 32 necessarily displace into the channels 14 between the ribs 32 . Nevertheless, to the extent that a rib 32 occludes part of a channel 14 , it will tend to open up the adjacent channel 14 on the opposite side of the rib 32 .
[0091] In the illustrated embodiment, it has been found that comfort, fit, and ease of application are all well served by the fitting 11 made in accordance with the illustrated embodiment, and lacking any rim 34 interconnecting the flutes 12 . One may form the ribs 32 to be of any suitable thickness and height, depending on comfort for the wearer. That is, for example, the thickness of the ribs 32 will influence the effective pressure exerted by the ribs 32 on the flutes 12 . The flutes 12 , in turn, exert pressure against the skin of a user.
[0092] It has been found effective to make the fitting 11 in the dimensional relationships illustrated, of a silicone material in three different sizes. A larger diameter size is for adults having a larger outer ear channel, the medium size is for other adults, and the smaller size is for children and those adults having a comparatively narrower ear channel. The safety passages 14 carry environmental sound into the outer ear channel improving safety of a wearer.
[0093] The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative, and not restrictive. The scope of the invention is, therefore, indicated by the appended claims, rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope.
[0094] What is claimed and desired to be secured by United States Letters Patent is:
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A fitting provided for earbud-type personal audio speakers may be formed as a homogeneous, integral component molded from an elastomeric polymer, such as silicone, urethane, or other elastomeric resins. A sleeve fitted to the speaker engages the fitting to the speaker, while ribs extending from the sleeve terminate in flutes conformal to an ear canal of a user. Axial insertion of the fitting and speaker into an ear of a user results in localized deflection of flutes and ribs in order to accommodate size and shape of an ear canal, resulting in transmission of sound from the speaker directly through the sleeve into an ear canal of a user, while also permitting environmental sounds to pass along a parallel path over the outside of the sleeve, between the ribs.
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This is a divisional of application Ser. No. 08/600,707 filed Feb. 13, 1996.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to flue gas heat recovery systems in general and more particularly to a combined system of flue gas heat recovery and pollutant removal utilizing a condensing heat exchanger in combination with a wet flue gas desulfurization system.
2. Description of the Related Art
Condensing heat exchangers such as the one shown in FIG. 1, recover both sensible and latent heat from the flue gas as well as removing pollutants such as fly ash, S0 2 etc. all in a single unit. The arrangement provides for the flue gas to pass down through heat exchanger modules while the water passes upward in a serpentine path through the tubes. Condensation occurs within the heat exchanger modules as the gas temperature at the tube surface is brought below the flue gas dew point temperature and is exhausted at the bottom. Gas cleaning occurs within the heat exchanger as the flue gas particulate impact the tubes and flows through the falling drops of condensate.
The heat exchanger tubes and inside surfaces of the heat exchanger are made of corrosion resistant material or are covered with Teflon® to protect them from corrosion when the flue gas temperature is brought below the acid dew point. Interconnections between the heat exchanger tubes are made outside the tube sheet and are not exposed to the corrosive flue gas stream.
Since the condensate flows downward in the direction of the flow of the flue gas, gas to water contact is not maximized. Also, there is no provision for external spray of reagents to eliminate non-particulate pollutants such as HCl, HF, SO 2 , SO 3 and NO x . As such the system is relatively limited in cleaning ability and is relatively inefficient.
The Integrated Flue Gas Treatment (IFGT™) condensing heat exchanger, shown schematically in FIG. 2, is a condensing heat exchanger designed to enhance the removal of both gaseous pollutants and particulate matter from the flue gas stream. It is made of corrosion resistant material or has all of the inside surface covered with Teflon®.
There are four major sections of the IFGT™ system; the first heat exchanger stage (10), the interstage transition region (12), the second heat exchanger stage (14), and the mist eliminator (16). The major differences between the integrated flue gas treatment design and the condensing heat exchanger design of FIG. 1 are:
1.) the integrated flue gas treatment design uses two heat exchanger stages instead of one.
2.) the interstage transition region, located between the two heat exchanger stages, is used to direct the gas to the second heat exchanger stage and acts as a collection tank and allows treatment of the gas between the stages,
3.) the gas flow in the second heat exchanger stage is upward, rather than downward,
4.) the gas outlet of the second heat exchanger stage is equipped with an alkali reagent spray system, and
5.) a mist eliminator is used to separate the carryover formed by the reagent sprays and condensation from the flue gas.
Most of the sensible heat is removed from the gas in the first heat exchanger stage (10) of the IFGT™ system. The transition region (12) can be equipped with a water or alkali spray system (18). This system saturates the flue gas with moisture before it enters the second heat exchanger stage (14) and also assists in removing sulfur and halogen based pollutants from the gas. The transition piece is made of corrosion resistant fiberglass-reinforced plastic. The second heat exchanger stage (14) is operated in the condensing mode, removing latent heat from the gas along with pollutants. The top of the second heat exchanger stage (14) is equipped with an alkali solution spray system (20). The gas in this stage is flowing upward while the droplets in the gas fall downward. This counter current gas/droplet flow provides a scrubbing mechanism that enhances particulate and gas pollutant removal, and the reacted reagent alkali solution is collected at the bottom of the transition section. The flue gas outlet of the IFGT is also equipped with the mist eliminator (16) to reduce the chance of moisture carryover into the exhaust.
The design, while an improvement over the FIG. 1 system, does not offer a single heat exchanger integrated system where pollutants are removed in a counter-current flow of the flue gas to reagent flow across the entire heat exchanger to maximize contact time. Only the second stage utilizes such flow making the system expensive and relatively inefficient.
Prior art also includes wet chemical absorption processes (i.e. wet scrubbers 22 such as shown in FIG. 3), and in particular those applications wherein a hot gas is typically washed in an up flow gas-liquid contact device such as a spray tower with an aqueous alkaline solution or slurry to remove sulfur oxides and/or other contaminants.
Wet chemical absorption systems installed by electric power generating plants typically utilize calcium, magnesium or sodium based process chemistries, with or without the use of additives, for flue gas desulfurization.
In addition, prior art for wet scrubbing is described in a number of patents such as U.S. Pat. No. 4,263,021, assigned to the Babcock & Wilcox Company issued on Apr. 21, 1981 entitled "Gas-Liquid Contact System" which relates to a method for obtaining counter-current gas-liquid contact between a flue gas containing sulfur dioxide and a aqueous slurry solution. This system is currently referred to as a tray or gas distribution device. In addition, Babcock & Wilcox has retrofitted trays into wet FGD spray towers for the purpose of improving the scrubber performance.
Other wet scrubbers utilize various types of packing inside the spray tower to improve gas-liquid distribution which works well with clear solution chemistry processes, but are prone to gas channeling and pluggage in slurry services.
Most wet scrubbers use mist eliminators (24, 26) normally 2-3 stages to remove entrained water droplets fro the scrubbed gas.
SUMMARY OF THE INVETION
The present invention is directed to solving the problems associated with prior art systems as well as others by providing a combined flue gas heat recovery and pollutant removal system using a condensing heat exchanger in combination with a wet flue gas desulfurization system to provide an improved method to further enhance the removal of particulate, sulfur oxides and other contaminants including air toxics from a flue gas stream produced by the combustion of waste materials, coal, oil and other fossil fuels which are burned by power generating plants, process steam production plants, waste-to-energy plants and other industrial processes.
To accomplish same, one or more tubular condensing heat exchanger stages are installed upstream (with respect to gas flow) of the absorption zone sprays of a high velocity wet scrubber and downstream of an electrostatic precipitator. Saturated flue gas velocities through the wet scrubber may fall within the range of 10 ft/sec to 20 ft/sec or more and are considered high velocities compared to the normal velocites encountered in prior art devices. A final stage mist eliminator device may also be installed downstream of the absorber. In addition, one or more stages of perforated plates (trays) are provided upon which the liquid is sprayed to further promote gas-liquid contact and eliminate pollutants.
In view of the foregoing it will be seen that one aspect of the present invention is to provide a high velocity flue gas flow through a condensing heat exchanger for conditioning the flue gas prior to wet scrubbing same.
Another aspect of the present invention is to provide a compact high velocity flue gas treatment system using a condensing heat exchanger and a wet flue gas scrubber.
Yet another aspect of the present invention is to provide a flue gas condensing heat exchanger to treat the flue gas prior to wet scrubbing to increase removal of air toxics such as heavy metal particles by the wet scrubber.
The various features of novelty which characterize the invention are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and specific objects attained by its uses, reference is made to the accompanying drawings and descriptive matter in which a preferred embodiment of the invention is illustrated.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 is a schematic drawing of a downflow condensing heat exchanger;
FIG. 2 is a schematic of an integrated flue treatment (IFGT) system having two separate heat exchanger stages;
FIG. 3 is a schematic of a prior art wet flue gas treatment system;
FIG. 4 is a schematic of the combined condensing heat exchanger and high velocity wet scrubber of the present invention;
FIG. 5 is a schematic of an alternate embodiment of the FIG. 4 system using flue gas from an electrostatic precipitator cross-current flow in of gas and liquid; and
FIG. 6 is a schematic of an alternate FIG. 5 embodiment.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention as best seen in FIG. 4 discloses a flue gas treatment system (28) which provides an improved high velocity flue gas treatment (FGT) system which further enhances the removal of particulates, sulfur oxides and other contaminants including air toxics from a flue gas stream produced by the combustion of waste materials, coal, oil and other fossil fuels which are burned by power generating plants, process steam production plants, waste-to-energy plants and other industrial processes.
The system comprises a tubular condensing heat exchanger (30) of one or more stages installed upstream with respect to flue gas flow of the absorption zone sprays (22) of the high velocity wet scrubber system (28). Saturated flue gas velocities through the wet scrubber (28) may fall within the range of 10 ft/sec to 20 ft/sec or more. A final stage mist eliminator device (24, 26) is installed downstream of the absorber. In addition, one or more stages of perforated plates (trays) (32) of known design are provided upon which the liquid is sprayed from the spray zone (22) to further promote gas-liquid contact.
Flue gas containing water vapor, particulate (fly ash), sulfur oxides/acid gases, and other contaminants including air toxics in vaporous, liquid and solid forms, enters the condensing heat exchanger (30) where heat is recovered from the flue gas by heating a fluid (i.e. a gas such as air or a liquid such as water). The fluid is at a low enough temperature to promote condensation of gases, with the major condensed gas being water vapor. The cooled flue gas then proceeds to a wet scrubber area (34) and is in counter-current contact with a liquid solution or slurry which is introduced near the top by the known spray system (22) and discharged from the bottom of the wet scrubber (34). The indirect cooling of the flue gas as it comes in contact with the heat exchanger and later, the liquid sprays, results in the condensation of acid gases (such as sulfur trioxide) and other contaminants including vaporous air toxics. As acid gases and other contaminants including vaporous air toxics condense on the tube (30) surfaces, they are removed from the gas stream along with the condensed water. Acid gases and other air toxics are further removed in the wet scrubber (34).
The described system (28) thus offers the following advantages over the known prior art systems:
1. The high velocity scrubbing system reduces the equipment size resulting in considerable capital cost savings.
2. The condensing heat exchanger reduces both the latent heat and sensible heat content of the flue gas and reduces the scrubber makeup water requirements.
3. Lowering the scrubber inlet temperature reduces the partial pressure of the gaseous pollutant components by increased solubility and condensing effects. This enhances the removal of air toxics from the flue gases including mercury and condensed fine heavy metal particulate (selenium, lead, chromium, etc.) which are considered toxic.
4. Short stacks can be used to disperse the flue gas which is virtually free from gaseous pollutants.
5. Mist eliminators placed at the inlet to the stack along with drain collection devices remove entrained moisture and recover it for reuse purposes.
6. The condensing heat exchanger conditions the flue gas prior to scrubbing while simultaneously lowering the gas volume and reducing the problems associated with the wet dry interface i.e., the location at the wet scrubbers entrance where the hot gas first comes in contact with the scrubbing liquid.
7. Pollutant removal is increased in the scrubber due to the increase in the mass transfer coefficient which is a direct result of operation at higher gas velocities.
Gas liquid contact through the absorption zone sprays may also be cross-current as is shown in FIGS. 5 and 6. Flue gas enters the heat exchanger in a downward direction from an electrostatic precipitator (not shown). Condensation of water vapor and air toxics occurs within the higher velocity heat exchanger (30) as the gas temperature at the tube surface is brought below the dew point. As the condensate falls as a constant rain over the tube array which is covered with Teflon or an inert coating, some gas cleaning as described above occurs, further enhancing the collection of air toxics, particulate, and residual sulfur oxides/acid gases through the mechanisms of absorption, condensation, diffusion, impaction, and interception in the integral apparatus. The liquid in the exchanger (30) enters at a temperature of approximately 100° F. more or less and is heated by condensate to about 185° F. at the exhaust. The air toxics components referred to here are mainly volatile organic compounds (VOC), HCl, SO 3 , HF, heavy metal compounds including oxides, chlorides and/or sulfates of Al, As, Ca, Cd, Cu, Co, Mg, Na, Pb, Fe, K, Zn, Be, V, Hg, Se and organic compounds including hydrocarbons (Chlorinated dibenzo -p- dioxins (CDD), chlorinated dibenzo-furans (CDF), polycyclic aromatic hydrocarbons (PAH), polychlorinated biphenols (PCB), etc.). Most of these air toxics and organic compounds are generated from municipal solid waste (MSW) or fossil fuel fired combustion processes.
The condensate from the condensing heat exchanger along with reagent water from a mixing tank (36) sprayed through a series of nozzles (38) land on the tray (32) through which the lowered temperature flue gas passes and enters a horizontal cleaning chamber (40) having oxidation air holes (42). This chamber has a second series of spray nozzles (44) located upstream of the mist eliminators (24, 26). A series of spray wash water nozzles (46) are located therebetween. The cleaned flue gas enters a short wet stack exhaust (48) which is preceded by final mist eliminator 50.
The FIG. 6 embodiment is similar to FIG. 5 except that the horizontal run chamber (40) is made into a vertical run chamber (52). Both of the FIG. 5 and FIG. 6 embodiments provide easy access and maintenance of the various mentioned components. Also, the additional mist eliminators found therein reduce entrainment and thus no reheat is required.
Certain modifications and improvements have been deleted herein for the sake of conciseness and readability but are intended to be within the scope of the following claims. As an example, the short stack could be fitted with a booster fan that is physically smaller in volumetric capacity (i.e. size/cost) to include draft pressure in lieu of a larger more costly forced draft fan. Also, a horizontal flow (horizontal tubes) condensing heat exchanger unit could be employed for the horizontal FIG. 5 embodiment.
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An integrated flue gas treatment desulfurization system for treating flue gas exhausted from an electrostatic precipitator and passing at a flue gas flow velocity in the range of 10-20 ft./sec. or more through a condensing heat exchanger and a wet flue gas scrubber. The scrubber sprays a reagent throughto the flue gas effectively remove pollutants and metals prior to exhausting same in a dry form after treatment by mist eliminators located downstream of the system.
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BACKGROUND OF THE INVENTION
The present invention relates to a technique for reproducing compressed image data which may be recorded on optical discs, magnetic discs or the like and, more particularly, to such technique wherein the image data is compressed by a moving or motion picture experts group (MPEG) system.
A MPEG system may be utilized to compression-encode digital image signals which may be recorded in a digital video disc (hereinafter, a DVD). In the MPEG system, compression may be performed by utilizing predictive encoding and discrete cosine transform (DCT).
FIG. 8A illustrates a structure for interframe prediction in accordance with predictive encoding in an MPEG system. As shown therein, such structure or arrangement includes a plurality of frames or pictures. Each of such pictures is either an intraframe predictively encoded (I) picture, an interframe predictively encoded (P) picture or a bi-directionally predictively encoded (B) picture. A plurality of frames or pictures in a sequence of motion pictures may form a so-called group of pictures (GOP). For example, the GOP 1 of FIG. 8A has 15 frames which include one I picture or frame, four P pictures or frames, and ten B pictures or frames. A GOP may be utilized as an encoding unit.
An I picture may be formed or generated by using only image data of that one respective frame or picture and, as such, is an intraframe predictively encoded picture. A P picture may be formed from image data representing a temporally preceding and previously decoded I or P picture and, as such, is an interframe predictively encoded picture. In other words, a P picture is an interframe predictive encoded picture in a forward direction formed with reference to an already encoded and preceding (in time) I or P picture or frame. A B picture may be formed by using image data representing two frames--one preceding and another succeeding in time so as to be bi-directionally predictive encoded.
The above-described formation of the I, P and B pictures is illustrated in FIG. 8A. That is, the arrows illustrated in FIG. 8A indicate the picture or pictures utilized to form a respective picture. For example, the P picture P 0 is predictively encoded with reference to I picture I 0 , P picture P 1 is predictively encoded with reference to P picture P 0 , P picture P 2 is predictively encoded with reference to P picture P1 and so forth. As another example, B pictures B 0 and B 1 are each predictively encoded with reference to both I picture I 0 and P picture P 0 , B pictures B 2 and B 3 are each predictively encoded with reference to P pictures P 0 and P 1 , and so forth. Since I picture I 0 is predictively encoded by using only image data of that respective frame or picture, there are no arrows which indicate that picture I0 is formed with reference to another picture or pictures. As is to be appreciated, other I, P and B pictures are similarly formed.
Since an I picture may be predictively encoded by use of data within only the I picture or frame itself, such I picture may be decoded by use of only the I picture. On the other hand, since a respective P picture is predictively encoded with reference to the preceding I picture or P picture in time, such preceding I or P picture is required for the respective P picture to be decoded. In a similar manner, since a B picture is predictively encoded with reference to the preceding and succeeding I or P picture in time, such preceding or succeeding I or P picture is required for the B picture to be decoded. As a result, pictures may be rearranged such that the picture(s) required for decoding a respective picture are decoded prior to decoding the respective picture. For example, the pictures may be rearranged as shown in FIG. 8B. That is, since B pictures B -1 and B -2 require I picture I 0 upon decoding, I picture I 0 is arranged to precede B pictures B -1 and B -2 Since B pictures B 0 and B 1 require I picture I 0 and P picture P 0 upon decoding, P picture P 0 is arranged to precede B pictures B 0 and B 1 . (As is to be appreciated, I picture I0 already precedes B pictures B 0 and B 1 .) Since B pictures B 2 and B 3 require P pictures P 0 and P 1 upon decoding, P picture P 1 is arranged to precede B pictures B 2 and B3. (As is to be appreciated, P picture P 0 already precedes B pictures B2 and B 3 .) Since B pictures B 4 and B 5 require P pictures P 1 and P 2 , P picture P 2 is arranged to precede B pictures B 4 and B 5 . (As is to be appreciated, P picture P 1 already precedes B pictures B4 and B 5 .) For similar reasons, P picture P 3 is arranged to precede B pictures B 6 and B 7 .
The I, P and B pictures arranged as shown in FIG. 8B may be recorded in a DVD or other recording medium. Since the pictures are encoded by a MPEG system or in accordance with a MPEG standard as previously described, the quantity or amount of codes associated with each of the pictures may not be identical, but instead may be different depending on the complexity and the flatness of the respective images.
Pictures recorded in a DVD may arranged within sectors in which each sector enables a predetermined quantity or amount of codes or data to be stored therein. As a result, one picture may occupy one, less than one or more than one sector. Furthermore, each picture is successively recorded in the sectors in a wrap-around manner. An example of a plurality of pictures recorded within sectors is illustrated in FIG. 9. As shown therein, I picture I 0 is recorded in sector m, sector (m+1) and a portion of sector (m+2); B picture B -2 is recorded in the remaining region of sector (m+2) and sector (m+3); and so forth. In this example, 1 GOP is recorded from sector m to sector (m+21). However, the quantity of codes or data may be different for each GOP depending on the complexity or flatness of the images represented therein. Accordingly, the number of sectors required for recording the data of one GOP may be different between GOPs.
An apparatus for reproducing data which has been compressed and recorded by a MPEG system from a DVD is illustrated in FIG. 7. As shown therein, such apparatus generally includes a pickup 2, a demodulation circuit 3, a sector detection circuit 4, a ring buffer 5, a control circuit 6, a track jump judging circuit 7, a servo circuit 8, a phase locked loop (PLL) 9, an error correction circuit (ECC) 20 and a decoder 30. Such decoder 30 may include a video code buffer 10, an inverse variable length coding (VLC) circuit 11, an inverse quantization circuit 12, an inverse discrete cosine transform (DCT) circuit 13, an addition circuit 14, a motion compensation circuit 15, and a frame memory 16 which are coupled as shown in FIG. 7.
Digital data compressed by a MPEG system is recorded in tracks or sectors having a fixed length (as in FIG. 9) on a disc 1. A sector sync and a sector header may be added to a predetermined portion of each of the sectors, such as the top thereof. The disc 1 may be rotated in a predetermined rate or manner by a spindle motor (not shown). The pickup 2 produces a laser beam which is irradiated on the tracks of the optical disc 1 so as to read out the recorded data. Control for the pickup 2, such as focus control and tracking control, may be performed by the tracking and focus servo circuit 8. That is, the circuit 8 may provide a focused error signal and/or a tracking error signal to the pickup 2. Such focused and tracking error signals may be obtained from information read out from the pickup 2.
The read out digital data from the pickup 2 are supplied to the demodulation circuit 3, whereupon a predetermined demodulation such as EFM-demodulation is performed. (EFM is eight-to-fourteen modulation wherein a symbol having eight bits is converted to a symbol having fourteen bits.) The demodulated data is supplied to the sector detection circuit 4. The read out data from the pickup 2 are further supplied to the PLL circuit 9 so as form or regenerate clock signals which are supplied to the demodulation circuit 3 and the sector detection circuit 4. Such clock signals may be utilized in controlling the timing of the processing performed by the circuits 3 and 4.
As previously described, the sector detection circuit 4 receives demodulated data from the demodulation circuit 3. From such received data, the sector detection circuit 4 detects the sector sync so as to determine the boundary of the sectors and detects a sector address or the like from the sector header. An output signal representative of such detection(s) is supplied to the control circuit 6.
The demodulated data is supplied by way of the sector detection circuit 4 to the ECC circuit 20, whereupon error detection and correction may be performed. The error corrected data from the ECC circuit 20 is supplied to the ring buffer 5 and is written therein in accordance with a write control signal supplied by the control circuit 6.
The control circuit 6 generates the write control or write pointer (WP) signal based on the sector address for each of the sectors detected by the sector detection circuit 4 and supplies the WP signal to the ring buffer 5. Such WP signal indicates a write address wherein a sector may be written into the ring buffer 5. As a result of the WP signal, data from the ECC circuit 20 may be written into designated address locations of the ring buffer 5. The control circuit 6 further generates a read pointer (RP) signal based on a code request signal from the video code buffer 10 (in the succeeding stage of FIG. 7B) and supplies the RP signal to the ring buffer 5. Such RP signal indicates an address of data written into the ring buffer 5 which is desired to be read out. As a result, upon receiving a RP signal, data from the desired address location or position of the ring buffer 5 is read out and supplied to the video code buffer 10, whereupon such data is stored therein.
Therefore, the video code buffer 10 may generate a code request signal (which requests that data from the ring buffer 5 be transmitted to the video code buffer 10) and supply the same to the control circuit 6 whereupon, in response thereto, data is supplied from the ring buffer 5 to the video code buffer 10. The video code buffer 10 may further receive a code request signal from the inverse VLC circuit 11. In response thereto, data stored in the video code buffer 10 may be supplied to the inverse VLC circuit 11, whereupon inverse VLC processing is performed. Upon completing such inverse VLC processing, the processed data may be supplied to the inverse quantization circuit 12 and another code request signal may be supplied to the video code buffer 10 so as to request new data therefrom. The inverse VLC circuit 11 may also supply the size of a quantization step to the inverse quantization circuit 12 and a motion vector information signal to the motion compensation circuit 15.
The inverse quantization circuit 12 inversely quantizes the data received from the inverse VLC circuit 11 in accordance with the size of the quantization step and outputs the obtained processed signal to the inverse DCT circuit 13, whereupon inverse DCT processing is performed. An output signal from the inverse DCT circuit 13 is supplied to one input terminal of the addition circuit 14. An output from the motion compensation circuit 15 formed in accordance with the type of picture (that is, I, P or B), as hereinafter more fully described, is supplied to another input terminal of the addition circuit 14. The addition circuit 14 adds the received signals and supplies the obtained summed signal, by way of a switch 16d, through the appropriate one of contacts A-C to one of memories 16a, 16b and 16c of the frame memory bank 16 so as to be stored therein. Stored signals from the memories 16a, 16b and 16c may be supplied to the motion compensation circuit 15.
The operation performed by the motion compensation circuit 15 and the frame memory bank 16 will now be further described. For this discussion, assume that a recording frame shown in FIG. 8B is reproduced. If the respective reproduced frame is an I picture or frame, then interframe prediction is not applied to such I picture upon decoding. As a result, a zero or no output signal is supplied from the motion compensation circuit 15 to the addition circuit 14 so that the output signal from the inverse DCT circuit 13 is supplied to the frame memory bank 16. However, if the respective reproduced frame is a P picture or a B picture, then the decoded I or P picture(s) needed to decode such respective P or B picture (the decoded I or P picture corresponds to the picture or pictures utilized during predictive encoding) is supplied from the appropriate one of the memories 16a, 16b or 16c of the frame memory bank 16 to the motion compensation circuit 15, wherein a motion prediction image signal is formed with the motion vector information supplied from the inverse VLC circuit 11 and supplied to the addition circuit 14. As a result, the motion prediction image signal and the output signal from the inverse DCT circuit 13 are added in the addition circuit 14 so as to decode the respective picture and the decoded picture is stored in the frame memory bank 16.
Data from the memories 16a-16c of the frame memory 16 are read out under control through contacts A-C by way of a switch 16e so as to restore the original frame order, such as to that shown in FIG. 8A. The read out data are converted by a digital-to-analog (D/A) converter 17 into analog video signals and supplied to a display 18 so as to be displayed thereon.
Therefore, the control circuit 6 causes data stored in the ring buffer 5 to be supplied to the video code buffer 10 in accordance with the code request signal from the video code buffer 10. When data processing of relatively simple video images is being performed and the amount of data transmitted from the video code buffer 10 to the inverse VLC circuit 11 decreases, the amount of data transmitted from the ring buffer 5 to the video code buffer 10 may also decrease. As a result, the amount of data stored in the ring buffer 5 may increase so as to cause an overflow condition of the ring buffer 5. In other words, the amount of data written into the ring buffer 5 by use of the WP signal may surpass the amount read out therefrom by use of the RP signal. To avoid such overflow condition, the quantity of data currently stored in the ring buffer 5 may be determined or calculated by, for example, utilizing address positions of the WP and RP signals controlled by the control circuit 6. Such determination may be performed by the track jump judging circuit 7. If the amount of the data determined to be stored in the ring buffer 5 exceeds a predetermined reference value, a track jump instruction signal is generated by the track jump judging circuit 7 and supplied therefrom to the tracking servo circuit 8. As a result, the pickup 2 may move or jump from the current track to another track. Therefore, the track jump judging circuit 7 determines if the ring buffer 5 may overflow and outputs a track jump instruction signal in response to such determination so as to cause the pickup to jump.
The rate at which data is transmitted from the ring buffer 5 to the video code buffer 10 may be equal to or smaller than the rate at which data is transmitted from the ECC circuit 20 to the ring buffer 5. As is to be appreciated, such arrangement of transmission rates prevents the ring buffer 5 from being depleted of data. Furthermore, such arrangement of transmission rates enables the video code buffer 10 to transmit a code request signal to the ring buffer 5 irrespective of the timing of the track jump. As previously described, such code request signal requests that data from the ring buffer 5 be transmitted to the video code buffer 10.
Therefore, the data reproducing apparatus of FIG. 7 causes the pickup 2 to track jump in accordance with the memory capacity of the ring buffer 5. As a result, overflow or underflow of the video code buffer 10 may be prevented, irrespective of the complexity or flatness of the video images recorded in the disc 1, so as to enable video images of uniform image quality to be continuously reproduced.
Although the data reproducing apparatus of FIG. 7 may perform satisfactorily when operating in a normal reproduction mode, problems may arise when such apparatus performs so-called random accessing or operates in other modes such as a mode transition. More specifically, compression-encoded picture data having an order of . . . , B -4 , B -3 , P -1 , B -2 , B -1 , I 0 , B 0 , B 1 , P 0 , . . . as shown in FIG. 10A may be rearranged as described above and as shown in FIG. 10B and recorded in the disc 1 (FIG. 7). In a normal reproduction or regeneration mode, if picture data read out from the disc 1 are decoded successively and stored in the memory bank 16, the stored decoded data can be read out from the frame memory bank 16 in the display order shown in FIG. 10A. However, when random accessing (such as, a track search, a chapter search or a time code search) or a mode transition is to be performed, an entry point is utilized. For example, such entry point may be defined at a position corresponding to I picture I 0 as shown in FIG. 10C. In this example, picture data are read out from the disc 1 in the order of I 0 , B -2 , B -1 , P 0 , B 0 , B 1 , . . . , as shown in FIG. 10C. The I picture I 0 is an intraframe predictively encoded image which can be decoded by utilizing only the I 0 picture. However, the B pictures B -2 and B -1 require P picture P -1 and I picture I 0 for decoding. Since processing begins at the entry point of the I picture I 0 , the P picture P-1 has not been read out and decoded. Accordingly, the B pictures B -2 and B -1 cannot be correctly decoded. As a result, incorrectly decoded B pictures B-2 and B-1 are supplied from the decoder 30 to the display 18 (FIG. 7B), thereby causing deformed images to be displayed thereon.
OBJECTS AND SUMMARY OF THE INVENTION
An object of the present invention is to provide a method and apparatus for reproducing encoded data such that proper images are displayed even during a mode transition, random accessing or the like.
More specifically, it is an object of the present invention to provide a method and apparatus as aforesaid wherein, when image data normally incapable of being properly decoded (such as may occur during random accessing or a mode transition) is read or detected, images are properly decoded and displayed after an intraframe predictively encoded (I) image picture and either another intraframe predictively encoded (I) image picture or an interframe predictively encoded (P) image picture are detected.
Another object of the present invention is to provide a method and apparatus as aforesaid wherein blue back images or previously stored decoded images are displayed when image data normally incapable of being properly decoded is read until properly decoded images can be displayed which occurs after the I image picture and either the second I image picture or the P image picture are detected.
A further object of the present invention is to provide a method and apparatus as aforesaid wherein video signals compression-encoded by an MPEG system and recorded along with audio signals onto a digital video disc or similar medium are reproduced.
In accordance with an aspect of the present invention, a method is provided for reproducing compressed encoded image data from a recording medium by utilizing correlation in a direction of a time axis in which the encoded image data represents a plurality of frames which correspond to at least one group of pictures (GOP) having a picture or pictures unable to be properly predictively decoded wherein each GOP includes different types of pictures including intraframe predictively (I) encoded and interframe predictively (P) encoded pictures. The method comprises the steps of: detecting the image data corresponding to a first intraframe predictively encoded (I) picture and either a second intraframe predictively encoded (I) picture or an interframe predictively encoded (P) picture; and outputting properly decoded image data after the detection of the image data corresponding to the first intraframe predictively encoded (I) picture and either the second intraframe predictively encoded (I) picture or the interframe predictively encoded (P) picture.
In accordance with another aspect of the present invention, an apparatus for reproducing compressed encoded image data is provided. The apparatus comprises a device for reading the encoded image data from a recording medium by utilizing a correlation in a time axis direction, wherein the image data represents a plurality of frames which correspond to at least one group of pictures (GOP) in which each GOP includes different types of pictures including intraframe predictively (I) encoded and interframe predictively (P) encoded pictures; and a picture type detection device for detecting the type of pictures of the read image data. The apparatus further comprises a device for decoding the read image data and for outputting the decoded image data. The decoding device is operative to properly decode and output the read image data after detection of the image data corresponding to an intraframe predictively encoded (I) picture and either another intraframe predictively encoded (I) picture or an interframe predictively encoded (P) picture when the reading device reads image data corresponding to a respective GOP having a picture or pictures normally unable to be properly predictively decoded.
In the present invention, when picture image data is read which is normally unable to be properly decoded, such picture image data is not decoded and outputted until after the detection of an I picture and either another I picture or a P picture. Upon such detection, the detected P and/or I pictures may be stored within a memory and utilized for decoding such picture image data. As a result, such picture image data may be properly decoded and displayed, thereby preventing the display of deformed images. Furthermore, previously decoded or blue back images may be displayed after picture image data is read which is normally unable to be properly decoded until such picture image may be properly decoded and outputted (which occurs after the detection of an I picture and either another I picture or a P picture). As a result, differences or incongruities in the display images during random accessing, mode switching or the like may be minimized.
The previously decoded image data, or selected portions thereof, may be stored within a memory such as a frame memory. As previously described, such stored decoded image data may be outputted when the read picture image data is unable to be properly decoded until such read picture image data may be properly decoded and outputted.
Other objects, features and advantages of the present invention will become apparent from the following detailed description of the illustrated embodiments when read in conjunction with the accompanying drawings in which corresponding components are identified by the same reference numerals.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A and 1B are diagrams illustrating an apparatus for reproducing encoded data according to an embodiment of the present invention;
FIGS. 2A to 2F are diagrams to which reference will be made in explaining writing/reading timing to and from a frame memory bank in the present reproducing apparatus;
FIGS. 3A and 3B are diagrams illustrating an apparatus for reproducing encoded data according to another embodiment of the present invention;
FIGS. 4A and 4B are diagrams illustrating an apparatus for reproducing encoded data according to still another embodiment of the present invention;
FIG. 5 is a flowchart to which reference will be made in explaining the operation of the present reproducing apparatus;
FIGS. 6A to 6D are diagrams to which reference will be made in explaining the writing/reading timing to and from a frame memory bank in the present reproducing apparatus;
FIGS. 7A and 7B are diagrams illustrating an apparatus for reproducing encoded data to which reference will be made in explaining the background of the present invention;
FIGS. 8A and 8B are diagrams respectively illustrating a structure for interframe prediction and a recording structure in accordance with a MPEG standard;
FIG. 9 is a diagram to which reference will be made in explaining a mode of recording pictures by sectors in a MPEG system; and
FIGS. 10A to 10C are diagrams of a frame structure to which reference will be made in explaining the operation of the present reproducing apparatus during normal reproduction and random accessing.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
FIG. 1 illustrates an apparatus for reproducing encoded data according to a preferred embodiment of the present invention. With the exception of a picture header detection circuit 19, a blue back signal generator 51, a switch 53 and a control section 99, the apparatus of FIG. 1 is similar to that of FIG. 7. That is, the apparatus of FIG. 1 generally includes the pickup 2, the demodulation circuit 3, the sector detection circuit 4, the ring buffer 5, the control circuit 6, the track jump judging circuit 7, the servo circuit 8, the PLL 9, the ECC 20, the video code buffer 10, the picture header detection circuit 19, the inverse variable length coding (VLC) circuit 11, the inverse quantization circuit 12, the inverse DCT circuit 13, the addition circuit 14, the motion compensation circuit 15, the frame memory 16, the blue back generator 51, the switch 53 and the control section 99 which are coupled as shown in FIG. 1.
In a manner similar to that previously described, digital data compressed by a MPEG system is recorded in tracks or sectors having a fixed length (as in FIG. 9) on the disc 1. A sector sync and a sector header may be added to a predetermined portion of each of the sectors, such as the top thereof. The disc 1 may be rotated in a predetermined rate or manner by a spindle motor (not shown). The pickup 2 produces a laser beam which is irradiated on the tracks of the optical disc 1 so as to read out the recorded data. Control for the pickup 2, such as focus control and tracking control, may be performed by the tracking and focus servo circuit 8. That is, the circuit 8 may provide a focused error signal and/or a tracking error signal to the pickup 2. Such focused and tracking error signals may be obtained from information read out from the pickup 2. The read out digital data from the pickup 2 are supplied to the demodulation circuit 3, whereupon a predetermined demodulation such as EFM-demodulation is performed. The demodulated data is supplied to the sector detection circuit 4. The read out data from the pickup 2 are further supplied to the PLL circuit 9 so as form or regenerate clock signals which are supplied to the demodulation circuit 3 and the sector detection circuit 4. Such clock signals may be utilized in controlling the timing of the processing performed by the circuits 3 and 4. From the demodulated data received from the demodulation circuit 3, the sector detection circuit 4 detects the sector sync so as to determine the boundary of the sectors and detects a sector address or the like from the sector header. An output signal representative of such detection(s) is supplied to the control circuit 6. The demodulated data is supplied by way of the sector detection circuit 4 to the ECC circuit 20, whereupon error detection and correction may be performed. The error corrected data from the ECC circuit 20 is supplied to the ring buffer 5 and is written therein in accordance with a write control signal supplied by the control circuit 6. The control circuit 6 generates the write control or write pointer (WP) signal based on the sector address for each of the sectors detected by the sector detection circuit 4 and supplies the WP signal to the ring buffer 5. Such WP signal indicates a write address wherein a sector may be written into the ring buffer 5. As a result of the WP signal, data from the ECC circuit 20 may be written into designated address locations of the ring buffer 5. The control circuit 6 further generates a read pointer (RP) signal based on a code request signal from the video code buffer 10 (in the succeeding stage of FIG. 1B) and supplies the RP signal to the ring buffer 5. Such RP signal indicates an address of data written into the ring buffer 5 which is desired to be read out. As a result, upon receiving a RP signal, data from the desired address location or position of the ring buffer 5 is read out and supplied to the video code buffer 10, whereupon such data is stored therein. Therefore, the video code buffer 10 may generate a code request signal (which requests that data from the ring buffer 5 be transmitted to the video code buffer 10) and supply such signal to the control circuit 6 whereupon, in response thereto, data is supplied from the ring buffer 5 to the video code buffer 10.
The data stored in the video code buffer are supplied to the picture header detector 19, whereupon the picture header is detected so as to determine the type of picture, that is, whether the respective picture is an I, P or B picture. As hereinafter more fully described, control of the displayed image data is provided based on the detected picture type information.
A data signal from the picture header detector 19 is supplied to the inverse VLC circuit 11, wherein inverse VLC processing is performed. Upon completing such inverse VLC processing, the inverse VLC circuit 11 supplies an output processed data signal to the inverse quantization circuit 12 and a code request signal to the video code buffer 10. In response to the received code request signal, new data may be transmitted from the video buffer to the inverse VLC circuit by way of the picture header detection circuit 19.
In a manner similar to that previously described, the inverse VLC circuit 11 may also supply the size of a quantization step to the inverse quantization circuit 12 and a motion vector information signal to the motion compensation circuit 15. The inverse quantization circuit 12 inversely quantizes the data received from the inverse VLC circuit 11 in accordance with the size of the quantization step and outputs the obtained processed signal to the inverse DCT circuit 13, whereupon inverse DCT processing is performed. An output signal from the inverse DCT circuit 13 is supplied to one input terminal of the addition circuit 14. An output from the motion compensation circuit 15 formed in accordance with the type of picture (that is, I, P or B) is supplied to another input terminal of the addition circuit 14. The addition circuit 14 adds the received signals and supplies the obtained summed signal, by way of a switch 16d, through the appropriate one of contacts A-C to one of memories 16a, 16b and 16c of the frame memory bank 16 so as to be stored therein. Stored signals from the memories 16a, 16b and 16c may be supplied to the motion compensation circuit 15. Data from the memories 16a-16c of the frame memory 16 are read out under control through contacts A-C by way of a switch 16e so as to restore the original frame order, such as to that shown in FIG. 8A. The read out data are converted by a digital-to-analog (D/A) converter 17 into analog video signals and supplied to a display 18 so as to be displayed thereon. Therefore, the control circuit 6 causes data stored in the ring buffer 5 to be supplied to the video code buffer 10 in accordance with the code request signal from the video code buffer 10. When data processing of relatively simple video images is being performed and the amount of data transmitted from the video code buffer 10 to the inverse VLC circuit 11 decreases, the amount of data transmitted from the ring buffer 5 to the video code buffer 10 may also decrease. As a result, the amount of data stored in the ring buffer 5 may increase so as to cause an overflow condition of the ring buffer 5. In other words, the amount of data written into the ring buffer 5 by use of the WP signal may surpass the amount read out therefrom by use of the RP signal. To avoid such overflow condition, the quantity of data currently stored in the ring buffer 5 may be determined or calculated by, for example, utilizing address positions of the WP and RP signals controlled by the control circuit 6. Such determination may be performed by the track jump judging circuit 7. If the amount of the data determined to be stored in the ring buffer 5 exceeds a predetermined reference value, a track jump instruction signal is generated by the track jump judging circuit 7 and supplied therefrom to the tracking servo circuit 8. As a result, the pickup 2 may move or jump from the current track to another track. Therefore, the track jump judging circuit 7 determines if the ring buffer 5 may overflow and outputs a track jump instruction signal in response to such determination so as to cause the pickup to jump. The rate at which data is transmitted from the ring buffer 5 to the video code buffer 10 may be equal to or smaller than the rate at which data is transmitted from the ECC circuit 20 to the ring buffer 5. Such arrangement of transmission rates prevents the ring buffer 5 from being depleted of data. Furthermore, such arrangement of transmission rates enables the video code buffer 10 to transmit a code request signal to the ring buffer 5 irrespective of the timing of the track jump. As previously described, such code request signal requests that data from the ring buffer 5 be transmitted to the video code buffer 10. Therefore, the data reproducing apparatus of FIG. 1 causes the pickup 2 to track jump in accordance with the memory capacity of the ring buffer 5. As a result, overflow and/or underflow of the video code buffer 10 may be prevented, irrespective of the complexity or flatness of the video images recorded in the disc 1, so as to enable video images of uniform image quality to be continuously reproduced.
Timing of the writing/reading of the decoded pictures into and from the frame memories 16a-16c of the frame memory 16 for normal reproduction will now be described with reference to FIGS. 2A-2F. For this situation, the decoded pictures are arranged in the order shown in FIG. 8B. Furthermore, assume that the P picture P -1 has already been written into the frame memory 16b.
The I picture I 0 is decoded and supplied from the addition circuit 14. The switch 16d is set to contact a so as to connect frame memory 16a to the output of the addition circuit 14. As a result, the I picture I 0 is stored in the frame memory 16a.
The picture data stored in the frame memories 16a-16c may be supplied to the motion compensation circuit 15 along with the motion vector information from the inverse VLC circuit 11 so as to form a motion prediction or compensated signal which, in turn, is supplied to the addition circuit 14 so as to be added to the output signal from the inverse DCT circuit 13. As such, the B picture B -2 may then be decoded with reference to the I picture I 0 stored in the frame memory 16a and the P picture P -1 stored in the frame memory 16b. The switch 16d is set to contact c and, as a result, the decoded B picture B -2 is stored in the frame memory 16c. Furthermore, the switch 16e is set to contact c and, as a result, the B picture B -2 stored in the frame memory 16c is supplied therefrom and displayed on the display 18.
Similarly, the B picture B -1 may be decoded with reference to the I picture I 0 stored in the frame memory 16a and the P picture P -1 stored in the frame memory 16b and then stored by way of the switch 16d into the frame memory 16c. The switch 16e is set to contact c and, as such, the B picture B -1 stored in the frame memory c is supplied therefrom and displayed on the display 18.
The P picture P 0 may then be decoded with reference to I picture I 0 stored in the frame memory 16a. The switch 16d is set to contact b so as to overwrite or store the P picture P 0 into the frame memory 16b. Furthermore, the switch 16e is set to contact a and, as such, the I picture I 0 stored in the frame memory 16a is supplied therefrom and displayed on the display 18.
The B picture B 0 may then be decoded with reference to I picture I 0 stored in the frame memory 16a and the P picture P 0 stored in the frame memory 16b. The switch 16d is set to contact c so as to store the B picture B 0 in the frame memory 16c. Further, the switch 16e is set to the contact c and, as such, the B picture B 0 is supplied therefrom and displayed on the display 18.
Thereafter, and in a similar manner, the switches 16d and 16e are successively switched at the timing shown in FIGS. 2A and 2E, respectively, so as to provide an output from the frame memory bank 16 in the order of B 1 →P 0 →B 2 →B 3 →P 1 →. . . and so forth for display on the display 18.
Therefore, by utilizing the frame memory bank in the manner previously described, the pictures may be rearranged and supplied to the display 18 in the original order shown in FIG. 8A.
The operation of the present apparatus for reproducing encoded data during special processing, such as during a mode transition, random accessing or the like, will now be explained with reference to the flowchart of FIG. 5.
As shown in step S10, when random accessing or the like is being performed, the data reproducing apparatus stops the image decoding processing. Such termination of decoding processing may be performed by the control section 99. Furthermore, the switch 53 may be set to contact e so as to couple the blue back signal generator 51 to the display 18 by way of the D/A converter 17. The blue back signal generator 51 is adapted to generate a blue back signal. As such, when the switch 53 is set to contact e, a blue back screen is displayed on the display 18 instead of an output from the frame memory bank 16.
When random accessing is performed, an entry point may be set to an I picture, such as the I picture I 0 as indicated by an arrow in FIG. 10C. In this situation, a preceding P picture P -1 is required to properly decode succeeding B pictures B -2 and B -1 . However, since the I picture I 0 is the entry point, the P picture P -1 has not been written or stored in the ring buffer 5. As a result, the B pictures B -2 and B -1 cannot be properly decoded. Accordingly, if the B pictures B -2 and B -1 are decoded without utilizing the P picture P -1 , a deformed image may be displayed. As such, the switch 53 is set to contact e so as to display a blue back screen instead of a deformed image or screen.
As a result of the above-described situation, a search instruction may be sent to the pickup driving device at step S20 to access data of another GOP which is different from that of the current GOP. Such search instruction may be generated by the control section 99 and supplied either directly or indirectly to the pickup 2. Processing then proceeds to step S30 wherein a portion(s) of the ring buffer 5 and the video code buffer 10 in which the newly accessed GOP data are to be written are cleared prior to writing such new GOP data. The new GOP data is then written into the cleared portion(s) of the ring buffer 5 and the video code buffer 10. Such data is read from the video code buffer 10 and supplied to the picture header detector 19 (FIG. 1B). The picture header detector 19 detects the type of pictures (I, P, B) corresponding to the picture data by utilizing the picture header which may be located at the top of each of the picture data.
At step S40, a search instruction or request for P and/or I pictures is supplied to the decoder 30 so as cause the same to detect such pictures. Such search request may be generated by the control section 99 and supplied to the decoder 30. Processing then proceeds to step S50 wherein a determination is made as to whether a first I picture has been detected. If an I picture has not been detected, then such determination continues. If, however, an I picture is detected at step S50, processing then proceeds to step S60 wherein a determination is made as to whether a second I picture or a P picture has been detected. If a second I picture or P picture has not been detected, then such determination continues. However, if a second I or P picture has been detected at step S60, then processing proceeds to step S70.
At step S70, the image decoding or the supplying of decoded image data is delayed by a predetermined delay time as hereinafter more fully explained. Processing then proceeds to step S80 wherein the switch 53 is switched to contact d so as to connect the frame or buffer memory 16 to the display 18 (by way of the D/A converter 17) so as to display the newly and properly decoded images.
Thus, in the situation in which the entry point is as shown in FIG. 10C, the I picture I 0 and P picture P 0 may be detected. As a result, succeeding pictures including B pictures may be correctly decoded. The timing is set at td as shown in FIG. 2.
The above-mentioned delay time of the decoder 30 will now be explained with reference to FIGS. 6A to 6D which are enlarged partial sections of FIGS. 2A and 2D-2F.
Although the timings for writing and reading shown in FIGS. 2A to 2F may indicate that some reading and writing operations are conducted simultaneously, such operations may not actually occur simultaneously and, in fact, may be nearly impossible to occur simultaneously. Instead, the reading (writing) timing may be delayed by a predetermined amount, such as by 1 field as illustrated in FIG. 6, relative to the writing (reading) timing. For example, the switch 16d may be set to contact c so as to be coupled to the frame memory 16c at timing t4 (as shown in FIG. 6A) wherein the B picture Bo is written into the frame memory 16c during a time period from the timing t4 to t5 (as shown in FIG. 6B). In this example, the switch 16e may be set to contact c so as to be coupled to the frame memory c at a timing point intermediate between t4 and t5 (as shown in FIG. 6C), whereupon the B picture Bo may be read out from the frame memory 16c and displayed (as shown in FIG. 6D). In this example, the distance between the adjacent timing points, such as t4 and t5, corresponds to 1 frame and the distance from the adjacent timing point (t5) to the intermediate point corresponds to 1 field. As such, the reading time is delayed by 1 field as compared with the writing time.
Delaying the reading time by 1 field relative to the writing time presents no difficulty. That is, since data may be continuously written into the frame memory and may be read out therefrom starting at the top or first written data, 1 field of data of a frame may be already written into the frame memory upon commencement of the reading operation. Therefore, as indicated in step S70 of FIG. 5, the decoded data are outputted from the frame memory bank 16 after being delayed by a time amount corresponding to at least 1 field.
FIG. 3 illustrates an apparatus for reproducing encoded data according to another embodiment of the present invention. As shown therein, with the exception that a frame memory 52 and a switch 54 replaces the blue back signal generator 51 and the switch 53, the apparatus of FIG. 3 is similar to that of FIG. 1. Accordingly, only these differences between the apparatus of FIG. 3 and that of FIG. 1 will be described herein.
The frame memory 52 is adapted to receive and store therein decoded image data from the frame memory bank 16. The switch 54 enables either the decoded image data from the frame memory bank 16 or the stored image data from the frame memory 52 to be supplied to the display 18. More specifically, and in a manner similar to that of the blue back signal generator 51 and switch 53 of FIG. 1, the switch 54 is (i) set to contact F so as to supply the decoded image signals from the frame memory bank 16 to the display 18 when such decoded signals are properly decoded and (ii) set to contact G to supply the stored image signals from the frame memory 52 to the display 18 when properly decoded signals can not be supplied from the frame memory bank 16 until correct images may be provided from the decoder 30. The frame memory 52 may be coupled to the frame memory bank 16 in a cascade arrangement inside the decoder 30 or outside the decoder.
FIG. 4 illustrates an apparatus for reproducing encoded data according to another embodiment of the present invention. As shown therein, with the exception that a contact D replaces the frame memory 52 and switch 54 of FIG. 3 or the blue back signal generator 51 and switch 53 of FIG. 1, the apparatus of FIG. 4 is similar to that of either FIGS. 1 and 3. Accordingly, only these differences between the apparatus of FIG. 4 and those of FIGS. 1 and 3 will be described herein.
The switch 16d may be set to contact D during the period in which data is not properly decoded in the decoder 30 and is outputted from the addition circuit 14. As a result, such arrangement causes the improperly decoded data to be skipped. During the period in which data is properly decoded, the switch 16d operates in a normal manner. Alternatively, instead of the contact D for the switch 16d, a similar contact D may be arranged and utilized for the switch 16e.
Furthermore, since the picture data written into the frame memory bank 16 after access to the new GOP and until the picture data is properly decoded represent an I picture and either another I or a P picture, only two of the frame memories 16a-16c are utilized. Accordingly, one of the frame memories 16a-16c may not be utilized. As such, images previously decoded and written into the one remaining frame memory may be outputted therefrom. Thus, in this situation, already decoded images may be displayed until correctly decoded data are obtained without utilizing a new frame memory.
Therefore, during special processing such as a mode transition, random accessing and the like, image data may not be decoded and outputted until after the detection of an I picture and either another I or a P picture. The detected P and/or I pictures may be utilized to properly decode the image data, whereafter the properly decoded image data is supplied to the display. As a result, deformed images may be prevented from being displayed. Further, since previously decoded images or a blue back image may be displayed during the time period in which properly decoded images are unavailable, a sense of incongruity in the displayed images may not be observed during a mode transition, random accessing or the like.
The present invention is not limited to the above-described situations, but may be applied to a number of other situations. For example, consider a situation wherein an error which is difficult, if not impossible, to correct has been detected. The present invention may be utilized in this example to reproduce data by jumping to a neighboring GOP.
Although preferred embodiments of the present invention and modifications thereof have been described in detail herein, it is to be understood that this invention is not limited to these embodiments and modifications, and that other modifications and variations may be effected by one skilled in the art without departing from the spirit and scope of the invention as defined by the appended claims.
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A method and apparatus for reproducing data compressed in accordance with a motion picture experts group (MPEG) standard and recorded on a recording medium. The data represents a plurality of frames which correspond to a plurality of groups of pictures (GOPs), in which each of the GOPs includes different types of pictures including intraframe predictively (I) encoded and interframe predictively (P) encoded pictures. The compressed data is read from the recording medium, and the type of pictures corresponding to the read data is determined. The read image data is decoded and supplied to a display device. When special processing (such as, random accessing) is performed, image data may not be properly decoded during an initial period. During this time period, an auxiliary signal may be supplied to the display device. Such supply of the auxiliary signal continues until image data corresponding to an intraframe predictively encoded (I) picture and either another intraframe predictively encoded (I) picture or an interframe predictively encoded (P) picture are detected, whereupon the respective image data is properly decoded by utilizing the image data corresponding to the detected P and/or I pictures and supplied to the display device instead of the auxiliary signal.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates to the field of measurement technology. More specifically, the invention relates to a method and apparatus for digitizing electromagnetic radiation measurements by a high-resolution control of camera shutter speed.
[0003] 2. Description of the Related Art
[0004] In electromagnetic radiation measuring instruments with built-in electromagnetic radiation source the electromagnetic radiation level is normally kept at a constant level and is turned on and off according to the process performed by the instrument. An electromagnetic radiation sensitive device in the instrument is usually adjusted until it is able to properly detect the amount of electromagnetic radiation from a test and/or reference object. Other imaging systems, not fitted with an electromagnetic radiation source, are adjusted to the ambient electromagnetic radiation level. An example is the photographic (film) camera. In order to expose the film correctly the shutter speed and lens aperture are adjusted, usually after measuring the electromagnetic radiation (usually visible light) from the test object with an electromagnetic radiation meter. Digital cameras are also constructed to be able to measure and use the ambient light. For these cameras the light meter is usually the electromagnetic radiation sensitive image chip itself. Digital cameras normally contain an electronic shutter, which is used to adjust the amount of electromagnetic radiation recorded.
[0005] Problem to be Solved by the Invention
[0006] Inexpensive digital cameras, like those used as web-cameras, are normally not used in precision electromagnetic radiation measurement instruments. They tend to have limited output resolution range. In addition the signal output tends to be a non-linear function of the received electromagnetic radiation intensity.
[0007] U.S. patent application Ser. No. 09/952,382, by the same inventor as the present application, solves the problem with non-linear electromagnetic radiation sources by a method and system that controls the intensity of the electromagnetic radiation source to achieve a constant output from the electromagnetic radiation sensitive device, and this application is incorporated herein by reference.
[0008] However, the measuring range and the measurement accuracy of such cameras mentioned above can be improved by a high-resolution control of the shutter speed. Nearly all cameras, for example those used for digital video, works in a similar way. The pixels in each line of the camera-chip are charged to a given voltage at a time T 0 . After charging is finished the electromagnetic radiation quanta, absorbed by the pixels, will lead to an electric current that de-charge the pixels. The more electromagnetic radiation the faster the discharge will be. After a time T 1 (the shutter speed) the charge (or voltage) of the pixels in a line is transferred to an output circuit and digitized. Normally the T 1 timing is set as a given number of line periods.
[0009] The line period time is usually 64 μs in a standard PAL TV image for example, but in most cameras the shutter speed can electronically be adjusted down to a few μs. The shortest time is obtained by charging the line-pixels one line before readout. The next exposure step is obtained by adding the time of one line to the delay, thereby increasing the exposure time by 100%. However, if the time between lines can electronically be adjusted with a small amount, say Δt=50 ns, a precise and flexible intra-line exposure time can be introduced in the camera thereby permitting use of the camera for example for exposure until a fixed target value is obtained from the pixels with a resolution determined by the Δt time.
[0010] Means for Solving the Problem
[0011] The invention solves the aforementioned problem by using an Electromagnetic Radiation Sensitive Device (ERSD), such as for example a camera system containing a CMOS- or a CCD-image chip, to perform precise measurements by digitally controlling the shutter speed of the CCD camera chip (CMOS: Complementary Metal-Oxide Semiconductor; CCD Charge Coupled Device). A constant output value is obtained from the ERSD such that any non-linearity and range limitation of the ERSD output is circumvented. The measurement methods and system are applied to chemical tests and analytes, which are used for diagnostic purposes. The method can be used to measure reflectance, transmittance, fluorescence and turbidity in accordance with U.S. patent application Ser. No.: 09/952,382.
[0012] These and other objects and features of the invention are provided by a method for control of the shutter speed, a system using said method, and a search-method to obtain the measurement result quickly is presented.
BRIEF SUMMARY OF THE INVENTION
[0013] The present invention comprises a method for digitizing electromagnetic radiation to recorded from an illuminated test object by controlling the shutter speed. The electromagnetic radiation from the test object is recorded. The shutter speed of the camera chip is varied until a requested Target output from the ERSD is obtained. If the test object is changed, the amount of electromagnetic radiation from it will normally also change. The shutter speed is then changed until the ERSD output again is equal, or nearly equal to the Target value. The necessary adjustment of the value for the shutter speed controller is used to compute the amount of electromagnetic radiation from each test object. Thus the effect of limited range and non-linearity of an ERSD can be circumvented.
[0014] The method of digitizing electromagnetic radiation levels by successive approximation to measure an electromagnetic radiation value, comprises:
[0015] Identifying an output target value of an electromagnetic radiation sensitive device receiving electromagnetic radiation signals modified by a test object;
[0016] Defining an initial step value of an analog to digital converter (ADC) connected to a part of the electromagnetic radiation sensitive device;
[0017] Setting the initial step value to be the value of the Δt shutter time controlling a shutter speeds wherein the shutter settings has an N bit resolution;
[0018] Repeating one or more shutter tine adjustments and corresponding Δt time shutter speeds based on a relationship between the shutter value and the ADC value of the output target value for up to N−1 iterations while using corresponding Δt time adjustments until the ADC value is equal to the output target value when the adjustments are completed; and
[0019] Identifying the final shutter value (final corresponding Δt time adjustment value) as a measure of the value of the electromagnetic radiation signals.
[0020] For example, with a shutter speed adjustment step value of Δt=50 ns, a pixel line exposure time of 64 μs per line (shutter speed), the pixel line will be divided into 1280 exposures of 50 ns each, which will provide an increase of the total resolution of the image from the electromagnetic radiation sensitive device by aproximately 10 bits.
[0021] The present invention furthermore disclose a method of digitizing electromagnetic radiation measurements by controlling a shutter speed, to obtain a constant or near constant signal from the electromagnetic radiation sensitive device, the method comprising:
[0022] Illuminating an illumination region by a plurality of electromagnetic radiation signals;
[0023] Modifying the plurality of electromagnetic radiation signals;
[0024] Recording the plurality of modified electromagnetic radiation signals;
[0025] Transmitting an output signal corresponding to the plurality of modified electromagnetic radiation signals; and
[0026] Calculating the Δt adjustments of shutter speed based on the output signal, such that the output signal is constant.
[0027] The present invention also comprises a system for digitizing electromagnetic radiation measurements by controlling a shutter speed, to obtain a constant or near constant signal from said electromagnetic radiation sensitive device. The system comprises:
[0028] An electromagnetic radiation source illuminating an illumination region, having a test object, by a plurality of electromagnetic radiation signals;
[0029] An electromagnetic radiation sensitive device configured to record the plurality of electromagnetic radiation signals generally modified by the test object in the illumination region and transmit an output signal corresponding to the modified plurality of electromagnetic radiation signals;
[0030] A data processor system configured to receive the output signal and generate a controlling signal; and
[0031] A Δt shutter speed controller, receivable connected to the data processor system via the controlling signal, the Δt shutter speed controller controlling the operation of the shutter, whereby the received electromagnetic radiation signals are adjustably controllable such that said output signal is constant.
[0032] In an alternative embodiment, the system comprises:
[0033] A data processor system configured to generate a controlling signal;
[0034] A Δt shutter speed controller responsive to the controlling signal;
[0035] An electronic shutter responsive to the Δt shutter speed controller;
[0036] An illumination region, including a test object, illuminated by the electromagnetic radiation source; and
[0037] An electromagnetic radiation sensitive device, configured to image the electromagnetic radiation modified by the test object, and communicate an output signal representative of the modified electromagnetic radiation to the data processor system, whereby the modified electromagnetic radiation signal is adjustably controllable such that the output signal is constant.
[0038] The method and apparatus of the present invention can be used to determine the characteristics of an unknown electromagnetic radiation source. By using a known reference source and removing the Target object from the system, the system be calibrated with this known source permitting an unknown source to be identified after replacing the known source with the unknown source in the system.
[0039] The present invention also comprises a method for controlling a shutter speed in a camera-chip, the method comprising;
[0040] A counter is reset and the clock of the camera-chip is halted when a pixel line has finished being exposed (shutter speed time).
[0041] The counter counts the clock pulses and when the counter reaches a predefined value, the halting of the camera clock is removed and the camera-chip is again clocked until the next pixel line has been exposed.
[0042] The present invention also includes a device performing the above-mentioned method for controlling the shutter speed. The functional blocks and their interactions of said device are depicted in FIG. 3.
[0043] Electromagnetic radiation from the test object is received by an ERSD, for example a digital camera, and the Analog-to-Digital output Converter (ADC) of the camera is connected to the microprocessor system. The computer system can then adjust the Δt shutter time until a given Target value output from the ERSD is obtained by comparing the received digitized electromagnetic radiation values, and by comparing with the target value, iterate the Δt dime shutter speed until the target value is reached. The procedure can be performed by using a single picture element pixel) in the camera image of the test object or a group of pixels. Reflected, transmitted, re-transmitted (as for fluorescence) and/or diffused electromagnetic radiation from the test object can be measured by this method.
[0044] Shutter speed adjustments corresponding to Δt adjustments to obtain the Target value are done by a successive approximation search-method. The number of shutter speed adjustment steps in this method will then define the resolution (number of bits) in the answer. The number of bits is also equal to the number of shutter speed settings and subsequent readings of ADC values. However, the search can be executed faster: By initially calibrating the system set-up (with a Reference test object), a faster search can be performed by doing a fast search in the calibration table, combined with necessary numbers of image capture.
BRIEF DESCRIPTION OF THE DRAWINGS
[0045] [0045]FIG. 1 illustrates the system set-up according to an embodiment of the invention, using the method in accordance with the invention. The system uses a microprocessor system to control the shutter speed of the camera. The electromagnetic radiation source illuminates a test object. An Electromagnetic Radiation Sensitive Device receives electromagnetic radiation from the test object. The output from the device is received by the processor system.
[0046] [0046]FIG. 2 illustrates an example of how the analog output of an Electromagnetic Radiation Sensitive Device can be digitized.
[0047] [0047]FIG. 3 shows the control device for camera pixel exposure control.
[0048] FIGS. 4 - 6 are flowcharts illustrating the successive approximation method (SAM) applied for digitization of electromagnetic radiation levels using Δt time shutter speed iterations, FIG. 4 illustrating a single pixel SAM, FIG. 5 illustrating a meta-pixel SAM, FIG. 6 illustrating a fast meta-pixel SAM.
DETAILED DESCRIPTION OF THE INVENTION
[0049] Referring now to FIGS. 1 - 6 , the system according to an embodiment of the present invention comprises:
[0050] An electromagnetic radiation source 60 (e.g. LEDs of different colors);
[0051] A At shutter speed controller 20 ;
[0052] An electromagnetic radiation sensitive device (ERSD) 30 (e.g. digital or analog camera), and an ERSD shutter 10 ;
[0053] An output level detector 40 ;
[0054] A data processor system 50 ; and
[0055] An illumination region (where the test object is disposed).
[0056] The invented method of electromagnetic radiation measurement may be used in the system in accordance with the invention shown in FIG. 1. The system comprises a closed chain of the following functional units:
[0057] 1. A processor (computer) 50 that controls the shutter speed device 20 (see thick arrow in FIG. 1).
[0058] 2. The output of the shutter speed controls the Δt shutter speed device 10 .
[0059] 3. The electromagnetic radiation source illuminates a test object disposed in an illumination region 60 .
[0060] 4. An Electromagnetic Radiation Sensitive Device (ERSD) 30 receives modified (e.g. reflected, transmitted, diffused, etc.) electromagnetic radiation from the test object.
[0061] 5. The ERSD output is digitized if the output is an analog signal, and
[0062] 6. The digitized ERSD output is read by the processor system 50 (see thick arrow in FIG. 1).
[0063] Referring now to FIG. 3 the shutter speed controller comprises the following functional blocks and operations:
[0064] 1. The horizontal sync. pulse resets the Counter 100 .
[0065] 2. When the Counter 100 is reset, the camera 101 input clocks 102 is halted (by the Stop signal) in the Gate 103 .
[0066] 3. The Counter 100 starts counting clock 102 pulses.
[0067] 4. The Comparator 104 detects the event of the Counter 100 reaching the count value N, placed in the Latch 105 by the Controller 106 .
[0068] 5. The Stop signal is removed and clocking of the camera 101 continues until the next hor. sync. pulse.
[0069] [0069] 6 . The loop 1 - 5 is then repeated.
[0070] By this system, the shutter speed can be adjusted to obtain a constant Target value from the ERSD. The setting of a Δt shutter speed will vary for varying test objects and is used as a measure for the electromagnetic radiation received from the test object by the ERSD.
[0071] Spectral information of the electromagnetic radiation from the test object can be obtained by either using electromagnetic radiation sources with different spectral emission or filtering a broadband electromagnetic radiation source before the electromagnetic radiation reaches the (broad-band) ERSD. LED colors can include the visual spectrum, as well as the Near Oared and the Near Ultra Violet spectral range.
[0072] The specific units of an embodiment of the system according to the invention will now be described in further detail:
[0073] 1. The processor 50 is able to control the shutter speed device 20 by the following method when the camera chip in use issues a horizontal synchronization signal whenever the camera has finished an exposure of a line of pixels (shutter speed).
[0074] a) The horizontal synchronization signal resets a counter register to zero.
[0075] b) When the counter register is reset the camera input clock is halted (by a Stop signal).
[0076] c) The counter register is incremented with the rate of the camera clock pulses.
[0077] d) A comparison detects tie event of the counter register reaching the count value N, said value N is placed in a register by the processor.
[0078] e) The Stop signal is removed when this occurs and clocking of the camera chip continues until the next horizontal synchronization signal.
[0079] f) The loop a) to e) is then repeated.
[0080] The aforementioned steps of the method for adjusting the shutter speed can preferably be implemented in an ASIC (Application Specific Integrated Circuit) circuit, programmable logic arrays and similar devices, etc., which has an internal set of functional blocks and interconnections as shown in FIG. 3.
[0081] 2. The electromagnetic radiation source 60 may be any one of
[0082] a) Electromagnetic radiation emitting diodes;
[0083] b) Incandescent lamps;
[0084] c) Gas discharge lamps;
[0085] d) Lasers;
[0086] e) Masers;
[0087] f) X-ray sources; or
[0088] g) γ-ray sources, etc.
[0089] The electromagnetic radiation from the electromagnetic radiation source can be spectrally filtered if necessary.
[0090] 3. A test object generally disposed in an illumination region receives electromagnetic radiation from the electromagnetic radiation source 10 . Modified (e.g. reflected, transmitted re-transmitted or diffused) electromagnetic radiation from the test object is received by the Electromagnetic Radiation Sensitive Device (ERSD) 30 .
[0091] 4. The ERSD 30 generally comprises an electromagnetic radiation detector and necessary support circuits and optics. Possible electromagnetic radiation detectors comprise:
[0092] a) A CCD camera chip
[0093] b) A CMOS camera chip
[0094] c) All pixel line by pixel line exposable electromagnetic sensitive devices
[0095] 5. The processor system 50 is able to read the output from the ERSD 30 . If the output is an analog signal (voltage or current), this is transformed into a digital signal. This can be done in one of several ways:
[0096] a) A comparator can be used, as illustrated in FIG. 2.
[0097] b) The voltage or current can be converted into pulses where the pulse rate increases (or decreases) when the voltage or current increases. This can be done by using a voltage (or current)-to-frequency converter. The processor can then measure the time between the pulses (by using its internal clock) and thus digitize the ERSD output signal.
[0098] c) An Analog-to-Digital Converter (ADC) can be used.
[0099] 6. The processor system 50 receives the output signal from the ERSD 30 .
[0100] a) If the digitizing method illustrated in FIG. 2 is applied, the following procedure may be used:
[0101] V ref is adjusted to a suitable output Target value inside the ERSD output range.
[0102] The processor 50 adjusts the output of the shutter speed controller 20 according to the Successive Approximation Method (SAM) described below.
[0103] b) If a camera 30 with digital output is applied, the following procedure may be used:
[0104] A digital Target output value T is selected at a suitable value inside the ERSD output range.
[0105] The processor 50 adjusts a Δt shutter speed according to the Successive Approximation Method (SAM) described below.
[0106] The fastest way of searching for the electromagnetic radiation level of an unspecified test object is by using the binary Successive Approximation Method (SAM). We will use the SAM when:
[0107] a) The relationship between input and output is unknown, or
[0108] b) The relationship between input and output is linear, or
[0109] c) The relationship between input and output is non-linear but monotonous increasing or decreasing. The SAM procedure may be described as follows (cf. flowcharts in FIGS. 4 and 5):
[0110] 1. An output Target value T of the ERSD is defined. If a digital camera system is used T can be any output value of the output range for the system, but preferably a value in the middle of its range. A single pixel output, or the average of a set of pixel outputs can be used as Target value. See details below. If an ERSD with analogue output, connected as shown in FIG. 2, is used the V ref is adjusted to a suitable value (preferably in the middle of the ERSD response range).
[0111] 2. An initial Step Value (SV=Δt) of the shutter speed is defined as the maximum value +1 of the shutter speed divided by two. If the shutter speed has 10-bit resolution its maximum value will be 1023 and the initial SV will be 512.
[0112] 3. The initial output of the shutter speed is set equal to SV and a Δt time shutter speed value corresponding to SV is transferred to the shutter speed control device.
[0113] 4. The steps below will be repeated N−1 times. N is the number of binary digits of the shutter speed. (If the shutter speed has 10 bit resolution N will be equal to 10).
[0114] The following loop is executed:
[0115] 5. The current Δt time shutter speed corresponding to the input shutter speed value is transferred to the shutter speed controller 20 and the current shutter speed value output is used as the V ref and the resulting output from the ADC is measured by comparing.
[0116] 6. If the ADC value is higher than T then:
[0117] The SV is divided by 2
[0118] The new SV value is subtracted from the current shutter speed output value and corresponding Δt time shutter speed is transferred.
[0119] The loop continues (N−1 times)
[0120] If the ADC value is lower than T then:
[0121] The SV is divided by 2
[0122] The new SV value is added to the current shutter speed output value and the corresponding Δt time shutter speed is transferred.
[0123] The loop continues (N−1 times)
[0124] If the ADC value is equal to T then (not used if the ADC has one bit output range):
[0125] The loop is terminated.
[0126] Loop end here
[0127] 7. After the loop is terminated the current (final) setting of the shutter speed is recorded and used as a measure of the electromagnetic radiation-value.
[0128] Each time the steps 5 and 6 are repeated the accuracy is improved by one binary digit (bit). To obtain an accuracy of {fraction (1/1024)} in the saved illuminance value a maximum of ten illuminance adjustments and image recordings have to be made. Most digital camera circuits can record around 10 images per second or more, thus enabling us to obtain an accurate electromagnetic radiation measurement in about one second or less.
[0129] The best mode embodiment of the invention comprises the system depicted in FIG. 1 where the shutter time adjustments are performed with an electronic device implementation of the steps and functional blocks depicted in FIG. 2.
[0130] Target Output Value Based on more than One Pixel
[0131] More than one pixel can be used to define a target output value from the camera. By letting the summed or averaged output value from a group of pixels represent a “meta-pixel” the same Target search procedure can be applied upon this “Meta-pixel” as on a single pixel. If the test object is a relatively homogenous surface, like a smooth white or colored area, the pixel values of the ADC camera output from this area will only vary within a limited range. If the pixel value range is narrow i.e. within a near-linear part of the response function the images recorded from the search-procedure described above can be used to adjust each pixel value to compute the shutter speed-value that yields the Target value. This can be done by linear approximation.
[0132] If the pixel value range is larger, they should be divided in subgroups, each lying within a near-linear part of the response function. The average of the main sub-group should be used to define the Target value in the search-procedure described above. For increased accuracy extra images with target values for each group can be recorded.
[0133] (Note: Even if the surface of the test object is absolute homogenous the pixel outputs from the test object image will vary, due to unavoidable irregularities in camera pixel sizes, homogeneity of illumination, camera optics, etc.)
[0134] Since the “meta-pixel” is an average of many pixels its numeric resolution better than that of the ADC output for a single pixel. Or opposite: If the ADC output is 10 bits of higher we can only save the 8 most significant bits and will still obtain high accuracy for the “meta-pixel” value.
[0135] Calibration
[0136] The relationship between the ADC outputs of the camera and the shutter speed settings of shutter speed can be obtained as follows: A Reference Test Object is used, preferably a white surface if reflectance is measured, or a clear object if transmittance or electromagnetic radiation scattering is measured. For each ADC value the corresponding shutter speed value is recorded in a calibration-table. (If the transfer function is a smooth curve only a limited number of measurements have to be made to establish the calibration table).
[0137] Depending on the setting of camera control parameters the relationship may be similar to the function for electromagnetic radiation from a white object presented in FIG. 3. If the relationship between shutter speed-value and electromagnetic radiation intensity is close to linear (or linear) this calibration curve can be later used to compute the reflectance for all test object (inside the measurement-range).
[0138] Any suitable ERSD device used in the present invention will, in addition to the target value output, include a background signal due to environmental conditions such as temperature and physical effects in the device it self as for example dark-currents etc. The measured target values have to be compensated for this background effect to maintain the high resolution of the measurements. This can be done by for example recording an image without the target object in the system thereby subtracting said recorded image from the images of the target object. The same effect can be achieved by taking a succession of images and then determine the background signal from this series of images.
[0139] Speeding up the Successive Appmoximation Method (cf. FIG. 6) (Note: This Method Cannot be used for a Single-Bit ADC True. Like the One Shown in FIG. 2).
[0140] When the relationship between shutter speed input and ADC output is calibrated for an illuminated reference object (usually a white object) then the calibration table can be used to obtain a result quickly by the processor system. Reading from tables in the processor memory is normally much faster than adjusting the shutter speed and subsequently recording the output from the ERSD.
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This invention relates to a method, device and apparatus for digitizing electromagnetic radiation measurements by control of camera shutter speed. The invention uses an Electromagnetic Radiation Sensitive Device (ERSD), such as for example a camera system containing a CMOS- or a CCD-image chip, to perform precise measurements by high-resolution digital control of the shutter speed. A constant output value is obtained from the ERSD such that any non-linearity and range limitation of the ERSD output is circumvented. The measurement methods and system are applied to chemical tests and analytes, which are used for diagnostic purposes. The method can be used to measure reflectance, transmittance, fluorescence and turbidity.
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BACKGROUND OF THE INVENTION
[0001] The subject matter disclosed herein relates to gas turbines and more particularly to optical flame holding and flashback detection.
[0002] In a gas turbine, fuel is burned with compressed air, produced by a compressor, in one or more combustors having one or more fuel nozzles configured to provide a premixing of fuel and air in a premixing zone located upstream of a burning zone (main combustion zone). Damage can quickly occur to the combustor when flame holding or flashback occurs in its fuel/air premixing passages. During desirable operation of the combustor, the premixed fuel and air combust downstream of the fuel/air premixing passages in the combustion zone. During flame holding or flashback, the fuel and air mixture in the premixing passages combusts. The flashback condition generally occurs when a flame travels upstream from the main burning zone into the premixing zone, which is not intended to sustain combustion reactions. As a consequence, serious damage may occur to the combustion system, potentially resulting in a catastrophic malfunction of the system and a concomitant substantial financial loss.
[0003] The use of ion-sensing detectors and other devices, such as thermocouples and fiber optics, to detect flashback is well known. However, these detectors simply detect the presence of a flame and do not discriminate the type of flame within the combustion system.
[0004] It is therefore desirable to provide a combustor with a flame detection system configured to discriminate flame types and arrest the flame holding or flashback event.
BRIEF DESCRIPTION OF THE INVENTION
[0005] According to one aspect of the invention, a combustor is provided. The combustor includes a combustor housing defining a combustion chamber having combustion zones and flame detectors disposed on the combustor housing and in optical communication with the combustion chamber. The flame detectors are configured to detect an optical property related to one or more of the combustion zones.
[0006] According to another aspect of the invention, a gas turbine is provided. The gas turbine includes a compressor configured to compress ambient air. The gas turbine further includes a combustor in flow communication with the compressor, the combustor being configured to receive compressed air from the compressor assembly and to combust a fuel stream to generate a combustor exit gas stream. The combustor includes a combustor housing defining a combustion chamber having combustion zones and flame detectors disposed on the combustor housing and in optical communication with the combustion chamber. The flame detectors are configured to detect an optical property related to one or more of the combustion zones.
[0007] According to yet another aspect of the invention, a method of operating a combustor is provided. The method includes introducing fuel and air within a premixing device, forming a gaseous pre-mix, and combusting the gaseous pre-mix in a combustion chamber, thereby generating a flame type. The method further includes monitoring the flame type to determine the presence of flame holding within the combustion chamber.
[0008] These and other advantages and features will become more apparent from the following description taken in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The subject matter which is regarded as the invention is particularly pointed out and distinctly claimed in the claims at the conclusion of the specification. The foregoing and other features, and advantages of the invention are apparent from the following detailed description taken in conjunction with the accompanying drawings in which:
[0010] FIG. 1 is a diagrammatical illustration of a gas turbine system in accordance with exemplary embodiments.
[0011] FIG. 2 is a diagrammatical illustration of a combustor having a premixing device employed in the gas turbine system of FIG. 1 in accordance with exemplary embodiments.
[0012] FIG. 3 diagrammatically illustrates a gas turbine 100 in accordance with exemplary embodiments.
[0013] FIG. 4 illustrates a plot of relative spectral response of the flame detectors 180 versus wavelength of the flame type.
[0014] FIG. 5 illustrates a plot of relative spectral response of the flame detectors 180 versus wavelength of the flame type.
[0015] FIG. 6 illustrates a flow chart of a method for operating a combustor in accordance with exemplary embodiments.
[0016] FIG. 7 illustrates a front view of the combustor can of FIG. 3 .
[0017] The detailed description explains embodiments of the invention, together with advantages and features, by way of example with reference to the drawings.
DETAILED DESCRIPTION
[0018] In exemplary embodiments, the systems and methods described herein detect flame holding/flashback in gas turbine combustors to inhibit damage to the engine hardware and for any approach to actively stop the flame holding event. Optical flame detection is implemented in Dry-Low NOx (DLN) units using a detector with a response to ultraviolet emission lines. The SiC solid state flame detector more recently utilized has a responsivity envelope that includes emission sensitivity to wavelengths between about 200 nm and 430 nm. This in contrast to a Geiger Muller tube that responds to only the shorter wavelength region below about 250 nm. The most intense emission at about 300 nm is produced by the excited OH molecule which is a direct product of the combustion process. Because of the SiC photodiodes responsivity characteristics it is not very sensitive to combustor hot wall blackbody radiation or 350 to 450 nm radiation from soot. Excessive radiation from soot is an indication of a diffusion flame in contrast to a flame resulting from a premixing of air and fuel prior to combustion (a premixed flame). When combustion occurs, as indicated by an optical detection of emission lines, the gas turbine continues to operate with expected optimum operating conditions. Premixed flames are desirable because they allow for lower firing temperatures, which for instance are desirable for reducing undesirable emissions into the atmosphere using DLN combustors. If a flame holding/flashback event occurs, as indicated by an optical detection of soot emission lines, the flame detection system can take action such as reducing or eliminating fuel flow into the combustor to prevent damage to the gas turbine. As such, during a flame holding/flashback event in the fuel nozzle additional photoemissions from thermal soot emissions or other richer flame species are measured. While current flame detectors have a broad enough response curve to detect a diffusion flame a two or multi-color detection system that can separately detect the presence of combustion (e.g. OH band emission) and soot emissions would enable the discrimination of flame types. In further exemplary embodiments, the flame detectors described herein can detect thermal emissions from the fuel nozzles. By monitoring the thermal emissions from the fuel nozzles, the system can determine if a flame is within the fuel nozzle because the thermal emissions would indicate a higher temperature than would be expected in the fuel nozzles. For example, thermal emissions indicating flame holding/flashback could be measured at the swirler vanes, burner tube, or diffusion tip of the fuel nozzles or other downstream components. As such, increased photoemissions from a flame holding/flashback event are measured in the combustor to determine if flame holding/flashback is occurring within the fuel nozzle using one or multiple color detectors. An increase in thermal emissions from the fuel nozzle components could be implemented to detect flame holding within the fuel nozzle.
[0019] As discussed in detail herein, exemplary embodiments function to detect enhance flame holding/flashback in combustors such as in combustors employed in gas turbines. In particular, exemplary embodiments include a flame detection system and method configured to detect flame holding/flashback in a gas turbine combustion chamber and to take appropriate action to prevent damage to the gas turbine. Turning now to the drawings and referring first to FIG. 1 a gas turbine 10 having a combustor 12 is illustrated. The gas turbine 10 includes a compressor 14 configured to compress ambient air 16 . The combustor 12 is in flow communication with the compressor 14 and is configured to receive compressed air 18 from the compressor 14 and to combust a fuel stream 20 to generate a combustor exit gas stream 22 . In addition, the gas turbine 10 includes a turbine 24 located downstream of the combustor 12 . The turbine 24 is configured to expand the combustor exit gas stream 22 to drive an external load such as a generator 26 . In the illustrated embodiment, the compressor 14 is driven by the power generated by the turbine 24 via a shaft 28 . The combustor 12 employs a flame detection device configured to detect flame holding/flashback in a gas turbine combustion chamber and to take appropriate action to prevent damage to the gas turbine 10 .
[0020] FIG. 2 is a diagrammatical illustration of an exemplary configuration 40 of the combustor 12 having a flame detection device 60 employed in the gas turbine system 10 of FIG. 1 in accordance with exemplary embodiments. As illustrated, the combustor 40 includes the premixing device 42 configured to mix fuel 20 and air 18 to form a gaseous pre-mix 44 . Further, the combustor 40 includes a combustion chamber 46 configured to combust the pre-mix fuel 44 to form the combustor exit gas stream 22 . Further, the combustor exit gas stream 22 is directed to a downstream process 48 such as to the turbine 24 (see FIG. 1 ) for driving the external load 26 (see FIG. 1 ). The premixing device 42 can further include a plurality of swirler vanes 50 configured to provide a swirl movement to the fuel 20 and/or air 18 to facilitate mixing of the fuel 20 and air 18 . In exemplary embodiments, the combustor 40 further includes the flame detection device 60 , which can be coupled to and in communication with either or both of the premixing device 42 and the combustion chamber 46 . It is appreciated that when the flame detection device 60 is configured to detect soot production and diffusion flames, as evidenced by flames having particular optical properties within the combustion chamber, the flame detection device is coupled to and in optical communication with the combustion chamber 46 . However, if the flame detection device 60 is configured to detect thermal emissions from fuel nozzle hardware surface, then the flame detection device 60 is coupled to and in optical communication with the pre-mixing device, proximate the fuel nozzle hardware under detection. The combustor 40 can further include a control unit 65 coupled to the flame detection 60 . The control unit 65 is configured to receive signals from the flame detection that correspond to the flame type present in the combustion chamber 46 . The control unit 65 is further in communication with the source of the air 18 and the fuel 20 . As further described herein, if the control unit 65 receives signals that indicate there is flame holding/flashback in the combustion chamber 46 , the control unit 65 can take appropriate action to mitigate damage to the gas turbine. The appropriate action that the control unit 65 can take includes ceasing fuel and air flow to the combustion chamber or some modification of the air and fuel flow to reduce or eliminate the flame holding/flashback.
[0021] FIG. 3 diagrammatically illustrates an example of a gas turbine 100 including a plurality of flame detectors 180 in accordance with exemplary embodiments. The example of the gas turbine illustrates the flame detectors coupled to and in optical communication with a combustion chamber 140 of the gas turbine and configured to detect the wavelengths of several flame types within the combustion chamber 140 .
[0022] Similar to FIG. 1 , the gas turbine 100 includes a compressor 110 configured to compress ambient air. One or more combustor cans 120 are in flow communication with the compressor 110 via a diffuser 150 . The combustor cans 120 are configured to receive compressed air 115 from the compressor 110 and to combust a fuel stream from fuel nozzles 160 to generate a combustor exit gas stream 165 that travels through a combustion chamber 140 to a turbine 130 . The turbine 130 is configured to expand the combustor exit gas stream 165 to drive an external load. The combustor cans 120 include an external housing 170 , which includes a series of flame detectors 180 affixed to the housing 170 . The flame detectors 180 are coupled to and in optical communication with the combustion chamber 140 and the combustor exit gas stream 165 .
[0023] In exemplary embodiments, the series of flame detectors 180 are each configured to detect a particular wavelength. As such, the combustor cans 120 include multiple flame detectors configured to detect photoemissions at multiple wavelengths. For example, the combustor cans 120 may each include three flame detectors 180 , as illustrated. One detector includes a spectral response that peaks closest to the wavelength of a hydrocarbon flame (approximately 306 nm). A second detector can include a spectral response that peaks closes to the wavelength of soot from diffusion (approximately 380 nm). A third detector can include a spectral response that peaks closest to the wavelength of soot from pre-mixed fuel and non-pre-mixed fuel in an undesirable combustion zone from CO—O recombination reaction (approximately 400 nm). However, it is appreciated that since the wavelengths for both soot from diffusion and soot from undesirable pre-mix combustion are relatively close to one another such that a single detector having a spectral response that peaks in the approximate region of 350 nm to 450 nm can be implemented for flame holding/flashback events that generate both types of soot. As such, each of the series of flame detectors 180 can include a spectral response that peak at differing wavelengths.
[0024] It is appreciated that the flame detectors 180 can be configured in a variety of ways to be configured to detect the multiple wavelengths of multiple flame types to discriminate the flame types. It is well known the spectral response of optical detectors (e.g., photodiodes) is primarily determined by the band gap voltage of the material used in the optical detectors. SiC has a band gap voltage of 3.1 volts and has a spectral response that peaks at about 270 nm and has a wavelength limit if about 400 nm. SiC detectors are currently in use for detection of flames in combustion chambers of gas turbines.
[0025] FIG. 4 illustrates a plot 400 of the relative spectral characteristics of the flame emissions versus wavelength of various flame types. A SiC responsivity curve 410 is illustrated. An emission characteristic curve 420 of a premixed hydrocarbon flame with an expected OH— emission spectral peak at about 306 nm is also illustrated. Currently, a SiC detector is implemented for detection of a hydrocarbon flame, which suitably detects the flame. However, it is appreciated that the relative spectral response is about 70% of the maximum at 306 nm. For current systems, the 70% relative spectral response is acceptable for simple hydrocarbon flame detection. FIG. 4 further illustrates an optical spectral emission curve 430 for soot produced by a diffusion flame and a spectral curve 440 for soot due to premixed fuel burning in the combustion chamber 140 (see FIG. 3 ) based on a typical premixed combustor flame temperature. It is appreciated that the spectral intensity versus characteristics wavelength changes and shifts as a function of local flame temperature. As such, the spectral characteristics described in the example of FIG. 4 is illustrative and other spectral characteristics are contemplated in other exemplary embodiments. It is further appreciated that currently implemented SiC detectors have a lower spectral responsivity for wavelengths between 380 nm and 400 nm that are associated with the diffusion soot and the premix soot flame optical emissions intensities respectively, as described above. In exemplary embodiments, a first of the detectors 180 can include a spectral response that occurs at or near the spectral peak of the wavelength (about 306 nm) of a hydrocarbon flame, can be coupled to the combustion chamber 140 . A second of the detectors 180 can include a spectral response that occurs at or near the peak of a wavelength (about 380 nm) of a flame due to diffusion soot. A third of the detectors 180 can include a spectral response that occurs at or near the peak of a wavelength (about 400 nm) of a flame due to premix soot. As discussed above, since the emission spectra due to diffusion and premix soot flames are relatively close, a single detector having a spectral peak that occurs at or near an average peak of the two soot flames, can be implemented. It is appreciated that since the wavelengths of the spectral peaks of the soot flames are both longer than the peak wavelength of the hydrocarbon flame, the hydrocarbon flame can be adequately discriminated from the soot flames using existing or modified detectors. In exemplary embodiments, the material of the detectors 180 can be fabricated (e.g., by adjusting the band gap voltage via doping of the material) such that the spectral peaks occur closest to the spectral peaks of the respective flame types. Furthermore, the material can be further fabricated to bring the upper and lower wavelength limits closer to the spectral peak, this creating a narrow peak at the spectral peak of wavelength of the respective flame type. It is appreciated that modification of a SiC detector can further be modified (e.g., via doping) to shift the spectral peak of the SiC detector closer to 306 nm to better correspond with the spectral peak of the hydrocarbon flame.
[0026] FIG. 5 illustrates a plot 500 of relative spectral response of the flame detectors 180 versus wavelength to accomplish the goals described herein. In the plot 500 , a first detector spectral response of a SiC flame detector 180 that has been modified to have a spectral responsivity overlapping the spectral peak of OH in a hydrocarbon flame (e.g., 306 nm), is shown by curve 510 . Furthermore a second detector spectral response curve 550 corresponds to a flame detector 180 that has been configured to have a spectral peak corresponding to the thermal emission spectral peaks of one or both of the diffusion soot and premix soot, as shown by curves 530 and 540 (approximately 380 nm and 400 nm respectively). In this example, the response curve 510 has a lower limit of about 250 nm and an upper limit of about 360 nm. The response curve 550 has a lower limit from about 340 nm and an upper limit from about 450 nm. Each of the detector response curves 510 , 550 both have a width of about 100 nm. The lower and upper limits and widths are shown to illustrate that there is little to no overlap of the spectral responses of the flame detectors 180 for each individual flame types. As such, the detector configured to detect the hydrocarbon flame has little to no response in the spectral region for the soot flames. Similarly, the detector configured to detect the soot flames has little to no response in the spectral region for the hydrocarbon flame. It is appreciated that the upper and lower limits and the width described above are for illustrative purposes only and that other lower and upper limits and widths are contemplated in other exemplary embodiments.
[0027] In exemplary embodiments, the flame detectors 180 can be of a single material type having a lower limit below the spectral peak for hydrocarbon flames and an upper limit above the spectral peak for the soot flames. In this way a single detector type may be implemented to detect both flames types. The individual flame detectors can further include optical filters such that a flame detector used for the hydrocarbon flame can filter the wavelengths for the soot flames and the flame detector for the soot flames can filter the wavelength for the hydrocarbon flame. For instance the first detector's responsivity ( 510 ) can be accomplished by placing an optical bandpass filter either on a SiC photodiode chip or as a layer on the optical window of the SiC photodiode package. The advantage of using SiC is that it is already relatively unresponsive to wavelengths above about 380 nm which makes the filter relatively easy to design and implement. One choice for a detector with responsivity 550 would be a Silicon photodiode covered with a phosphor to increase its sensitivity in the violet and near ultraviolet region. Unfortunately the silicon photodiode has a responsivity that extends to lower wavelengths as far as the infrared region (1000 nm) so blackbody and visible radiation can blind it easily. The bandpass filter required to accomplish responsivity 550 would therefore be difficult to design and fabricate. An alternative method would be to use an optical fiber connected to a CCD spectrometer. This device would scan the entire emission spectrum from 250 to 450 nm and signal processing software programming would enable a rapid and continuously scan of the signal strengths between the two spectral regions described above.
[0028] In exemplary embodiments, the control unit 65 can detect the signal responses from multiple detectors (e.g., the flame detectors 180 ) and implement a voting algorithm to determine the type of action taken by the control unit 65 in response to a flame holding/flashback condition. For example, if two of the three detectors 180 determine that a flashback condition exists, the control unit 65 can then cut off or reduce the fuel to the combustor cans 120 . Similarly, if only one flame detector 180 detects flashback, the control unit 65 can decide to continue the fuel until the flame detectors 180 make another reading. Furthermore, multiple detector elements can reside in an enclosure corresponding to the flame detectors 180 . The multiple detector elements can be multiplexed in order to aggregate the signals detected in the combustor cans 120 . In this way, the aggregate signal can be implemented to determine the results of the voting algorithm.
[0029] FIG. 6 illustrates a flow chart of a method for operating a combustor in accordance with exemplary embodiments. At block 705 , fuel nozzles (e.g., 160 FIG. 3 ) introduce fuel into a premixing device (e.g., 42 FIG. 2 ) and a compressor (e.g., 110 FIG. 3 ) introduces air into the premixing device. At block 710 , the premixing device forms a gaseous pre-mix. At block 715 , the combustor (e.g., combustor cans 120 FIG. 3 ) combust the premix in a combustions chamber (e.g., 140 FIG. 3 ). At block 720 , the flame type within the combustion chamber is monitored. At block 725 , the flame detectors can monitor spectral peaks of the flame types in the combustion chamber. If the flame detectors detect a spectral peak that corresponds to a soot flame, then at block 730 , the controller can modify the fuel flow into the premixing device or other appropriate action described herein. In the flame detectors do not detect a spectral peak corresponding to a soot flame or simply detect a normal hydrocarbon flame, then the process can continue at block 705 .
[0030] Exemplary embodiments have been described for detecting flame holding/flashback in the combustion chamber 140 of the combustor cans 120 . As described herein, the exemplary embodiments can also be implemented to detect thermal emissions from the fuel nozzles 160 . By monitoring the thermal emissions from the fuel nozzles 160 , the system can determine if a flame is within the fuel nozzle 160 because the thermal emissions would indicate a higher temperature than would be expected in the fuel nozzles 160 . For example, thermal emissions indicating flame holding/flashback could be measured at the swirler vanes, burner tube, or diffusion tip of the fuel nozzles 160 or other downstream components. As such, increased photoemissions from a flame holding/flashback event are measured in the combustor cans 120 to determine if flame holding/flashback is occurring within the fuel nozzle 160 using one or multiple color detectors (e.g., the flame detectors 180 ). An increase in thermal emissions from the fuel nozzle 160 components could be implemented to detect flame holding within the fuel nozzle 160 . In one example, combustion can occur inside the fuel nozzle 160 . The result can be soot thermal optical radiation or thermal emissions from the fuel nozzle components, which are exposed to the hot flame and would radiate unexpected thermal emissions. In exemplary embodiments, the flame detectors 180 can be oriented adjacent the fuel nozzles 160 as described above in order to detect thermal emissions form the fuel nozzles 160 . The control unit 65 (See FIG. 2 ) can then receive the signals from the flame detectors 80 and take appropriate action. For example, the control unit 65 can implement triangulation to detect even location and aid in root cause diagnostics. FIG. 7 illustrates a front view of the combustor can of FIG. 3 . The flame detectors 180 are oriented adjacent the fuel nozzles 160 or fuel nozzle circuit. Fuel from the premixed circuit could be redirected in the full or part to another fuel circuit, vented or unused fuel circuit such as the diffusion flame circuit. Furthermore, the flame detectors 180 are spaced such that each flame detector 180 shares a line of sight with one of the fuel nozzles 160 . As such, if two of the flame detectors indicate that there is a flame holding/flashback event, the control unit 65 therefore knows which of the fuel nozzles 160 is affected. In this way, the controller can selectively reduce the fuel or shut off the fuel to the one effected fuel nozzle 160 . It is appreciated that the combustor can 120 can experience minimal disruption when the control unit 65 acts upon only a single fuel nozzle 160 . As such, the affected fuel nozzle 160 can be serviced during the next scheduled outage. It is appreciated that triangulation is only one example of how the flame detectors 180 can be implemented to detect thermal emission from the fuel nozzles 160 during a flame holding/flashback event. Other detection implementations are contemplated in other exemplary embodiments.
[0031] While the invention has been described in detail in connection with only a limited number of embodiments, it should be readily understood that the invention is not limited to such disclosed embodiments. Rather, the invention can be modified to incorporate any number of variations, alterations, substitutions or equivalent arrangements not heretofore described, but which are commensurate with the spirit and scope of the invention. Additionally, while various embodiments of the invention have been described, it is to be understood that aspects of the invention may include only some of the described embodiments. Accordingly, the invention is not to be seen as limited by the foregoing description, but is only limited by the scope of the appended claims.
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Optical flame holding and flashback detection systems and methods are provided. Exemplary embodiments include a combustor including a combustor housing defining a combustion chamber having combustion zones, flame detectors disposed on the combustor housing and in optical communication with the combustion chamber, wherein each of the flame detectors is configured to detect an optical property related to one or more of the combustion zones.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates to a thermally insulating shipping container including a bottom piece, two longitudinal side pieces, two transverse side pieces and at least one cover piece, which enclose a shipping chamber and are made of an insulating material.
[0003] 2. Discussion of Related Art
[0004] Thermally insulating shipping containers are known and are extensively used, for example, for shipping temperature-sensitive foods, such as frozen food, or also for shipping warm food. For the purpose of efficient and cost-effective production, along with good thermal insulation properties, such shipping containers are often integrally produced from a molded particle foam on the basis of a polyolefin, such a polypropylene, so-called EPP, or also on the basis of polystyrene, so-called EPS.
[0005] However, in connection with known shipping containers, it has been found to be disadvantageous that, because of their integrally one-piece manufacture, they are very bulky when not in use and thus require a large shipping volume.
[0006] On the other hand, shipping containers are known which do not have a thermally insulating function and which, when not in use, can be folded in a space-saving manner. However, the folding mechanisms employed cannot be transferred to the previously discussed thermally insulating shipping containers, because the hinged connections, which customarily comprise hinged shafts and hinged bearings for the foldable connection of the individual parts, cannot be applied to or embodied as foamed EPP or EPS parts.
SUMMARY OF THE INVENTION
[0007] One object of this invention is to provide a thermally insulating shipping container of the type mentioned above but which has good insulation properties and occupies only a small volume when not in use, is easy to manufacture and has a large carrying capacity and stability in the unfolded state.
[0008] To attain the object, this invention relates to a thermally insulating shipping container having characteristics described in this specification and in the claims.
[0009] In accordance with this invention, the longitudinal side pieces and the transverse side pieces are pivotably maintained on the bottom piece around respective pivot axes, which extend parallel with respect to the bottom piece, so that they can be unfolded from a folded orientation, which extends parallel with respect to the bottom piece, into an orientation which is perpendicular to it, in which they enclose the shipping chamber and in which the shipping chamber can be subsequently closed by the at least one cover piece. Thus, in accordance with this invention, a bottom piece is proposed as a central element, on which the longitudinal and transverse side elements are pivotably fastened or maintained, such as all connecting elements required for this can be integrated into the bottom piece and correspondingly in the longitudinal and transverse side pieces, which leads to a particularly sturdy shipping container in the unfolded state.
[0010] In one embodiment of the shipping container in accordance with this invention, the bottom piece has a right-angled bottom area, wherein a corner protrusion, whose top projects upward, is formed in each corner area of the bottom piece. On its sides facing the longitudinal and transverse side pieces, each one of the corner protrusions has integrally molded hinge elements, which can be brought into an operational connection with correspondingly formed hinge elements of the longitudinal and transverse side walls. Accordingly, the corner protrusions of the bottom piece provide holding and pivotable linkage of the longitudinal and transverse side pieces at the bottom piece. Also, the corner protrusions can also be used as stops for the longitudinal and transverse side pieces brought into an unfolded position, for example placed perpendicularly with respect to the bottom piece, so that further unfolding is prevented by a stop against the corner protrusions, and a dimensionally stable shipping container is created.
[0011] In order to continue to be able to produce the thermally insulating shipping container in accordance with this invention with an efficient mode of production from a molded particle foam, the hinge elements are preferably integrally molded in the bottom piece and the longitudinal or transverse side walls.
[0012] In one embodiment of this invention, the longitudinal and transverse side walls are in the form of spherical heads or universal ball joint-shaped heads, which are maintained, pivotable around the hinge axes, in correspondingly embodied ball sockets provided, for example, in the area of the corner protrusions. However, the opposite arrangement is also possible, such as the ball sockets are integrally molded in the longitudinal and transverse side walls, while the corresponding spherical heads seated therein are molded in the bottom piece, preferably in the area of the corner protrusions. It is thus possible to omit additional parts, such as hinge shafts, which possibly require different materials.
[0013] It is also possible to provide heads in the shape of a truncated cone and corresponding linkage recesses in place of heads in the shape of a universal ball joint.
[0014] Not employing other materials does not only make sense from the viewpoint of economy of manufacture, because in this case additional assembly steps are saved. Further, the omission of additional materials makes possible recycling of only one type, or the easy disposal of a no longer required shipping container in accordance with this invention.
[0015] In one embodiment of this invention, the at least one cover piece can be placed on top of the unfolded longitudinal and transverse side pieces for closing the shipping chamber at the top. The shipping container in accordance with this invention has additional stiffening by the cover piece which, in the unfolded orientation of the longitudinal and transverse side pieces, can be placed on top of it, so that its sturdiness in the unfolded state approaches that of a shipping container formed in one piece.
[0016] Two cover pieces are provided in another possible embodiment of this invention, which together provide the closure at the top of the shipping chamber. Particularly advantageously, it is possible to provide pivotable fixation of each cover piece on one of the transverse side pieces, so that the cover pieces are not only connected with the further parts of the shipping container in accordance with this invention in a way in which they cannot be lost, but that, in the folded state of the transverse side pieces, they can also be folded in a space-saving manner above or below the transverse side pieces in a parallel orientation with respect to the latter.
[0017] Here, the cover pieces can be maintained, pivotable around hinge axes, on the transverse side pieces by linkage heads held in hinge elements in the form of hinge recesses, wherein the hinge elements are respectively integrally molded in the cover pieces and the transverse side pieces. For example, the linkage heads can have the shape of universal ball joints or truncated cones. In this way, the shipping container in accordance with this invention also makes do without additional hinge pieces, such as shafts, bushings, and the like and can be produced true-to-type, for example by known molded foam methods, in a single work step.
[0018] Within the framework of this invention, exterior carrying handles can be on the longitudinal and/or transverse side walls of the shipping container in accordance with this invention, to cause the user to carry and handle the shipping container in accordance with this invention, along with its possibly considerable filling weight, at defined locations which are particularly suitable for the transfer of force.
[0019] In accordance with a suggestion of this invention, it is possible to provide attachment strips, which respectively protrude at the top from the bottom piece, between two adjoining corner protrusions used for the hinged holding of longitudinal or transverse side walls, which strips are provided on their sides facing the respective corner protrusions with corresponding hinge elements, such as with the corner protrusions. Accordingly, the hinge elements are used to come into operational connection with correspondingly formed hinge elements of the longitudinal or transverse side walls, so that a particularly large degree of stability is achieved by this dual joint connection, and the longitudinal and transverse side walls are prevented from being released in an undesired manner from the hinge connection, even if a large load is absorbed inside the shipping container.
[0020] In accordance with a further embodiment of this invention, the longitudinal side walls are equipped with means for the snap-in reception of the transverse side walls in the unfolded orientation. Accordingly, if the shipping container in accordance with this invention is raised into its position of use by successively occurring unfolding of the longitudinal side walls and the transverse side walls, further increased stability is achieved by the snapped-in reception of the unfolded transverse side walls between the longitudinal side walls, wherein this snapped-in orientation of the longitudinal and transverse side walls can only be cancelled by a definite use of force, but is safe from accidental folding.
[0021] Also, the longitudinal and/or transverse side walls can be embodied with insertion strips which, in the unfolded orientation, are arranged at the top and can be inserted into corresponding insertion grooves formed at the bottom of at least one cover piece, so that the at least one cover piece can be positively attached to the top of the longitudinal and transverse side walls arranged in the unfolded orientation, and the cover piece is not only maintained secure against loss, but a positive connection, which increases the stability of the shipping container, is also achieved.
[0022] Other snap-in and locking options of the at least one cover piece on the longitudinal and transverse side walls arranged in an unfolded orientation are also possible within the framework of this invention. Within the framework of this invention, it is also possible to maintain the cover piece pivotably on the longitudinal and transverse side walls, wherein in such embodiments the cover piece can be of several pieces.
[0023] For arranging the shipping container in accordance with this invention and its individual parts as a compact unit also in the folded state, and to protect it from damage, the height of the corner protrusions extending in height above the bottom surface of the bottom piece is preferably of such a size, that at least the lateral side walls and the longitudinal side walls can be received in a parallel orientation with respect to the bottom piece between these corner protrusions. In this orientation the upper edge of the corner protrusions terminates flush with the cover piece placed on the longitudinal and transverse side walls.
[0024] The shipping container of this invention can preferably be produced from a molded particle foam, known per se, which has a particularly good thermal insulating effect and has a predominantly closed-cell foam structure, on the basis of a polyolefin, such as polyethylene or polypropylene, or on the basis of polystyrene. However, other material selections are also possible within the framework of this invention.
[0025] However, it is preferable if the shipping container is made of molded foam particles of an apparent density of at least 30 kg/m 3 , wherein the wall thickness of the bottom piece, the longitudinal and transverse side pieces and the cover piece should be in the range between 15 to 35 mm, preferably 25 to 30 mm.
[0026] In an alternative embodiment of the shipping container in accordance with this invention, if from molded parts, containing hollow chambers, on the basis of thermoplastic materials, can be produced in a cost-effective manner, and can have a great insulating effect because of their hollow chambers that are extremely sturdy. In such embodiment of the shipping container in accordance with this invention of molded parts, wall thicknesses of approximately 0.5 to 2 mm are preferably provided, if the molded parts are made of polypropylene. Such molded parts can be produced, for example, by a blow-molding method, wherein the hinge elements can also be integrally molded.
[0027] Also, the surfaces of the shipping container in accordance with this invention can have a liquid-proof coating, for example a foil, which is placed into the tool during the molded foam process and is integrally connected with the molded foam particles and that then forms the surface of the produced molded parts. A shipping container in accordance with this invention, produced from such surface-coated parts, can be easily washed off if dirty and, with an appropriate shaping of the bottom piece, can also form a leak-proof catch basin for liquid possibly exiting the materials shipped in the shipping chamber.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] Further embodiments and details of this invention will be explained in greater detail in view of an exemplary embodiment shown in the drawings, wherein:
[0029] FIG. 1 a is a perspective view of a first embodiment of the shipping container in accordance with this invention, in the unfolded state;
[0030] FIG. 1 b is a perspective view of the shipping container in accordance with FIG. 1 , in the folded state;
[0031] FIG. 2 is a perspective view of the bottom piece of the shipping container, in accordance with FIGS. 1 a and 1 b;
[0032] FIG. 3 a is a perspective view of the transverse side piece of the shipping container in accordance with FIGS. 1 a and 1 b;
[0033] FIG. 3 b is a perspective view of the transverse side piece in accordance with FIG. 3 a in a further perspective representation;
[0034] FIG. 4 shows a longitudinal side piece of the shipping container in accordance with FIGS. 1 a and 1 b , in a perspective view;
[0035] FIG. 5 shows a cover piece of the shipping container in accordance with FIGS. 1 a and 1 b , in a perspective view;
[0036] FIG. 6 shows a top view from above on the shipping container with the cover pieces removed;
[0037] FIG. 7 shows a perspective view of two shipping containers stacked on top of each other, each in the unfolded state, in accordance with FIG. 1 a;
[0038] FIG. 8 shows a perspective view of two shipping containers stacked on top of each other, each in the folded state, in accordance with FIG. 1 b;
[0039] FIG. 9 shows a perspective view of a further embodiment of the bottom piece of a shipping container in accordance with this invention;
[0040] FIG. 10 shows a perspective view of a further embodiment of a transverse side piece of a shipping container in accordance with this invention; and
[0041] FIG. 11 shows a perspective view of a further embodiment of the shipping container in accordance with this invention with pieces in accordance with FIGS. 9 and 10 .
DETAILED DESCRIPTION OF THE INVENTION
[0042] A thermally insulating shipping container is represented in FIGS. 1 to 6 , which includes a bottom piece 1 , two longitudinal side pieces 2 , two transverse side pieces 4 and a two-piece cover piece 6 a , 6 b , which can be placed, parallel with the bottom piece 1 , on the longitudinal and transverse side pieces 2 , 4 , so that in the position of use a shipping chamber is enclosed.
[0043] The thermally insulating effect of the shipping container is a result of the above mentioned pieces being produced from a thermally insulating material, for example EPP of an apparent density of at least 30 kg/m 3 and a wall thickness of preferably 25 to 30 mm and with a predominantly closed-cell foam structure.
[0044] The shipping container represented in the drawing figures during non-use can be folded together in a space-saving manner, as shown in FIG. 1 b , and can be unfolded for use, as will be explained in greater detail in this specification and as shown in FIG. 1 a.
[0045] The basis, or the basic element of the shipping container is the bottom piece 1 , whose details are shown in FIG. 2 .
[0046] The bottom piece 1 has a rectangular bottom area 10 , wherein an upwardly projection corner protrusion 11 is molded in each corner area of the bottom piece 10 .
[0047] Two attachment strips, shaped in the manner of stair steps and projecting from the top and identified by the reference numeral 12 , can be seen between adjoining corner protrusions 11 along oppositely located edge areas of the bottom piece 10 . The edge areas of the bottom piece 10 containing the attachment strips 12 face the longitudinal side pieces 2 , the closer details of one of which are shown in FIG. 4 .
[0048] Now, in order to assure a foldable or unfoldable orientation of the longitudinal and transverse side pieces 2 and 4 on the bottom piece 1 , such as shown in FIG. 1 a or 1 b , each corner protrusion 11 of the bottom piece 1 has hinge elements in the form of spherical or half-shell-shaped linkage recesses, which can also be called ball sockets 14 , 15 , on its sides facing the longitudinal or transverse side pieces 2 , 4 . Here, the ball sockets identified by the reference numeral 14 face the longitudinal side wall 2 , for example they are molded in the corner protrusions 11 in the direction of the attachment strips 12 of the bottom piece 1 , while the ball sockets identified by the reference numeral 15 face the transverse side walls 4 and are molded at right angles with respect to the ball sockets 14 in the corner protrusions 11 .
[0049] One essential characteristic of these hinge elements in the form of ball sockets 14 , 15 is that they are integrally molded in the corner protrusions 11 , so that the one-piece manufacture of the bottom piece 1 , such as shown in FIG. 2 , of the shipping container by a molded foam process of expanded polypropylene particle foam or expanded polystyrene (EPP or EPS) is made possible without requiring additional materials or individual parts.
[0050] For being pivotably held on the bottom piece 1 embodied in this way, the longitudinal side walls 2 , such as shown in FIGS. 4 a and 4 b , are embodied with a hinge strip 24 which, in the unfolded orientation, is arranged on the underside and extends past or beyond the lateral face 20 . Corresponding to the ball sockets 14 provided for this, half-shell-shaped or universal ball joint-shaped spherical heads 240 , which project from the corner protrusions 11 and can be inserted into oppositely located ball sockets 14 of adjoining corner protrusions 11 parallel with an attachment strip 12 , are integrally molded on the hinge strip 24 at the two front ends of the hinge strip 24 on the underside. Therefore the longitudinal side pieces 2 , together with their hinge elements in the form of spherical heads 240 , can also be produced in one piece, for example by a molded foam process.
[0051] In the same way, the transverse side pieces 4 shown in FIGS. 3 a and 3 b are embodied with a hinge strip 44 which, in the unfolded orientation, projects on the underside past the lateral face 40 and has a lesser width, which again has half-shell-shaped spherical heads 440 as hinge elements on its two front ends, which can be inserted into correspondingly provided ball sockets 15 between two adjoining corner protrusions 11 of the bottom piece 1 .
[0052] As shown in FIG. 2 , the ball sockets 15 used for receiving the spherical heads 440 of the transverse side pieces 4 can be arranged with respect to the bottom area 10 of the bottom piece at a greater height than the ball sockets 14 used for receiving the spherical heads 240 of the longitudinal side pieces 2 , and thus as can be seen in FIG. 1 b , can arrange the two longitudinal side pieces 2 on the bottom area 10 in a folded orientation, such as extending parallel with respect to the bottom piece 1 and its bottom area 1 Q, and to also arrange thereon the two transverse side pieces 4 , also in a parallel orientation with respect to the bottom area 10 of the bottom piece 1 . Then it is possible to place the cover pieces 6 a or 6 b , visible in FIG. 5 , on this arrangement of transverse side pieces 4 and longitudinal side pieces 2 , wherein the height of the corner protrusions 11 is preferably selected so that they then terminate flush with the top of the folded-up transverse side pieces 4 , and the transverse side pieces 4 and the longitudinal side pieces 2 are received between the corner protrusions 11 . In this folded orientation, the shipping container in accordance with FIG. 1 b needs only little storage space.
[0053] If used in accordance with its purpose, for example to enclose a shipping chamber in which temperature-sensitive material can be shipped, the longitudinal and transverse side pieces 2 , 4 are placed into a folded-open position, which can be seen in FIG. 1 a . First, starting with the folded state in accordance with FIG. 1 b , the transverse side pieces 4 with the cover pieces 6 a , 6 b , which are fastened on them in a manner yet to be described, are raised into a vertical position. In the process, unfolding takes place around a pivot axis S 4 , which is defined by the hinge elements in the form of the ball sockets 15 and the spherical heads 440 and extends at right angles in relation to the pivot axis S 2 of the longitudinal side pieces 2 .
[0054] Now the longitudinal side pieces 2 can be reached, which are accessible above the bottom piece 1 and are in the folded-up orientation, such as extending parallel with the bottom area 10 . Because of their pivotable seating between the ball sockets 14 of the corner protrusions 11 and the spherical heads 240 , they are now raised on the hinge strips 24 of the side pieces 2 around a pivot axis identified by S 2 into an orientation extending vertically with respect to the bottom area 10 of the bottom piece 1 , in which, with a contact protrusion 2 a on their underside, they come into contact with the respective attachment strip 12 , so that they assume an exactly right-angled orientation with respect to the bottom piece 1 .
[0055] It is understood that the respective heights of the longitudinal and transverse side pieces 2 , 4 in the unfolded state should be matched, i.e. should be identical, and the heights should be selected so that the oppositely located longitudinal side walls 2 or transverse side walls 4 can be folded completely over the bottom piece 1 .
[0056] After the longitudinal and transverse side pieces 2 , 4 thus designed are brought into their unfolded orientation, such as extending vertically with respect to the bottom area 10 of the bottom piece 1 , the shipping container in accordance with FIG. 6 can be filled and, following this, the cover pieces 6 a , 6 b can be placed on the top edge areas of the side pieces 2 , 4 , in order to close the shipping chamber inside the shipping container. For this purpose, the longitudinal side walls 2 have top insertion strips 21 along their edge areas which are on top in the unfolded orientation, which strips positively engage correspondingly designed grooves 61 on the underside of the cover piece 6 , in the cover pieces 6 a , 6 b as shown in FIG. 1 b . A shipping container unfolded in this way and plugged together by positive connections has extremely high sturdiness and stability and can be used for shipping even heavy sensitive materials.
[0057] Moreover, all performed positive locking processes and also the pivot movements are reversible, i.e. following its use the shipping container can again be folded into its folded, space-saving orientation as shown in FIG. 1 b , and is therefore suitable for repeated or returnable use.
[0058] Although it would be possible to only provide a single cover piece which can be applied and removed, the shipping container preferably has a multi-section cover piece, comprising two cover pieces 6 a , 6 b , wherein the two cover pieces 6 a , 6 b each cover approximately one-half of the shipping chamber in the interior of the shipping container and together cover it on the top in the orientation shown in FIG. 1 a.
[0059] Also, the two cover pieces 6 a , 6 are pivotably held on the horizontal edge of the transverse side pieces 4 which lie on top in the folded-open state of the transverse side pieces 4 .
[0060] For this purpose, each pair of transverse side pieces 4 , whose greater details can also be seen in FIGS. 3 a and 3 b and which, in their folded-open state, lie on top, has hinge receptacles 400 , which are each spaced apart by an interspace 400 a.
[0061] Linkage recesses 401 are integrally formed out of the facing inner surfaces of the respective pairs of hinge receptacles 400 which, for defining an insertion channel, are upwardly widened in the shape of a step or in the shape of a ramp, which is indicated by the reference numeral 401 a.
[0062] Correspondingly, the two cover pieces, for example the cover piece 6 b shown in FIG. 6 , have a hinge element 63 , which is integrally molded on the cover piece 6 b and fits into the interspace 400 a and on whose two sides facing the linkage recesses 401 protruding linkage heads 630 of a truncated-cone shape are molded, so that, without the addition of separate hinge elements, a pivotable seating of the two cover pieces 6 a , 6 b on the transverse side pieces 4 can be provided by the integral shaping of the hinge elements formed in this way. A ramp-shaped flattening 630 a is provided for easy introduction of the linkage heads 630 into the linkage recesses which, together with the insertion channels 401 a , makes possible the easy attachment and, if required, also the removal, of the cover pieces 6 a , 6 b.
[0063] The hinge connection realized in this process between the transverse side pieces 4 and the respective cover pieces 6 a , 6 b defines pivot axes S 6 parallel with respect to the pivot axes S 4 of the transverse side pieces 4 , which assure the pivotability of the cover pieces 6 a , 6 b by at least 270°.
[0064] Because of this great pivot angle it is not only possible, as shown in FIG. 1 a , to place the cover pieces 6 a , 6 b on the upper edge area of the longitudinal and transverse side pieces 2 , 4 for closing the shipping chamber, but also to fold them open for access to the shipping chamber which is made easier by forming out grip recesses 64 on the top of the cover pieces 6 a , 6 b.
[0065] If, for the purpose of returning or because of non-use, the shipping container thus designed, as shown in FIG. 1 b , first, following the folding open of the cover pieces 6 a , 6 b , folding of the longitudinal side pieces 2 into an orientation extending parallel with respect to the bottom piece 1 is provided in the already explained way by the pivotable seating of the transverse side pieces 4 around the pivot axis S 2 on the bottom piece 1 . Thereafter, the two cover pieces 6 a , 6 b are brought out of their position represented in FIG. 7 a into a parallel position with respect to the transverse side pieces 4 , which are still in the unfolded state, on the two facing outsides of the same and, as a result of their already mentioned pivotable seating around the pivot axis S 4 , subsequently the transverse side pieces 4 are brought into their position which is shown in FIG. 1 b , in which they come to rest in a space-saving manner parallel with the previously folded-in longitudinal side pieces 2 and the bottom piece 1 . The cover pieces 6 a , 6 b rest above and parallel with the transverse side pieces 4 .
[0066] As shown in FIGS. 1 a and 2 , in an edge area between the corner protrusions 11 facing the transverse side pieces 4 , the bottom piece 1 has a raised attachment edge 110 , which assures an exact right-angled placement of the transverse side pieces 4 in the folded-open state.
[0067] In order to urge the user to grasp the shipping container at the transverse side pieces 4 connected in this way in a positive manner with the bottom piece 1 , the carrying handles identified by the reference numeral 43 are integrally molded on the outside of the transverse side pieces 4 between the respective hinge receptacles 400 . Finally, the representation of the longitudinal side piece 2 in accordance with FIG. 4 shows the forming of snap-in pins 26 which, in the folded-open state of the longitudinal side pieces 2 , engage corresponding recesses 420 in the transverse side pieces 4 and assure a great sturdiness of the shipping container, such as shown in FIGS. 3 a and 6 .
[0068] Because the bottom piece 1 , of the above explained embodiment in accordance with FIG. 2 , has an edge running around the top, formed by the attachment strips 12 , 110 , it is also used as a catch basin for liquid possibly exiting the shipped material in the shipping chamber. With an appropriate dimensioning of the encircling edge it is possible, for example, to assure a capacity of 1 l of liquid or more inside the bottom piece 1 .
[0069] It is a substantial characteristic of the shipping container that all individual pieces, including their functional elements, in particular the hinge elements, can be molded integrally from a particle foam without the use of separate individual parts, which makes possible a shipping container which is true-to-type and cost effective, but is extremely sturdy. Here, all linkage heads used can have the shape of a truncated cone or universal ball joint, and all linkage recesses a shape matching this.
[0070] Finally, the bottom piece 1 also has outside recesses 110 a which are designed corresponding to the hinge connections between the transverse side pieces 4 and the cover pieces 6 a , 6 b , so that several shipping containers can be stacked on top of each other, secure against slipping, in the unfolded state, see FIG. 7 , as well as in the folded state, as shown in FIG. 8 .
[0071] A further possible embodiment of the shipping container is shown in FIGS. 9 to 11 , wherein like elements have the same reference numerals as in the previously represented and described embodiments and will not be separately explained in what follows, provided this is not necessary for understanding this invention.
[0072] The shipping container represented in its position of use in FIG. 11 has a bottom piece 1 represented in greater detail in FIG. 9 and is equipped, as in the previously described embodiments, with an upwardly projecting corner protrusion 11 in each corner area.
[0073] In the area used for the pivotable fastening of a transverse side piece 4 , a fastening strip 110 , which upwardly projects past or beyond the bottom piece 1 , is formed between the facing corner protrusions 11 and the hinge elements, identified by the reference numeral 15 , in the corner protrusions, which strip, at the two ends located opposite the two corner protrusions 11 , itself has corresponding hinge elements 15 a , which are integrally molded and which correspond in their configuration to those of the recesses 15 in the corner protrusions 11 . The respective insertion opening 15 b for a hinge element of the transverse side piece 16 to be received in it, and which is shown in FIG. 10 by reference numerals 440 , extends parallel with respect to the bottom area 10 of the bottom piece 1 and is identified by the reference numeral 15 b.
[0074] As shown in the overview in accordance with FIG. 11 , each transverse side piece 4 , which also has the carrying handles 43 for carrying the shipping container, is doubly held on both sides of each formed-on hinge strip 44 by appropriately projecting hinge elements 440 in the corresponding hinge receptacle 15 or 15 a of a corner projection 11 or fastening projection 110 and, in the folded-open position shown in FIG. 11 , cannot be removed out of the receiving position, even in case of large loads arranged inside the shipping container. Thus, it is possible also with this embodiment to ship large loads inside the shipping container without the danger of the hinge connection between the bottom piece 1 and the transverse side piece 4 being overwhelmed.
[0075] As shown in the embodiment in accordance with FIG. 11 , the recesses 22 a are cut into the longitudinal side pieces 2 , which are used as opening aids for the two cover pieces 6 a , 6 b.
[0076] A further functionality of the represented shipping container corresponds to the exemplary embodiment previously described in detail by FIGS. 1 a to 8 , so that it is possible to omit further functionality explanations to prevent repetitions.
[0077] It is understood that, in place of producing them from particle foam, each one of the previously explained embodiments of the shipping container in accordance with this invention can also be produced, for example, from molded parts made of a thermoplastic material, such as polypropylene or polyethylene, which have hollow chambers, are therefore especially light and at the same time thermally insulating. Such hollow-chambered molded parts can for example be produced in accordance with a blow-molding method, such as now known for producing panel parts for the automobile industry and the like.
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A thermally insulating transportation box, including a base part, two longitudinal side parts, two transverse side parts and at least one top part, which parts bound a transportation space and are produced from a thermally insulating material. The longitudinal side parts and the transverse side parts are pivotably mounted on the base part about pivot axes which each run parallel to the base part, so that they can be folded open from a folded-together arrangement, which extends parallel to the base part, into an arrangement which is perpendicular to this and in which they bound the transportation space, and the transportation space can subsequently be closed by the at least one cover part.
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RELATED APPLICATIONS
This application is a continuation of U.S. patent application Ser. No. 11/980,005, now U.S. Pat. No. 7,866,916 B2, filed Oct. 30, 2007, which is a continuation-in-part of application U.S. Ser. No. 10/706,341 filed Nov. 11, 2003 now U.S. Pat. No. 7,353,634, which is, in turn, a continuation-in-part of my application U.S. Ser. No. 09/849,453, filed May 4, 2001, now U.S. Pat. No. 6,651,383 issued Nov. 25, 2003, which is, in turn, a continuation-in-part of my application U.S. Ser. No. 09/565,735 filed May 5, 2000, now U.S. Pat. No. 6,374,539 issued Apr. 23, 2002, which is, in turn, a continuation-in-part of my application U.S. Ser. No. 09/110,789 filed Jul. 6, 1998, now U.S. Pat. No. 6,071,411 issued Jun. 6, 2000, the disclosures of which prior applications are herein incorporated by reference.
BACKGROUND OF THE INVENTION
The present invention relates to methods for deicing roads.
Water purification typically produces a first effluent of relatively “clean water” and a second effluent of “waste water” which includes unwanted contaminates. The softening of hard water by the removal of calcium and magnesium is required for both industrial and household use.
Known water softening processes proceed either by way of ion-exchange, membrane softening or precipitation. In the ion-exchange processes, the calcium (Ca++) and magnesium (Mg++) ions are exchanged for sodium (Na+) and regeneration of the ion-exchange resin is achieved with a large excess of NaCl. This process creates a regeneration effluent that is relatively concentrated aqueous solution of sodium, calcium and magnesium chlorides which has to be discarded.
Alternatively, it is possible to use weak acid resins which exchange hydrogen (H+) for calcium (Ca++) and magnesium (Mg++), and to regenerate the spent resins with a mineral acid. While this method creates less waste water, it is more expensive and yields relatively acidic soft water which is corrosive. Meanwhile, membrane softening concentrates the calcium, magnesium salts and salts of other divalent ions to produce waste waters which require costly disposal techniques.
The precipitation process has traditionally been carried out by the “lime soda” process in which lime is added to hard water to convert water soluble calcium bicarbonate into water insoluble calcium carbonate. This anti-erosion agent process also results in waste water which is difficult to filter.
My previously issued patent, U.S. Pat. No. 5,300,123 (which is incorporated herein by reference), relates to the purification of impure solid salts. Even this process produces salty waste water which must be disposed of.
The disposal of waste water has become an expensive problem for society. For example, approximately 1.61 billion gallons of waste water containing approximately 800,000 tons of mixed sodium, calcium, magnesium chlorides and sulfates is produced from water treatment operations and oil fields in the state of California alone. This waste water must be disposed of, costing the state of California millions of dollars each year. Meanwhile, the disposal of waste water has become even more problematic in other parts of the world.
Accordingly, it would be highly advantageous to provide improved methods deicing roads by use of salty waste waters.
Ironically, though there is an overabundance of waste waters that are contaminated with the salts of Na, K, Ca, Mg, Fe, Cl, SO4, and/or CO3 that, as discussed above, is extraordinarily expensive to dispose of, millions of dollars are spent each year on salts such as sodium chloride for deicing highways. It would thus be advantageous if the salts in waste water could be used for deicing highways.
SUMMARY OF THE INVENTION
Briefly, in accordance with the invention, I provide methods for economically deicing or preventing icing of roadways, using waste waters, particularly those produced from oil and gas wells, and irrigation drainage. These waste waters are processed to create both solid and aqueous mixtures of salts which are applied to roads and highways for deicing and for reducing the tendency of water to form into ice on roads and highways.
Thus, according to my method for deicing or preventing icing of roadways, comprises, in combination, the steps of collecting water contaminated with the 0.15% or more by weight of the salts of Na, Ca, Mg, Cl, SO4, or CO3 or combinations thereof, processing the contaminated water to produce a first effluent of clean water and a second effluent of waste water and applying the waste water to roadways.
According to another embodiment of the invention, my methods include the further step of concentrating the solid salts in the waste water by solar evaporation before applying the concentrate to roadways.
In still another embodiment of the invention, the salts in the waste water are separated therefrom by solar evaporation and the solid separated salts are applied to roadways.
The waste waters of the present invention are any waters which are produced as a result of the purification of water, and particularly purified “oil field produced waters” and irrigation drainage, which results in a first effluent of clean water and a second effluent of a waste water. As defined herein, clean water refers to water which has been treated by one or several methods for public or industrial use. For example, in the drinking water industry, clean water is the final delivered water. Typical water purification processes and water softening processes of the present invention include reverse osmosis, electro dialysis, distillation, evaporation, ion exchange and lime softening. These processes create waste water having various levels of salt content. For the purposes of this invention, I define “waste water” as water containing about 0.15% or more by weight of the salts of Na, K, Ca, Mg, Fe, Cl, SO4, and CO3 or a combination thereof.
Accordingly, it is an object of the invention to provide cost effective means of disposing of waste water produced from the purification of water. To this end, it is a principal object of the invention to provide new methods for utilizing waste water produced from water purification.
The principal object of the present invention to provide methods for producing solid and liquid mixtures for deicing roads and highways, using waste waters as the starting material.
These and other, further and more specific objects and advantages of the invention will be apparent to those skilled in the art from the following detailed description taken in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a flow chart of the preferred method of the invention;
FIG. 2 is a flow chart of another preferred method of the invention;
FIG. 3 is a flow chart of still another preferred method of the invention; and
FIG. 4 is a flow chart of a preferred method of the present invention including evaporation to produce substantially solid sodium chloride;
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
While the present invention is susceptible of embodiment in various forms, as shown in the drawings, hereinafter will be described the presently preferred embodiments of the invention with the understanding that the present disclosure is to be considered as an exemplification of the invention and it is not intended to limit the invention except as indicated in the claims.
Water softening is the removal of the “hardness” from the water which means predominantly removing or altering the calcium and magnesium ions from the water. These calcium and magnesium ions combine with carbonates, sulfates, oils and fat to create bathtub scum, spotted dishes, gray sheets, etc. In addition, unsoftened water has been found to cause scaling of industrial water heaters and commercial boilers causing early substantial energy losses through impaired heat transfer and early shutdown for the removal of scale. Several methods for effecting water softening are known. The best known process for softening water is “ion-exchange.” Ion-exchange entails the exchange of sodium, which is introduced into water, for calcium, magnesium, iron and other divalent mineral ions which are transferred out of the water and into a resin. When the resin approaches saturation with these hard ions, the resin is regenerated most often with solutions of sodium chloride leaving an effluent containing 3 to 25% sodium, calcium and magnesium salts which must be disposed of. The exact concentration of the effluent depends on the shop practice and, in particular, on the amount of rinse water included in the effluent, if any. Less often, mineral acids like sulfuric acid or hydrochloric acid are used for water softening and these also produce effluents. Conversely, reverse water softening also involves ion exchange in which calcium and magnesium are introduced into the water to separate sodium.
Membrane systems have recently become economically feasible. These systems, such as electro dialysis and reverse osmosis, include the use of a membrane which also produces a salty effluent. For critical uses such as electronics, and particularly for use in the manufacture of computer chips, the first product of clean water may be further purified by dual bed or mixed bed ion-exchange treatment. This “polishing treatment” also produces an effluent containing the removed salts.
Each of these water purifying processes produce a clean water effluent and a waste water effluent which is expensive and difficult to dispose of. Moreover, in U.S. Pat. No. 5,300,123, I disclose a method for reducing the soluble and insoluble impurity levels in salt. In the practice of the invention of the '123 patent, salt crystals are initially reduced in size by fine grinding the crystal mass. The crystal mass is then added to a substantially saturated solution of salt and the strain induced in fine grinding process causes them to dissolve in the substantially saturated solution to the extent that the solution becomes supersaturated and new purified crystals form and grow. This dissolving and reforming is continued until substantially all of the original finely ground particles of salt have dissolved and reformed as new purified crystals. The new purified crystals are separated by size from the solution and rinsed, while the fine insoluble impurities which do not grow appreciably, if at all, remain in the now impure solution of sodium, calcium and magnesium chlorides, along with minor impurities from the original waste salt.
For the purposes of this invention, “waste water” is defined as any water containing sufficient salts as to have no acceptable use due to costs or contamination levels. In general, waste water containing about 0.15% or more by weight of the salts of Na, K, Ca, Mg, Fe, Cl, SO4, and CO31 or combinations thereof are considered as having no acceptable use and must be disposed of.
With reference to FIG. 1 , in a preferred embodiment, water is collected which is contaminated with salts including Na, K, Ca, Mg, Fe, Cl, SO4 and CO3. The contaminated water is purified by any means known to those skilled in the art, including distillation, reverse osmosis, electrolysis, evaporation, ion exchange, etc. The contaminated water is processed to produce a first effluent of relatively clean water which is useful for agricultural purposes, drinking water, industrial purposes, etc. The processing also produces a second effluent of waste water. The waste water is analyzed for hazardous materials to confirm that the waste water is safe to use. Thereafter, the waste water, comprising an aqueous solution of salts, is analyzed for individual amounts of sodium, calcium, and magnesium and total dissolved solids to determine the best application.
With reference to FIG. 2 , in a second preferred embodiment, water is collected which is contaminated with the salts of Na, Ca, Mg, Fe, Cl, SO4, and CO3. The water is then tested to confirm that it is free of hazardous materials. The contaminated water is then purified by ion exchange. As the name implies, the amount of salts in the effluents does not change. However, the cations are exchanged. By this process, a first effluent of clean water is produced having an increase in sodium or potassium and a waste water having decreased NaCl, KCl, Na(OH)2 or acid, but having increased calcium and magnesium.
With reference to FIG. 3 , in a fourth preferred embodiment, water is collected which is contaminated with the salts of Na, K, Ca, Mg, Fe, Cl, SO4, and CO3. The water is then tested to confirm that it is free of hazardous materials. This contaminated water is then purified by a membrane system to remove large molecules. A first effluent of clean water having decreased multivalent ions is produced from the membrane softening process. Where the original sodium content of the contaminated water is relatively low, it is preferred that the clean water be used for potable water. Where the original sodium content of the contaminated water is relatively high, it is preferred that the clean water effluent be used for laundries, low pressure boilers, cooling towers, pond sealing and soil stabilization. The membrane system also creates a waste water having significant calcium, magnesium, iron, sulfates, etc. For application of the present invention, it is preferred that this waste water processed to yield products which can be used for roadway deicing or icing prevention.
As shown in FIG. 4 , in a fourth embodiment of my invention, water contaminated with the salts of Na, K, Ca, Mg, Fe, Cl, SO4, and CO3 is collected. The contaminated water is desalted to produce a first effluent of relatively clean water, and a second effluent of waste water. The second effluent of waste water undergoes further evaporization processing to produce a first product of 90% or more NaCl, and a third effluent solution of substantially saturated CaCl2 and MgCl. For practice of the invention, the NaCl is then used by application to a roadway to prevent icing or to rid the roadway of ice already formed. Alternatively, the second effluent waste water liquid can be applied directly to roadways by spraying to prevent or rid the roadway of ice.
Moreover, I have found that the waste water can be processed through evaporation, or in accordance with the methods disclosed in my U.S. Pat. No. 5,300,123, to produce substantially solid sodium salt which can be applied to roads to lower the freezing point of water on the roads. In addition, even though the calcium and magnesium solution is typically aqueous, it can also be applied to roads and highways to inhibit the formation of ice on the roads as calcium and magnesium salts also lower the freezing point of water. Thus, any water previously on the road will freeze at a lower temperature once mixed with the calcium and magnesium solution which has been produced as a result of evaporating the waste water.
EXAMPLE
Tests were run so as to duplicate, on a reduced scale, the typical solar evaporation practice with two or more evaporation stages, in series, to get best evaporation efficiency. Evaporation was carried out in duplicate pans 33 cm×63 cm×10 cm deep, lined with polyethylene film. Daily ambient highs were 38-42° C. and night lows were 15° to 17° C. less. Daytime relative humidity was 15 to 25%. The specific gravity (sg) of the Salton Sea water was 1.03.
On the second day of evaporation (sg 1.047) white flakes were forming with many floating on the brine surface. By morning of the third day, at (sg 1.057), the flakes formed an almost continuous covering. The evaporation rate varied between 0.9 and 1.2 centimeters per day until the specific gravity was at 1.145 and the floating crystals, now including other salts, formed a thick continuous (surface) skin. After a continuous skin formed on the surface the brine temperatures were as high as 48 C.
Evaporation was continued to sg 1.22 and sodium chloride was observed. A sample of the crystallized salt was taken from the pan from which much of the calcium solids had been removed for the first analysis. With even this minimum of preparation, this salt met the specifications of most states for deicing salts.
A second run using the same evaporation pans and a similar procedure was made in late September as the nights started to cool. Analysis of the recovered salts followed the pattern of the first tests. All salt samples contained more than 90% sodium chloride without washing or separation of windblown dirt and dust. These samples are suitable for use in road deicing.
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Roadways are deiced or ice formation on roadways is prevented by applying salt compositions derived from waste water streams from water softening operations.
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FIELD OF THE INVENTION
The invention pertains to the field of ornamentation or reinforcement for clothing. More particularly, the invention pertains to patches which are especially adapted to being applied to soft clothing such as sweatsuits or the like.
BACKGROUND OF THE INVENTION
Decorative patches for clothing have been known for many years. They were originally used for insignia for uniforms such as worn by military, police, or organization such as Boy or Girl Scouts. Such patches were often treated with varying stiffening agents, and were usually fully embroidered, adding to the stiffness. The edges were usually reinforced with fairly heavy stitching to force the patches to retain their shape.
Originally, and in most cases to this day, these patches were sewn on to the uniform garments. As the use of the patches became more widespread, however, it became common to attach the patches adhesively, which made decorative patches much more accessible. Haigh, U.S. Pat. Nos. 3,657,060 and 3,816,211, presents a patch and method of manufacture, respectively, which allows the patch to be attached through the use of a common household iron. This "iron-on patch" was introduced in the 1970's and has become the most common method of adhesive attachment of patches. Many Boy- and Girl-Scout patches are now supplied routinely in iron-on form.
In addition to the insignia type patch, the iron-on technology has been applied to reinforcing patches, originally intended for the knees of denim jeans. The knee patch branched out to elbows, seats, etc, and became something of a fashion item, especially for children's clothing.
In recent years patches, especially decorative patches, have become very popular among children and teens. In addition to the military insignia type patches, cartoon characters, sayings, and simple shapes are common. These patches are easily ironed on to the denim jeans or jackets or heavier shirts which children wear. However, they pose a problem for the Softer, more flexible clothing such as the fleece sweatsuits which have become popular in recent years.
The stiffness of the patch, which is a desirable attribute for police arm patches or the like which should retain their appearance after many washings, is a detriment when applied to soft sweatshirts. The clothing flexes easily, leaving the patch shelving out uncomfortably. When used as knee patches for sweatpants, the patch impedes bending of the pants and looks odd.
Several attempts have been made at softer patches for the softer clothing in recent years, but these have not been entirely successful. The patches must be made of thin or soft material, but this is difficult to sew on sweatsuits. Most iron-on adhesive is too thick and stiff for the softer fabrics.
If the edges of the patches are solidly bound as the older patches were, they become too stiff. If the edges of the patches are not bound, they fray. Prior art soft patches were sometimes supplied with unbound edges, with instructions to apply decorative craft paint to reduce fraying.
SUMMARY OF THE INVENTION
The invention presents a soft, flexible patch especially suitable for decoration or reinforcement of fleece or flannel sweatsuits, as well as a method of manufacturing such a patch.
The patch is made of a layer of fleece material of specific weight, bonded to a layer of transfer web. The patch is trimmed to a pattern and bound with thread using a specific stitch density and type.
This results in a soft, flexible patch which will not fray, but which may be ironed on to the softest sweatsuits.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 shows a top view of a patch.
FIG. 1a shows a detail of the overlock stitch from FIG. 1.
FIG. 2 shows a cut-away side view of the patch, showing the layers.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows an iron-on patch made according to the teachings of the invention. The patch shown represents a sheep. Because of the operation of the serging machine preferably used to cut and bind the patch, the design will have at most one interior (acute) angle, where the serger begins and ends the cutting/binding operation. Therefore, simple geometric shapes such as circles or ovals, or designs with only one interior angle, such as hearts or the sheep shown, will be preferred for the patches. However, shapes with sharp corners are possible within the teachings of the invention. Such patches may require stitching to the clothing after they are ironed on, in order to reinforce the corners and minimize fraying.
The body of the patch (3) may be of a single color, or simple designs might be printed on it, either as part of the fabric, or imprinted later. In the patch shown, a single dark inverted triangle (4) is printed on the patch to represent the sheep's face.
The edge of the patch (1), for a depth of approximately 5 mm, is bound with thread (2). The depth of the stitching is not critical--a range of 3 to 7 mm has been used without significant difference in the patch.
I have found that the "three thread overlock stitch" is preferred for this application, though other overlock stitches may also be used, such as the "four thread overlock", if desired.
It is important that the proper stitch density (number of stitches per linear cm of edge) be used. If the stitching is too dense (too many stitches per cm), the patch will be too stiff around the edge. If the density is too low (too few stitches per cm), the fabric will tend to fray around the stitches. I have found a stitch density of 2.5 to 5 stitches per cm will work for the method of the invention, with a preferred density of approximately 3 stitches per cm.
Note: Some serging machines are calibrated in "stitch length" (really the spacing between stitches) measured in mm per stitch. This is effectively the reciprocal of the stitch density measure: a density of 2.5 to 5 stitches per cm is the same as a stitch length of 2 to 4 mm per stitch.
FIG. 2 shows a cut-away side view of the patch of the invention. The edges are bound with thread (12) using an overlock stitch as described above.
The outer surface (10) of the patch (the surface visible when the patch is affixed to a garment) is made of a soft, flexible fabric, so as not to affect the wearability of the lightweight garment to which it is attached. The weight of this material is important. If it is too light, the thread used for binding the edges will tear out. If it is too heavy, it will be too stiff for the purpose.
I have found that fleece material is preferred for this application. It is available in a variety of colors and patterns from many suppliers, and can be easily cut and edged according to the teachings of the method of the invention. Fleece material is similar in texture and stiffness to the material of the common sweatsuit, and is thus most appropriate for decorative patches for children's sweatsuits. It will be understood that other fabrics, such as lightweight cotton or cotton-blend, would also be useful within the teachings of the invention, so long as their weight and handling characteristics were similar to the preferred fleece.
A "transfer web" of heat-fusible material (11) is bonded to the back of the patch (the side to be affixed to the garment). This transfer web must be heavy enough to allow the patch to bond to the garment when it is ironed on, but must not significantly increase the stiffness of the fabric used for the outer surface. I have found Pellon® Wonder-Under® 100% polyamide transfer web, with a weight of 24 grams/meter, available from Freudenberg Nonwovens, 119 West 40th Street, New York, N.Y. 10018, to be ideal for this application.
The method of making the patch of the invention is as follows:
First, a sheet of the transfer web is bonded to the rear surface of the flexible fabric chosen for the patch. In the case of the Wonder-Under˜ transfer web, this is done by placing the paper-backed transfer web on the fabric and pressing the combination through the paper with a hot, dry iron for approximately 5-8 seconds. The paper backing may then be removed.
Then, the pattern for the patch(es) is transferred to the fabric, by any convenient means. Typically, this will be done by tracing a master pattern using carbon paper or the like, but the pattern may be drawn freehand or some other method used.
Next, the patches are cut along the pattern and the edges bound with thread.
Preferably, these last two steps are combined by using a serging machine which will cut and bind simultaneously. The model 560ED serging machine, manufactured by Husqvarna, has been used successfully for this application. The machine is set for a stitch depth of approximately 3 to 7 mm (5 mm is preferred), and a stitch density of 2.5 to 5 stitches per cm (2 to 4 mm length) (3 stitches per cm is the preferred density, which is the same as 3 mm length).
The patch is applied to a sweatsuit by placing it on the desired location, transfer web against the garment. A damp press cloth is then placed over the patch, and is heated with a dry iron on "wool" setting for approximately 10 seconds.
Accordingly, it is to be understood that the embodiments of the invention herein described are merely illustrative of the application of the principles of the invention. Reference herein to details of the illustrated embodiments are not intended to limit the scope of the claims, which themselves recite those features regarded as essential to the invention.
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A soft, flexible patch which will not fray, but which may be ironed on to the softest garments, especially suitable for decoration or reinforcement of fleece or flannel sweatsuits, as well as a method of manufacturing such a patch. The patch is made of a layer of fleece material such as flannel, bonded to a layer of heat-fusible transfer web. The patch is trimmed to a pattern and bound with thread using an overlock stitch of 2.5 to 5 stitch per cm density and approximately 5±2 mm depth.
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BACKGROUND OF THE INVENTION
Smooth floor coverings have ancient origins. In the Bronze Age (1600-1000 BC) water-worn pebbles were laid as floorings in Crete and also on the Greek mainland. The Greeks, refining this technique between the sixth and the fourth centuries BC, installed decorative pebble mosaics. Such mosaics were also made from marble, serpentine alabaster, some forms of granite, and other stones suitably polished. Timber flooring, originally used in rough form for a strictly functional purpose, was eventually made into smooth boards, and was later used decoratively in the parquetry designs.
In recent times, the use of finished wood floors has declined in favor of linoleum, asbestos tile, vinyl tile floor tile and carpeting, due to the ease of maintaining all of these materials and due to the soft warm feeling underfoot of the last-named. The warm and luxurious appearance of finished wood flooring has been recognized and is still recognized among those who appreciate quality construction and fine building materials. There have been attempts to make floor coverings of synthetic materials such as plastic which resemble wood but these have generally been inadequate for one or more reasons. For example, some wear poorly due to the inability of the material selected to withstand the punishment inflicted by normal walking traffic and any of a variety of activities normally carried on on the floor of the home or commercial building. Others merely resemble wood, appearing even to the casual observer as being a wood simulation. Attempts have been made to make smooth-surfaced flooring materials more resilient underfoot to give a more luxurious, comfortable feel but these attempts have been inadequate due to the deficiencies in physical properties of the materials selected. For example, many rubbery materials contain fillers which interact with materials present in the atmosphere such as moisture, causing undesirable buckling and distortion. This situation would create a tripping hazard which would be intolerable if such an item were used to cover floors, especially where water is commonly present, for example, on walkways near the entrances of buildings.
SUMMARY OF THE PRESENT INVENTION
The present invention provides a unique, aesthetically attractive functional resilient wood replication which can be employed as a floor covering material and which avoids problems described above. The replication of the invention is provided by a resilient, elastomeric polyurethane base having a molded textured wood-grain surface which is coated with wood stain to resemble wood and overcoated with a clear, tough, abrasion-resistant, flexible, water-resistant polyurethane protective coating. The preferred configuration of the resilient wood replication of the invention is a floor tile having two mating ends and two parallel sides and a surface configuration having a wood-grain appearance of a plurality of parqueted natural wood pieces. One mating end of the tile has a male end portion and the opposite end is a complimentary female end portion such that a multiplicity of the tiles can be applied to a floor with the tiles mated together to provide an integral parquet floor design with the actual lines between separate tiles being virtually indistinguishable to the casual observer.
The resilient wood replication of the invention has a unique feel when walked upon which may be likened to walking on a layer of soft resilient rubber, providing an extremely comfortable surface underfoot. Additionally, the unique product of the invention has the warm and luxurious look of wood, it being virtually indistinguishable from real wood, yet much easier to apply and maintain. Moreover, the product of the invention is not subject to problems normally present with wood, such as being sensitive to water which causes wood to expand, contract, crack and discolor.
BRIEF DESCRIPTION OF THE DRAWING
Understanding of the invention will be facilitated by referring to the accompanying drawing wherein:
FIG. 1 is a plane view of one embodiment of the resilient wood replication of the invention in the form of a floor tile; and
FIG. 2 is a greatly enlarged fragmentary sectional view of the article of FIG. 1 taken at line 2--2.
PRESENTLY PREFERRED EMBODIMENT
As depicted in FIG. 2, the resilient wood replication of the invention is formed of a thick resilient elastomeric polyurethane base 20 having a molded textured wood-grain surface 21 which is coated with wood stain 22 and overcoated with a clear, tough, abrasion-resistant, flexible polyurethane protective coating 23.
A preferred embodiment of the resilient wood replication of the invention is a floor tile, most preferably in the shape shown in FIG. 2. As shown, the preferred floor tile has parallel sides 10 and 11 and mating ends. The preferred mating end has male portion 12 which resembles an arrowhead with a complementary female portion 13. This configuration is arrived at by forming the tile which is an integral structure appearing as having a set of pieces arranged with two crossed diagonal pickets, triangular pieces between two opposed spaces formed by the cross configuration of the pickets, and a square piece 18 in another space of the cross, with the remaining space being capable of accommodating that triangular part of square piece 18 which protrudes beyond the generally square shape of the main body of the tile. Each picket is pointed on its ends to provide 90° angles which form the corners of the tile where these pieces terminate. One picket appears to be bisected by and have its midportion interrupted by the other picket.
Each of the pickets may be divided along on its longitudinal axis as shown in FIG. 1 to give the design more interesting lines, providing picket parts 14 and 15 along one diagonal and picket parts 16 and 17 along the other diagonal. Square shaped piece 18 lies with one side adjacent piece 14 and an adjacent side abutting piece 17 to complete the male end of the tile, exposing edges 19 and 30 to provide end 12.
Each of the triangles which fit within the opposed spaces of the triangular spaces within the crossed picket configuration may also be divided, to provide more design detail, by a line perpendicular to their hypotenuse providing equal smaller triangles 31 and 32 and 33 and 34, respectively.
The pieces preferably do not fit immediately adjacent to one another but are separated by a small depression 35 which may be stained the darker color than the remaining surface of the tile. Preferably the wood-grain pattern in the pieces runs in the longitudinal direction where the pieces are elongate (e.g., pieces 14, 15, 16 and 17), with the grain of the remaining pieces preferably running as shown in FIG. 1. Such an arrangement of the wood grain in parquet tile is well known in the art of wood parquet flooring.
DETAILED DESCRIPTION
The polyurethane material forming the elastomeric base of the wood replication of the invention is initially liquid and capable of being cured to a product which is flexible, durable and tough, fairly resilient, and water-resistant. (By water-resistant is meant the material should not undergo any appreciable dimensional changes upon immersion in water.) This material should also, in the liquid state, have the ability of filling fine depressions in a mold, and be capable of nearly perfectly reproducing a counterpart of the mold's surface on its surface upon curing.
Suitable cured polyurethane elastomer compositions for use in the article of the invention will have an elongation of at least 50%, preferably from 90% to 150% and a tensile strength of at least about 100 psi, preferably from 120 to 700 as measured by ASTM D-412. To provide the proper feel underfoot, the polyurethane elastomer should preferably have a hardness value within the range of about 20 to 90 Shore A durometer. The polyurethane elastomer composition should also be resistant to permanent deformation at temperatures in the range of about -30° C. to +70° C. to retain its desired shape. Compressive strength as measured by ASTM D-575 Method A should preferably range from 150-4000 psi at 50% deflection. Tear strength as measured by ASTM test D-624 preferably exceeds 20 lbs. per inch thickness.
The elastomeric layer has a minimum thickness of 30 mils to provide the necessary resilience and supporting surface for use as a floor tile. Typical thicknesses for this base layer will be on the order of 100 to 250 mils for floor covering applications. Other shaped articles as hereinafter described may have a thicker elastomeric base layer.
A preferred polyurethane elastomer material for this purpose may be formed by a pourable reaction mixture of poly(oxypropylene) polyol and an organic polyisocyanate with a suitable crosslinking catalyst.
Pourable reaction mixtures of poly(oxyalkylene) polyol and organic polyisocyanate which harden from a liquid state to a solid elastomeric state under ambient temperatures and pressures may be readily formed by mixing approximately equivalent quantities, i.e., 0.8:1 to about 1.2:1, of organic, and preferably aromatic, polyisocyanate, and polymeric poly(oxyalkylene) polyol, and preferably 1,2-propylene oxide derived polyols. The reaction mixtures are preferably reacted in the presence of a suitable polyol-soluble metal catalyst for the reactants so that the reaction proceeds at ambient temperatures with great rapidity, e.g., one hour or less from a liquid to a substantially completely reacted solid state.
A number of soluble metal compounds have been found to catalyze such reaction mixtures under ambient conditions as for example, organo-tin compounds, lead salts of carboxylic acids, mercuric compounds, a combination of a calcium or lead salt of a carboxylic acid, such as calcium or lead octoate, an ionizable monoorgano-mercuric compound, such as phenyl mercuric acetate, and lead oxide. The total amount of the catalyst should not be less than about 0.1% of the reaction mixture, and, to hasten the setting-up of hardening time desired, may be adjusted upwardly to about 3%; or to such higher percentage as desired before the accelerating effect is lost or undesirable side effects become apparent.
For the elastomer to form as a tough, wear and abrasion resistant rubbery product, some trifunctionality may be desired to facilitate cross-linking of the reactants as well as chain extension thereof. This is readily accomplished by including some triisocyanate or triol or both in the reaction mixture. Thus, for example, when the reaction mixture is comprised essentially of an aromatic diisocyanate and polypropylene glycol a certain amount of trifunctionality can be built in very readily by pre-reacting from 5% to 15% of a triol such as trimethylol propane with the aromatic diisocyanate to form some triisocyanate or by including as part of the monomer charge for making the starting polymeric polyol from about 5% to 15% of a triol such as trimethylol propane, glycerine or the like. The resulting hardened product is a result of the one stage continuous reaction of this reaction mixture.
The elastomeric composition may contain up to about 75% by weight of a finely divided inert inorganic filler to reduce cost. The fillers should be selected to be inert in an elastomeric composition in the environment selected for use for the ultimate article. For example, a resilient wood replication containing a moisture-sensitive filler would be unacceptable because, in some instances, such moisture susceptibility may cause the article to swell or increase in size, causing it to buckle where it is in a confined location such as an inlaid floor covering. The fillers are finely divided, i.e., are in the form of powders or powder-like substances with the particles in very fine size ranges, smaller than about 100 microns and generally less than about 10 microns. Preferred fillers include silica, dried calcium carbonate and the like.
The molded wood-grain surface of the base layer is provided by casting the liquid polyurethane precursor in a suitable mold which has a negative pattern corresponding the wood-grain desired. For this purpose, flexible molds made of RTV silicone rubber have been found to be especially suitable. Such molds may be prepared by pouring liquid silicone polymer into a suitable vessel containing a wood original, curing the polymer, and removing the wood.
The stain employed to provide the color or pigmentation to the textured surface of the elastomeric base of the article of the invention may be either the penetrating type or the wiping type. Such stains are water- or solvent-soluble dyes, or chemically reactive agents which normally color wood. These materials have been found to also color the polyurethane compositions forming the elastomeric base layer of the article of the invention. Such stains typically are formed of synthetic or naturally occurring chemical compounds in a liquid vehicle which may also contain a small amount of binder. Dyeing type stains are not preferred because they stain polyurethane elastomer poorly, staining its surface a monotone rather than providing the contrasting tones that one would expect from wood.
The penetrating type stain typically contains a liquid vehicle organic or aqueous solvent, pigment and a polymeric material such as nitrocellulose, ethyl cellulose or an acrylate binder. Such penetrating stains are painted on the surface and permitted to dry by evaporation of the vehicle and require no curing of the polymeric binder. Wiping stains on the other hand contain a drying oil base and pigment in a liquid vehicle. Typically, the drying oil base is linseed oil or an alkyd oil. As the name applies, the wiping type stain usually does not penetrate, but it is applied and remains on the surface much in the same manner as paint. Upon exposure, the liquid vehicle of the wiping stain evaporates, if one is used, and the drying oil polymerizes to form a non-tacky pigmented polymeric layer on the surface of the article being stained. Such stains typically will produce stained articles according to the invention in colors such as walnut, cherry, mahogany, pecan and the like. Virtually any desired color may be produced by the selection of the appropriately pigmented stain. Unlike when staining wood, the product of the invention stains quite uniformly because there are no areas on the surface of the elastomeric base which are more porous than other areas, as is typically found in wood.
Some stain formulations which have been found to be especially suitable include that sold under the trade identification "Natural Walnut 46-506" by the Elliot Paint and Varnish Company of Chicago, Illinois, "American Walnut Stain" by the Colony Paints Division of Conchem Company, Inc., "Spiced Walnut, Blondit Wood Finish" by James B. Day and Company and "American Walnut 640.00, Penchrome" by the O'Brien Corporation.
The polyurethane protective coating covering the wood-grain textured surface of the article of the invention is formed of a polymeric material which has good adhesion to the stained surface of the polymeric elastomer even under high stress, multiple flexing use, is highly abrasion resistant, flexible, transparent, water resistant and tough. For this purpose, the polyurethane forming this coating should have an elongation of from about 200 to 600% and a tensile strength of at least about 1500 psi. The thickness of the polyurethane protective coating should be no less than 1 mil to provide the proper protection for the surface of the elastomeric base. Typical thickness for this layer will vary within the range from about 2 mils to about 20 mils. The protective coating may be applied in a thickness sufficient to obviate any surface roughness on the texture surface of the elastomer base. This may be desired where a completely smooth floor covering is desired, for ease of cleaning.
An especially useful polyurethane protective coating may be formed of a prepolymer prepared by reacting poly(oxypropylene) glycol, poly(oxypropylene) triol and polymethylene polyphenyl isocyanate and reacting this prepolymer in the presence of moisture with an amine-terminated polyether hydrofuran.
Other useful polyurethane protective coating formulations include the following commercially available materials: (1) elastomeric polyurethane lacquer available from the Spencer Kellogg Company under the trade designation "DV 1666";(2) polyurethane elastomer adhesive composition available from the Spencer Kellogg Company under the trade designation "XP 2519"; and (3) polyurethane elastomeric lacquer composition sold under the trade designation "Permuthane" by the Beatrice Chemical Company.
Some commercially available polyurethane compositions which have been found to be unacceptable include the following: (1) polyurethane composition sold by Spencer Kellogg Company under the trade designation "M 21"; and (2) polyurethane composition sold by the Spencer Kellogg Company under the trade designation "M 22". The latter two compositions wrinkled the surface of the resilient wood replication article when it was subjected to stress.
While the general tenor of the foregoing has been to indicate utility of the resilient wood replication of the invention as being useful as a floor tile, the article of the invention, appropriately shaped, is useful for any of a wide variety of purposes. For example, the article of the invention may be shaped in the form of casings for windows or doors, baseboard molding, floor planking, wall covering, chair rails, decorative parts, picture frames, and the like. Modifications may be made in any of the articles mentioned above without departing from the scope of the invention. For example, the floor tile may be coated with pressure sensitive adhesive or other adhesive on its bottom side for ease of mounting and designs other than those described for the floor tile may be also employed. The floor tile may also be fitted with a foam backing to give it even more resilience or it may be made using a foamed polyurethane elastomer as a base.
The invention is further illustrated by reference to the following examples, in which all parts and percentages are by weight unless otherwise noted.
EXAMPLE 1
A wood original was prepared by cutting pieces of 3/4 inch thick oak in shapes substantially the same as those comprising the tile shown in FIG. 1 and permanently adhering them to a plywood backing in the arrangement shown in FIG. 1. The surface of the oak was brushed with a rotary wire brush to enhance the wood grain. Wooden strips 9/16 inch thick and 1/2 inch wide were then fastened to the plywood backing to form a continuous ridge adjacent the peripheral edge of the wood original, and additional wooden strips 1 inch thick and 1/2 inch wide were fastened to the plywood adjacent the aforementioned ridge to form the outer edges of a mold cavity to retain curable liquid silicone material which would be cured to form the flexible mold. The mold was then prepared by pouring sufficient room temperature vulcanizable (RTV) silicone resin sold under the trade designation "Silastic" J RTV to fill the cavity and completely cover the wood original, permitting the silicone liquid resin to cure for approximately 24 hours at room temperature and then separating the silicone rubber mold from the wood original. Several molds were prepared in this manner and attached end to end on an endless belt.
The liquid polyurethane precursor material which on curing would form the polyurethane elastomer base was prepared of the following ingredients:
______________________________________Part AIngredients Parts______________________________________Polypropylene glycol having a molecularweight of 2000 31.8SiO.sub.2 filler having a particle size onthe average of 2.8 microns 67.3Phenyl mercuric acetate catalyst 0.15Butylated hydroxy toluene (sold underthe trade designation "Ionol") 0.10TiO.sub.2 pigment 0.65______________________________________
______________________________________Part BIngredients (per 100 parts Part A)Polyphenylene polyisocyanate having anequivalent weight of 135 (sold underthe trade designation "Mondur" MRS) 5.3______________________________________
The Part A ingredients were blended in a paddle mixer for approximately one hour to form a homogenous mixture which was degassed to remove entrapped air and moisture and then pumped into a mixing head where the Part B ingredient was added with additional mixing. The resultant mixture was then pumped into an extruding head fitted with a die having a 20 inch wide rectangular extrusion orifice capable of filling the molds to a thickness of about 185 mils. The filled molds were then passed through a forced air oven heated at about 120° C. for a dwell time of about 10-20 minutes to cure the polyurethane elastomer. The cured elastomer had a Shore A hardness of 81, a tensile strength of 373 psi, a 132% elongation at break, and a tear strength of 66 lbs. per inch thickness.
The cured elastomer shape was removed from the mold, and then conveyed wood-grain-textured-surface down into a dip coater station where a soya alkyd resin based walnut stain was applied, the excess stain wiped from the stained surface and the resultant stain coating dried at about 120° C. for 5 to 10 minutes. The dried stained textured surface was then passed through a curtain coating station to provide a dry coating weight of from 4 to 8 mils of a polyurethane protective coating. The curtain coater was that manufactured by the Gasway Division of the Wolverine Pentromix Inc. of Chicago, Illinois. The polyurethane protective coating formulation consisted of the following ingredients:
Polyurethane Protective Coating Formulation
______________________________________Part AIngredient Parts______________________________________Solvent - a narrow range of mid- to highboiling hydrocarbons having 94% aromaticand 4% aliphatic constituents with a100° C. flash point 49.Polytetramethylene ether diol having amolecular weight of 1000 17.Poly(oxypropylene) triol having amolecular weight of 450 1.5Glycol mono-acetate (approx.) 7.Polyvinyl chloride powder flattening agent(sold under the trade designation"Marvinol" 53) 2.3Sodium silicate (sold under the tradedesignation "Syloid" 244)4.8Bentonite Clay thickening agent (soldunder the trade designation "Bentone" 34) 0.8Dibutyl tin dilaurate 0.031,1,1 Trichloroethane 6.7
______________________________________Part BAmine-terminated polyether hydrofuransolution 21.3% solids in toluene(sold under the trade designation"EPX" polymer solution) 54.Solvent - described in Part A 43.Triethylene diamine 1.3Dibutyl tin dilaurate 1.3______________________________________
The dried polyurethane protective coating had an elongation of 300-350% and a tensile strength of 4600 psi. Wear resistance evaluation of this cured polyurethane composition, determined by use of a "Taber" abrader device Model 503-1 according to ASTM D1242, resulted in a weight loss of range 6-13.0 mg after 5000 cycles with a load of 1 kg, this being a superior result as compared to other commercially available floor covering materials.
The backside of the resultant coated composite was ground to a uniform flat surface and thickness of 150 mils to produce a finished floor tile.
Examples 2-7 show other useful polyurethane elastomer base formulations.
EXAMPLE 2
______________________________________Part AIngredient Parts______________________________________Poly(oxypropylene) glycol having amolecular weight of 2000 30SiO.sub.2 (2.8 micron average particle size) 65Phenyl mercuric acetate catalyst 0.14Butylated hydroxy toluene (sold underthe trade designation "Ionol") 0.095______________________________________
______________________________________Part BIngredient Parts______________________________________Polyphenylene polyisocyanate having anequivalent weight of 135 (sold underthe trade designation "Mondur" MRS) 4.8______________________________________
EXAMPLE 3
Same as Example 2 but substituting the SiO 2 with an equal weight of calcium carbonate having a particle size less than 75 microns and a mean particle size of 12 microns.
EXAMPLE 4
______________________________________Part AIngredient Parts______________________________________Poly(oxypropylene) glycol having amolecular weight of 2000 51SiO.sub.2 (2.8 micron average particle size) 40Phenyl mercuric acetate 0.14______________________________________
______________________________________Part BIngredient Parts______________________________________Polyphenylene polyisocyanate having anequivalent weight of 135 "Mondur"Mondur[ MRS) 8.7______________________________________
EXAMPLE 5
Same as Example No. 4 but substituting the SiO 2 with an equal weight of calcium carbonate described in Example 3.
EXAMPLE 6
______________________________________Part AIngredient Parts______________________________________Poly(oxypropylene glycol having amolecular weight of 2000 16.3Poly(oxypropylene triol having amolecular weight of 1500 13.2Butylated hydroxy toluene 0.2Phenyl mercuric acetate 0.17SiO.sub.2 (2.8 micron average particle size) 62.86______________________________________
______________________________________Part BIngredient Parts______________________________________Toluene diisocyanate 7.23______________________________________
EXAMPLE 7
Same as Example No. 6 but substituting the SiO 2 with an equal weight of CaCO 2 described in Example 3.
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Resilient wood replication especially suited for use as floor covering is provided by a thick resilient elastomeric polyurethane base having a wood-stained molded textured wood-grain surface which is overcoated with a clear, tough, abrasion-resistant, flexible, water-resistant polyurethane protective coating. A preferred configuration of the resilient wood replication is a floor tile having opposed mating ends and two parallel sides and a surface configuration having a grain appearance of a plurality of parqueted natural wood pieces. A multiplicity of the tiles can be applied to the floor with complimentary ends fitted together to provide a continuous mass of tile having the actual lines between separate tiles virtually indistinguishable to the casual observer.
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BACKGROUND OF THE INVENTION
The present invention relates to a plastics metering pump, comprising two rotors which are coupled to each other by means of gearwheels and can be driven in opposite directions and which are mounted in a pump housing provided with suction connection and outlet connection, wherein each rotor has a rotor shaft, the rotor shaft ends of which are supported in the walls of the pump housing.
Metering pumps are known in all sizes and construction types. As plastics metering pumps are known, in particular, manually operated piston pumps, as are known on soap dispensers for liquid soaps or, as here particularly of interest, also in the hotel and catering industry, where, for instance in fast food outlets, mustard, ketchup or coffee cream are dispensed in metered volume with such manually operated piston pumps. Despite these metering pumps, the dispensed quantity varies relatively strongly however, since, in the metering pumps, in particular of the kind just described, the stroke path should actually be fully utilized with each actuation, yet this is generally not the case. Instead, one, two or three short strokes are often performed and the quantity accordingly varies very strongly. As long as this quantity is dispensed merely as the accompaniment to a hamburger, this is of only minor importance. However, where such metering pumps are also used to add a specific quantity of a liquid food to a recipe, the taste is varied by incorrect actuation, which is not always appreciated by the customers.
Although various different pumps are perfectly well known, in particular including rotor pumps, these are mostly designed as relatively high-precision metering pumps made of metal, and this is also necessary in the food industry, where large quantities have to be dispensed in metered volume. For commercial application, however, mostly very cheap disposable metering pumps are provided, generally free of charge. Accordingly, such metering pumps must be made of plastic, have a structure which is as simple as possible, and work reliably.
The plastics metering pump which is here of interest should in particular be conceived for foods which are dispensed in so-called tubular bags, or other flexible packagings made of plastics sheets.
Many liquid foods also contain relatively large solid components. Typical examples of liquid foods of this kind are, for instance, tartare sauce, mustard sauces with pickles, vanilla sauce with chocolate and almond slivers, etc. With the currently standard metering pumps, liquid foods of this kind cannot be dispensed in metered volume. In particular with so-called gear pumps, as one such is represented, for instance in FR-2313971, this is scarcely realizable. In the case of larger solid particles, such as, for instance, almond sticks, these are ground by the rotors or block the rotors. Accordingly, for such metering pumps, in particular metering pumps in which the rotors have two-bladed or multi-bladed rolling elements, enter into consideration. Examples of such pumps are known from U.S. Pat. No. 3,054,417, where a metering pump for liquid mediums for the admixture of further liquids is shown, wherein in this case each rotor has three impellers and these impellers roll one against another and thus transport the medium onward. In such pumps, between the housing and the individual rotor blades there is sufficient space to transport also liquids with solid parts. Here the larger solid parts are less a problem than, in fact, the smaller solid parts, which remain stuck to the rotor blades rolling mutually one against another and in the course of the rolling process, are completely crushed, whereupon a coating can form, which coating reduces the discharge capacity and can even lead to blockages.
The same also applies to a metering pump of WO 95/24556, in which only two-bladed rotors are represented, but which rotors likewise roll mutually both one against another and against the housing wall.
A further rotary piston pump is known from EP-1 892 417. This is conceived, however, as an insert for an outer metallic housing, but is created for single use and has a housing made of plastic. The toothed gear with which the correct relative position of the two rotors is ensured is a component part of a gearing disposed outside the actual pump and not a component part of the parts provided for single use. Although the rotors, which intermesh during operation, have concave recesses, these are not shaped in such a way that the rotary piston pump is particularly suitable for products with solid components. In particular, the comparatively tight radii of the concave recesses allow deposits to develop precisely in these regions, which deposits remain in the pump and, in the case of foods, possibly quickly perish through contact with the outside air.
SUMMARY OF THE INVENTION
Consequently, the object of the present invention is to provide an improved disposable metering pump which has a relatively large discharge capacity and is particularly suitable for the conveyance of solid-liquid mixtures without herein possessing the previously described drawbacks.
This object is achieved by a plastics metering pump of the type stated in the introduction, which is distinguished by the fact that each rotor has rotor blade shoes and concave recesses which are optimized in their shaping with regard to the attainment of minimal product residues.
Optimization with regard to the attainment of minimal product residues here means that the shaping of the rotor blade shoes and of the concave recesses is configured and mutually coordinated such that either no or only as few as possible product residues get stuck in the concave recess regions, or that stuck product residues in the concave recess regions are scraped off again, as fully and as continuously as possible, by the end edges of the rotor blade shoes during operation and transported onward.
In a preferred embodiment, each rotor has for this purpose partially cylindrical rotor blade shoes and concave recesses, the respective curvatures or radii of curvatures of which are in parts at least approximately equal in size. The precise curves are naturally obtained from the oppositely directed rolling or meshing motions of the two rotors.
BRIEF DESCRIPTION OF THE DRAWINGS
Further advantageous embodiments of the subject of the invention emerge from the dependent claims, and their importance and working method are described in the following description with reference to the appended drawing.
In the drawings, a preferred illustrative embodiment of the subject of the invention is represented, wherein:
FIG. 1 shows a preferred use of the disposable metering pump according to the invention, fitted on a tubular bag,
FIG. 2 shows a perspective view of the disposable metering pump of FIG. 1 with the fastening connections, wherein the detachable pump housing wall has been removed,
FIG. 3 shows the metering pump, once again, in a side view, the detachable pump housing wall having been omitted, while
FIG. 4 shows the two rotors in isolation in correct relative position to each other in perspective view,
FIG. 5 shows a single rotor in perspective view, viewed from the gearwheel side,
FIG. 6 represents a perspective partial view of the pump housing in isolation, and
FIG. 7 represents the detachable pump housing wall in perspective view with a view onto the inner side thereof,
FIG. 8 shows the meshing of the two rotors in two different angular positions.
DETAILED DESCRIPTION
In FIG. 1 , a preferred application of the metering pump according to the invention, denoted in its entirety by 1 , is represented symbolically on a tubular bag 2 . The metering pump 1 is held on the tubular bag 2 by means of a fastening connection 3 provided with a flange 4 . The connection of the flange 4 to the tubular bag 2 is preferably made by ultrasonic welding.
The metering pump itself possesses a pump housing 5 having a suction connection 6 and an outlet connection 7 . The suction connection 6 is screw-connected to the fastening connection 3 . The metering pump itself is here shown with a view onto a fixed end wall 8 of the pump housing 5 , wherein a rotor shaft end 15 , provided with a drive coupling part 16 , here juts through the aforementioned fixed end wall 8 and the drive coupling part 16 is apparent. The drive coupling part serves to be positively connected to a drive means (not represented here).
In FIG. 2 , the metering pump 1 with the fastening connection is represented in isolation. In this perspective view, the view is directed obliquely from above onto the aforementioned flange 4 and opening means 17 are apparent, which are here configured as perforating and cutting teeth and, in this position, prior to first use, still lie fully within the suction connection 6 . Prior to first use, the pump housing 5 , with its suction connection 6 , will be screwed in the fastening connection 3 as far as a stop, whereupon the aforementioned opening means 17 cut open an aseptically closed container, preferably a tubular bag made of plastics sheet. In that transport position of the metering pump 1 which is represented here, the outlet connection 7 is provided, moreover, with a closing cover 18 , which ensures that, during the transport and storage, no foreign substances or foreign particles can make their way into the metering pump.
In FIG. 2 , the pump housing 5 is represented open. While in FIG. 1 , as already mentioned, the view is directed onto the fixed end wall 8 of the pump housing 5 , here the metering pump 1 is represented rotated through 180° and the view is directed onto that side of the metering pump 1 which has a detachable end wall 9 . This detachable end wall 9 is shown laterally offset or detached. The detachable end wall 9 can also be referred to as a pump housing cover. In this figure, the view is directed onto the outer side of the pump housing cover and outwardly protruding, closed bearing bushings 19 are apparent, which on the inner side (see also FIG. 7 in this regard) are capable of receiving the rotor shaft ends 15 . The outwardly closed bearing bushings 19 are held stabilized with stiffening ribs 20 on the outer side of the detachable end wall 9 .
In FIG. 3 , the metering pump 1 is shown in side view, yet in the same usage position as in FIG. 2 , though with the detachable end wall 9 of the pump housing 5 having been omitted. In this view can clearly be seen the two rotors 10 , which are mounted in the pump housing 5 and onto which are formed, preferably integrally, gearwheels 11 , which cause the two rotors to move in opposite directions when one of the two rotors is driven. With regard to the exact configuration of the two rotors 10 , reference is made to the following FIGS. 4 and 5 . In FIG. 3 , it is apparent that each rotor is provided with a rotor shaft 12 , wherein the view is here directed onto the rotor shaft ends 15 , and wherein two mutually diametrically opposing rotor blade walls 13 are respectively formed onto the rotor shafts 12 . Onto the peripheral ends of the rotor blade walls 13 is respectively formed a rotor blade shoe 14 . Each rotor blade shoe possesses a partially cylindrical shape, which is matched in curvature to the cylindrical part of the pump housing 5 . As can be seen here (but also from FIG. 8 ), each rotor blade shoe 14 either bears constantly onto the inner side of the pump housing or, with an end edge 22 of the rotor blade shoe 14 , grazes a concave recess 24 of the adjacent rotor.
In FIG. 4 , the configuration of the two rotors can now be seen in detail. Although these are represented in isolation in a correct relative position as provided in the installation, the pump housing 5 has been omitted. The parts mentioned already in connection with FIG. 3 , namely the rotor shaft 12 and the corresponding rotor shaft ends 15 , are here referred to once again. The specific embodiment of the rotor blade shoes 14 and of the rotor blade walls 13 can be seen particularly clearly in this figure. As already mentioned, the rotor blade shoes 14 are integrally formed onto the peripheral ends of the rotor blade walls 13 . The rotor blade shoes 14 have a partially cylindrical outer face 21 having end edges 22 . The radius of curvature of this outer face corresponds to the distance between the axis A which passes through the middle of the rotor shaft 12 , running in the longitudinal direction thereof, and the outer face 21 of the rotor blade shoes 14 . Furthermore, concave recesses 24 are formed on both sides, between the rotor shafts 12 and the rotor blade shoes 14 , into the rotor blade walls and the rotor blade shoes 14 respectively. The bilaterally identical concave recesses 24 merge in a region close to the rotor shafts into the actual (relatively narrow) rotor blade walls 13 .
As already mentioned, the shaping of the rotor blade shoes and of the recesses is with regard to minimal product residues. As can be seen from FIG. 4 , the curvature of the partially cylindrical rotor blade shoes 14 and the curvature of the concave recesses 24 is at least approximately equal in size. With this design optimization, the aim is that, in the region of the concave recesses 24 , as far as possible no niches exist in which material residues could remain such that they cannot not be scraped off.
Preferably, both rotors 10 are absolutely identical in design, moreover, in order that only one injection mold is required for their production. This also has the advantage that also no source of error arises in the assembly when the two rotors have the same design.
The metering pump according to the invention is preferably designed practically such that the pump seals the connection between the suction connection 6 and the outlet connection 7 . To this end, the pump or its rotors 10 and the pump housing 5 have sealing elements. However, these sealing elements have at the same time also a cleaning effect and prevent deposits in the pump housing, which deposits which might lead to a reduction in quality and to leaks, and also, in the worst case, to blockages of the pump.
In FIG. 4 it is additionally apparent that the rotor blade walls 13 possess end faces 26 . On the end faces 26 , which in the installed state of the rotors in the pump housing 5 end up toward the detachable end wall 9 or the pump housing cover, is respectively arranged a sealing lip 27 , extending from the middle of the rotor shaft ends 15 to the outer face 21 of the rotor blade shoes 14 . Bearing onto the opposite end face, which is not visible here (see FIG. 5 in this regard), are the gearwheels 11 , such that these are integrally connected to the end faces. Here, such sealing lips will be fitted to the corresponding end face sections such that they run only from the corresponding gearwheel to the outer face 21 of the rotor blade shoes.
In order that also the rotor blade shoes 14 are sealed with respect to the rotor shaft 12 , also longitudinal scraping ribs 28 are fitted on the rotor shaft 12 . These longitudinal scraping ribs 28 run parallel to the axis A of the rotor shaft 12 . In principle, it is here sufficient to fit in each case one longitudinal scraping rib 28 on each rotor shaft 12 , though preferably two such longitudinal scraping ribs are respectively fitted on the same side. These longitudinal scraping ribs 28 not only have a sealing effect, but also clean the rotor blade shoes 14 , on the outer side 21 thereof, of any deposits which might form there. By virtue of these design features, to all intents and purposes a metering pump which is self-cleaning and very low in residues is formed.
For the purposes of better understanding, FIG. 5 shows another rotor in perspective view from the gearwheel side. Here, the integrally formed-on gearwheel 11 , as well as the drive coupling part 16 , are clearly apparent.
In FIG. 6 , the pump housing 5 is represented in isolation. The suction connection 6 and the outlet connection 7 can be seen only to some extent. In this view too, the pump housing cover, or the detachable end wall 9 of the pump housing 5 , is once again removed. The view is thus directed onto the inner side of the fixed end wall 8 of the pump housing 5 . Second bearing bushings 29 , 30 are formed herein. one second bearing bushing 29 being of closed design and the other second bearing bushing 30 being continuously open to the outside. Into this open bearing bushing 30 is preferably formed a circumferential sealing lip 31 of lesser height. A plurality of such circumferential sealing lips 31 can also however be present and thus form, to all intents and purposes, a type of labyrinth seal.
With reference to FIGS. 4 and 5 , it can be seen that the rotors 10 have on their rotor shafts 12 , on both sides, rotor shaft ends 15 , which are designed as bearing journals 35 . The bearing journals 35 on the side of the pump housing cover 9 have a smaller diameter, while the bearing journals 35 on the other, gearwheel side have a substantially larger diameter. Since as already mentioned, however, the two rotors are identical in design, both rotors also have on that rotor shaft end with the larger diameter the aforementioned drive coupling part 16 , which has already been described with reference to FIGS. 1 and 5 . While the open bearing bushing 30 is arranged on the left in FIG. 1 , and thus the drive coupling part 16 (which can of course be variously designed) is recognized there, the closed bearing bushing 29 is represented on the right in FIG. 1 . In FIG. 6 , in which the pump housing is now seen from the inner side, the closed, second bearing bushing 29 is consequently apparent on the left and the second, open bearing bushing 30 on the right. Only in the second, open bearing bushing 30 will the aforementioned circumferential sealing lip 31 be fitted.
In FIG. 7 , the detachable end wall 9 or the pump housing cover is now represented in isolation. On the circumferential rim can be recognized a plurality of flexible tongues 32 , which on the outside of the pump housing 5 , in the closed state of the pump housing cover, hook onto the latching means 33 with appropriate cams 34 .
As already mentioned, bearings are also formed into the detachable end wall 9 . These are here referred to, however, as closed bearing bushings 19 . Since these bearing bushings 19 are closed, no additional sealing means are necessary here. The diameter of these closed bearing bushings 19 is substantially smaller than the diameter of the two bearing bushings 29 and 30 . In these closed bearing bushings 19 engage the rotor shaft ends 15 , which are designed as bearing journals 30 , as can most clearly be seen in FIG. 4 .
Finally, by way of further illustration, FIG. 8 shows the meshing of the two rotors 10 in two different angular positions. Analogously to FIGS. 2-4 , the two rotors are shown on the left-hand side of the diagram in a correct first relative position, as in installation. Since the two rotors 10 rotate in opposite directions, the position thereof following rotation through an angle α is represented on the right-hand side of the diagram in turn in a correct second relative position. It is clearly apparent that the end edges 22 of the rotor blade shoes 14 touchingly brush the concave recesses 24 of the adjacent rotor. It is thus clearly illustrated that the end edges of the rotor blade shoes respectively follow the curvatures of the concave recesses, to be precise, as intended in such a way that any residues in the concave recesses are scraped off and transported onward. Because this brushing, in dependence on other design specifications for the disposable metering pump, may possibly not always be ideally achieved, with regard to the shaping of the rotor blade shoes and of the recesses, an optimization with regard to minimal product residues is spoken of. “Optimization” thus means, in the mathematical sense, that a pay-off function is minimized or maximized.
With the here described metering pump 1 , fluids, and also mixtures of fluids and solids, can be conveyed without difficulty. The size of the solid particles is here practically immaterial, though they must, of course, be of a size that is smaller than the distance between the two rotor shafts. Whether the solid parts are coarse-grained or fine-grained, and thus have a greater or lesser tendency to form deposits, is immaterial however. On the one hand, the solid parts are not ground and, on the other hand, the depositing thereof on the pump housing, as well as on the rotor blade shoes or on the rotor shafts, is continually removed by the means previously described. It is thereby ensured that the metering pump, which serves as a disposable metering pump, always operates reliably for the working life which is necessary. Since moreover, by virtue of the previously described design, a high sealing tightness exists between the outlet connection 7 and the tubular bag 2 , a practically aseptic state is maintained in the tubular bag throughout the emptying process. Accordingly, the food which is supplied in the fully closed aseptic tubular bag can be offered without, or at least with substantially less preservatives.
REFERENCE SYMBOL LIST
1 metering pump
2 tubular bag
3 fastening connection
4 flange
5 pump housing
6 suction connection
7 outlet connection
8 fixed end wall of the pump housing
9 detachable end wall of the pump housing (pump housing cover)
A axis of the rotor shaft
10 rotor
11 gearwheels
12 rotor shaft
13 rotor blade walls
14 rotor blade shoes
15 rotor shaft ends
16 drive coupling part
17 opening means
18 closing cover
19 closed bearing bushings
20 stiffening ribs
21 outer face of the rotor blade shoes
22 end edge of the rotor blade shoes
23 unused
24 concave recess
25 unused
26 end face
27 sealing lip
28 longitudinal scraping ribs
29 second bearing bushings, closed
30 second bearing bushings, open
31 circumferential sealing lip in open bearing bushing
32 flexible tongues
33 latching means
34 cams
35 bearing journals
α angle
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A disposable metering pump is made of plastic for products having solid fractions. The disposable metering pump has two rotors ( 10 ) which are coupled to each other by means of gears ( 11 ), can be driven in opposite directions, and are supported in a pump housing ( 5 ). Each rotor ( 10 ) has a rotor shaft, the rotor shaft ends ( 15 ) of which are supported in the walls of the pump housing ( 5 ). Each rotor ( 10 ) has two rotor blade walls ( 13 ), which are arranged diametrically opposite on the rotor shaft. One partially cylindrical rotor blade shoe ( 14 ) is formed at each of the peripheral ends of the rotor blade walls. The rotor blade shoes ( 14 ) lie against the cylindrical inner wall regions of the pump housing ( 5 ) in a sliding and sealing manner.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The subject invention relates to methods, apparatus and systems for mounting a hollow-cylindrical member and, from another aspect thereof, to tape recording methods, apparatus and systems and tape transports. By way of example, the subject invention more specifically relates to apparatus for mounting tape reels for winding and storing magnetic recording tape and other web-like material, herein sometimes generically referred to simply as "tape."
2. Disclosure Statement
The disclosure statement is made pursuant to the duty of disclosure imposed by law and formulated in 37 CFR 1.56(a). No representation is hereby made that information thus disclosed in fact constitutes prior art, inasmuch as 37 CFR 1.56(a) relies on a materiality concept which depends on uncertain and inevitably subjective elements of substantial likelihood and reasonableness, and inasmuch as a growing attitude appears to require citation of material which might lead to a discovery of pertinent material though not necessarily being of itself pertinent. Also, the following comments contain conclusions and observations which have only been drawn or become apparent after conception of the subject invention or which contrast the subject invention or its merits against the background of developments subsequent in time or priority.
Modern instrumentation tape recorders and data processing machines deliver to their tape reels very high torque which is subject to many frequent reversals, as the tape advance is rapidly reversed in such recorders and machines. This subjects tape reels to tremendous, rapidly varying forces which tend to loosen the reel on its mounting hub. Such looseness, in turn, causes pounding of the reel and tape mass on the mounting hub, progressively damaging reel and hub and adversely affecting the tape transport and recording/playback process.
None of the proposals consulted in preparation of the subject disclosure appears to offer any solution to this pressing problem. In particular, U.S. Pat. No. 1,928,979, by R. Levison, issued Oct. 3, 1933, provides a spool and spool holder for threads in which spool retention blades are biased radially by rubber bands and extend through corresponding slots in the spool, so as to be contacted by the wound material. U.S. Pat. No. 2,529,185, by H. G. Proctor, issued Nov. 7, 1950, employs wedge surfaces for forcing barrel segments in a collapsible takeup spool outwardly, thereby interlocking the barrel segments and a cover plate of the collapsible spool. U.S. Pat. No. 2,647,701, by W. H. Cannard, issued Aug. 4, 1953, discloses an expansible core chuck in which annular members of elastic material are expanded into the hollow-cylindrical inner member of a spool or reel. A spate of other expansible core chuck proposals is apparent from U.S. Pat. No. 2,749,133, by J. C. Rich, issued June 5, 1956, U.S. Pat. No. 2,903,200, by A. E. McDougall et al, issued Sept. 8, 1959, U.S. Pat. No. 3,002,705, by W. D. Isbell, issued Oct. 3, 1961, U.S. Pat. No. 3,108,757, by A. T. Williams et al, issued Oct. 29, 1963, and U.S. Pat. No. 3,510,082, by E. A. Sexton et al, issued May 5, 1970, while U.S. Pat. No. 3,712,561, by J. E. Williams, issued Jan. 23, 1973, proposes the employment of frictional pads which are forced into radial engagement with the inside of a tape reel.
In practice, none of these proposals would adequately retain a reel or spool against high and rapidly reversing torque forces. The same applies to proposals which employ radially expanding fingers or segments for reel or roll retention purposes, as may be apparent from U.S. Pat. No. 2,904,278, by C. C. Riemenschneider, issued Sept. 15, 1959, U.S. Pat. No. 3,214,107, by E. D. Atkin, issued Oct. 26, 1965, U.S. Pat. No. 3,278,132, by M. Camras et al, issued Oct. 11, 1966, U.S. Pat. No. 3,463,519, by J. C. Raymond, issued Aug. 26, 1969, and U.S. Pat. No. 4,079,896, by E. F. Plach, issued Mar. 21, 1978. Reference may also be had to U.S. Pat. No. 3,239,159, by W. D. Cohen, issued Mar. 8, 1966, and disclosing a tape-collecting reel employing resilient members for supposedly easy removal of the reel from its driving connection and of the tape itself from the reel.
The seriousness of the problem to which the invention addresses itself may be seen from the fact that otherwise outstanding reel hub constructions do not as such offer a solution to the subject problem in the sense of the present disclosure. Reference may in this respect be had to U.S. Pat. No. 3,140,061, by W. M. Benson, issued July 7, 1964, and employing inclined wedges for releasably retaining a reel on a rotating hub, U.S. Pat. No. 3,233,841, by J. J. Neff, issued Feb. 8, 1966, and disclosing bidirectionally acting reel hub segments for engaging the inside of a reel core, and U.S. Pat. No. 4,183,475, by H. M. Martija, issued Jan. 15, 1980, and disclosing a chuck for retaining reels of various widths employing an expansible split retention ring which is driven up a ramp on an annular reel hub member.
SUMMARY OF THE INVENTION
It is a broad object of this invention to overcome the disadvantages and satisfy the needs expressed or implicit in the above disclosure statement or in other parts hereof.
It is a germane object of this invention to provide improved methods, apparatus and systems for mounting hollow-cylindrical members, such as cores of tape reels.
It is a related object of this invention to provide improved methods, apparatus and systems for releasably retaining a hollow-cylindrical member on a rotatable hub against forces tending to loosen such member.
It is also an object of this invention to provide improved tape transports performing well under conditions of high torque and frequent torque reversals.
Other objects of the invention will become apparent in the further course of this disclosure.
From a first aspect thereof, the subject invention resides in methods and apparatus for releasably retaining a hollow-cylindrical member on a rotatable hub against forces tending to loosen such member. The invention according to this aspect resides, more specifically, in the provision of a wedge-shaped member for engaging the hollow-cylindrical member on the inside thereof, a ramp on the hub for the wedge-shaped member, and methods or means for driving the wedge-shaped member up the ramp into engagement with the inside of the hollow cylindrical member.
Looseness between the releasably retained hollow-cylindrical member and the hub are inhibited by urging the wedge-shaped member further up the ramp after engagement with the inside of the hollow-cylindrical member and continuously during rotation of the hub.
The sample just given of an aspect of the subject invention is not intended to have any limiting effect on the subject disclosure and its appendant claims, and other aspects of the invention are given in the more conveniently pursuable context of the description of preferred embodiments, without intending any limitation to any specific embodiment or group of embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention and its various aspects and objects will become more readily apparent from the following detailed description of preferred embodiments thereof, illustrated by way of example in the accompanying drawings, in which like reference numerals designate like or functionally equivalent parts, and in which:
FIG. 1 is a side view, partially in section, of a reel hub assembly with mounted reel, according to a preferred embodiment of the subject invention;
FIG. 2 is a view taken along the line 2--2 in FIG. 1; and
FIG. 3 is an exploded view of essential parts of the reel hub assembly of FIGS. 1 and 2.
DESCRIPTION OF PREFERRED EMBODIMENTS
The drawings show a reel hub assembly 10 for releasably retaining a hollow-cylindrical member, such as the core 11 of a tape reel 12 on a rotatable hub 13 against forces tending to loosen the member or core 11, particularly during rapid reversal of the sense of rotation of the reel mounting hub 13.
The hub 13 has a shaft 14 connected to a reel drive which, by way of example, may include a rapidly reversing electric motor with or without transmission gears. Reference may in this respect be had to the above mentioned U.S. Pat. Nos. 3,140,061, 3,233,841 and 4,183,475, herewith incorporated by reference herein. The rotatable drive shaft 14 carries a circular hub mounting plate 15 to which a mounting hub core 16, hereafter sometimes simply referred to as "hub" is attached by screws or other suitable fasteners.
The mounting hub assembly has wedge-shaped members or locking keys 17, 18 and 19 for engaging the hollow-cylindrical core 11 on the inside thereof. The hub 16, in turn, has or is provided with ramps 21, 22 and 23 for the wedge-shaped members 17, 18 and 19, respectively. A rotatable knob assembly 25 is coupled to the wedge-shaped members for driving such members 17 to 19 up the ramps 21 to 23 into engagement with the inside of the hollow-cylindrical core 11. In particular, this actuating assembly 25 may include an externally accessible, manually rotatable knurled knob 26 equipped with a circular frontal trim plate 27.
Fasteners 28, one of which is visible in FIG. 1, attach a retainer ring 29 and a retainer collar 31 to the knob 26 for rotation therewith. A retainer segment plate 32 with retainer segments or lugs 33, 34 and 35 for the reel locking members 17, 18 and 19, respectively, is retained between ring 29 and collar 31.
Each of the locking keys 17, 18 and 19 has a mounting pin 36, 37 or 38 connected to the corresponding retainer segment 33, 34 or 35 via a lost-motion connection 39. Compression springs 41, 42 and 43 normally cause the lost motion couplings 39 to bottom out.
As seen in FIG. 3, a reel hold down clamp 45 may be slidable in a corresponding slot 46 of the hub 16 and may be biased therein by a spring 47. The hold down clamp 45 also carries a frontal pin 48 which, in the assembled condition of the reel hub, enters an angular slot 49 of a cam 51. To avoid undue crowding of the drawing, the cam 51 has not been made visible in FIG. 1. However, such cam may in practice be coupled to the retainer ring 29 or to the knob 26. Preferably, a conventional rotary lost-motion connection is provided so that the cam 51 at its slot 49 causes the frontal pin 48 and thus the hold down clamp 45 to be radially pivoted inwardly, so that the lateral reel nabbing or retention lug 52 clears the outer cylindrical surface of the hub 16. The reel 12 with core 11 may thus be placed on the hub 16. Upon rotation of the knob 26 in a tightening direction, the cam 51 first releases the pin 48 whereby the reel hold down clamp 45 moves radially outwardly, thereby loosely holding the reel 12 on the mounting hub 16. This is broadly shown in FIG. 1 where the slot 46 and reel retention lug 52 are seen at the bottom of the hub assembly, rather than on the side as in FIG. 3.
This is a secondary feature that may be omitted, if desired.
Reverting now to the novel reel locking mechanism according to the subject invention and its illustrated preferred embodiment, the wedge-shaped members or keys 17 to 19 are driven up the ramps 21 to 23 toward the rear plate 15 of the hub and into engagement with the inside of the hollow-cylindrical reel core 11. To this end, the reel hub assembly has an axial threaded bolt 54 mounted on a transverse partition plate 55 of the hub body 16. The actuating knob 26 is threaded on that axial bolt 54, as seen in FIG. 1.
The retainer ring 29 and collar 31 rotate with the knob 26, but the retainer segment plate 32 is slidable therebetween, and is retained against rotation by suitable pins, such as the pins 36 to 38 of the locking keys 17 to 19. Accordingly, the segment plate 32 with retainer segments 33 to 35 moves translatorily or axially of the hub 16, upon rotation of the knob 26. This translatory motion continues, even after the reel hold down clamp 45 has been withdrawn preparatory to an insertion or removal of a tape reel 12, and even after such reel hold down clamp 45 has been expanded to its normal position upon insertion of a reel on the hub 16. To this end, a lost-motion connection, as mentioned above, or a conventional slip coupling may be provided between the reel hold down cam 51 and the knob 26 or retainer ring 29.
A reel 12 having been placed on the hub 16, the knob 26 is rotated until the wedges 17 to 19 have been sufficiently driven up the ramps 21 to 23 for an intimate engagement of the reel core 11.
According to a preferred embodiment of the subject invention, retention of the tape reel 12 against loosening and pounding during the winding of magnetic tape 57 thereon, and during rapid unwinding of tape therefrom, is substantially improved by providing one or more slots 61, 62 and 63 in the hollow-cylindrical reel core 11 at the inside thereof. The members 17 to 19 are then provided as locking keys for engaging the hollow-cylindrical member 11 at the slots 61 to 63, and the hub 16 is provided with ramps 21 to 23 for such locking keys. After the hollow-cylindrical member 11 has been placed onto the hub, the locking keys 17 to 19 are driven up the ramps 21 to 23 into engagement with the hollow cylindrical member 11 at the slots 61 to 63.
In practice, this inhibits looseness from occurring between the reel and its mounting hub. In accordance with a preferred embodiment or of a specific aspect of the subject invention, any looseness between the releasably retained hollow-cylindrical member 11 and the hub 16 is inhibited by urging the wedge-shaped members or locking keys 17 to 19 further up the ramps 21 to 23 after engagement with the inside of the hollow-cylindrical member 11. Such further driving or urging of the locking keys 17 to 19 preferably is continued during rotation of the hub and particularly during rapid reversal of such rotation.
According to the illustrated preferred embodiment, the previously mentioned springs 41 to 43 of the lost-motion couplings 39 may be provided as compression springs coupled to the wedge-shaped locking keys 17 to 19, for biasing such locking keys further up their ramps 21 to 23. A preferred embodiment of the invention thus provides ways and means for inhibiting any looseness between the releasably retained hollow-cylindrical member 11 and the hub 16 after engagement with the inside of such hollow-cylindrical member and continuously during rotation of the hub; with the term "rotation" for present purposes also including rapid rotation reversals. In particular, the inhibiting means according to the illustrated preferred embodiment include compression springs 41 to 43 backed by retainer segments 33 to 35 for urging the locking keys 17 to 19 further up their ramps and their shaped top portions further into the reel slots 61 to 63 after engagement with the inside of the hollow-cylindrical member and continuously during rotation of the hub. Any pounding of the reel and damage of reel and mounting hub is thus avoided, in addition to a significant improvement of the quality of the recording and playback operations relative to the recording tape 57.
From a somewhat broader aspect thereof, the subject invention provides slots in the hollow-cylindrical member or reel core 11 at the inside thereof. Locking members 17 to 19 for entering corresponding slots 61 to 63 at the inside of the hollow-cylindrical member 11 are provided on the hub 16. After the hollow cylindrical member 11 or reel 12 has been placed onto the hub, the locking members 17 to 19 are driven into the slots 61 to 63 for secure retention of the reel on its mounting hub.
As indicated above, the locking members 17 to 19 preferably are continuously urged into the slots 61 to 63 during rotation of the hub 16 and reel 12.
The slots 61 to 63 preferably are arranged in parallel to an axis of the hub, such as to the hub axis of rotation, as seen in the drawings. The locking members 17 to 19 are arranged in parallel to the slots 61 to 63 and preferably are arranged at least partially conextensively with these slots. As in the other embodiment, the compression springs 41 to 43, or equivalent biasing means continuously urge the locking members 17 to 19 into the slots 61 to 63 during rotation of the hub.
According to the illustrated preferred embodiment, and as seen from the drawings, each wedge-shaped member or locking key 17 to 19 is tapered in parallel to its corresponding ramp. In practice, each member 17 to 19 preferably is tapered also transversely to its corresponding ramp, as best seen in FIG. 3.
Each ramp 21 to 23 preferably is provided with a V-shaped groove extending in an axial direction of the hub. The expression "axial direction" in this context includes a direction which lies in a plane extending along the axis of rotation of the hub. Each wedge-shaped member or locking key 17 to 19 is accommodated in the V-shaped groove of its corresponding ramp. In particular, each member 17 to 19 may be provided with a V-shaped bottom slidable in the V-shaped groove of its corresponding ramp.
As seen in FIGS. 2 and 3, and in accordance with the best mode currently contemplated for carrying the subject invention into effect, each wedge-shaped member or locking key 17 to 19 is provided with a tapering rhomboid or diamond-shaped cross-section defining two sides slidable in the V-shaped groove of its corresponding ramp and two top sides shaped for entry into the reel slots 61 to 63. The diamond or rhomboid shape of the locking keys 17 to 19 thus assures positive contact with the reel slots.
Preparatory of a removal of the reel 12 from its mounting hub 16, the knob 26 is rotated in an opposite sense, whereby the retainer segments 33 to 35 engage the washers at the free ends of the pins 26, and, upon further rotation of the knob 26, positively pull the locking members 17 to 19 out of contact with the reel core 11 and out of the reel slots 61 to 63. This positive withdrawal of the locking keys or members assures that the reel 12 can be removed by supplying the necessary force to break it loose from its tightened condition. At the same time, the rotating cam withdraws the reel hold down clamp 45 inwardly, so that the reel may now easily be slid from its mounting hub.
In the illustrated preferred embodiment, the locking keys 17 to 19 are resiliently retained on their ramps 21 to 23 by screws 71 to 73 threaded into transverse bores 74 in the locking keys, and Belleville springs 75 retained between washers 76 and 77 on the shaft of screws 71 to 73. In particular, a resilient assembly 75 to 77 is located and acts on each screw 71, 72 or 73 and on a corresponding key hold down member 78 that slides in a groove or slot 79 extending in parallel to the corresponding ramp 21, 22 or 23. Slots 81 and 82 are provided in parallel to the groove 79 to provide sufficient clearance for each screw 71, 72 and 73 and each spring assembly 75 to 77 for effective movement of each locking key up and down its corresponding ramp.
The subject invention meets all of its initially stated objectives. Also, the present extensive disclosure suggests and renders apparent to those skilled in the art various modifications and variations within the spirit and scope of the invention.
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A hollow-cylindrical member, such as a reel, is releasably retained on a rotatable hub against forces tending to loosen the reel. To this end, a plurality of locking keys are inserted into corresponding axial slots in the reel at the inside thereof. These locking keys are first driven up corresponding ramps on the hub into engagement with the inside of the reel at corresponding slots. After such engagement, and during rotation of the hub and reel, the locking keys are continously biased or further urged into their corresponding slots in order to inhibit any looseness between the releasably retained reel and the rotating hub. By way of example, tape reels of large size and mass may thus be securely retained against strong inertial forces occasioned particularly during rapid reversals of the reel rotation as occurring, for instance, in modern instrumentation tape recording and data processing machines.
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FIELD OF THE INVENTION
The present invention generally relates to information handling systems, and particularly to networked information display systems.
BACKGROUND OF THE INVENTION
Rooms go unused even when they are set aside in a schedule. Previous methods of using written schedules and sign-up sheets to manage room usage are difficult to keep updated, due mainly to the inconvenience of changing the entry in a room log, or informing the person in charge of that room. Other types of information management systems, such as personal digital assistants, are not suitable for this use. These systems tend to be small, overly complicated, expensive to manufacture, and not able to manage information derived from a wide variety of sources to form a comprehensive system. It would be highly useful to present information regarding room usage in the place where it is needed most, at the entrance to the room. For example, by using a display as a door plate and connecting the display to a network interface so that the information display system may communicate over a network, important usage and scheduling information may be presented near the room. The network connection allows the schedule to be changed easily by anyone with access to the network, or at the door plate itself through an input/output device. The network connection also allows the system to incorporate information from a wide range of sources. Schedules regarding the use of conference rooms, patient information in doctor's offices, and the personal schedules of office occupants may be easily updated. Presenting this information on or near a door to the room would help to avoid the needless interruptions caused by people looking for a particular meeting or to check if that room is actually being used. In companies where it is necessary to share an office, or there is great movement between offices, the information display system may efficiently manage the office space. By using the information display system over a network, the name on the system may be changed easily, quickly, and more efficiently. There are times when vital information must be disseminated widely and quickly. By utilizing this invention, emergency information and other announcements may also be displayed on the information display system through the network interface. Name and title changes may also be updated and displayed through the system. For the foregoing reasons, there is a need for an information display system that may be located near an entryway, and that contains scheduling information that may be easily updated through a network interface.
SUMMARY OF THE INVENTION
The present invention is directed to an information display system. An information display system for scheduling the utilization of a facility, comprising a controller connected to a display and a network interface.
The present invention is further directed to a method for scheduling the utilization of a facility. The method comprises displaying scheduling information, controlling the information on the display, and interfacing the controller with a network interface for coupling the information display system to a network to a remote device.
The present invention is further directed to a system for coordinating and displaying information regarding the utilization of a facility, comprising a server and an information display system connected to the server. The information display system comprising a display for displaying information a controller for controlling said display a network interface, coupled to said controller, for coupling the information display system to a network to a remote device and wherein the display is disposed proximal to the facility such that scheduling information for the facility transmitted from the remote device over the network to the information display system is capable of being displayed on the display.
It is to be understood that both the forgoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention as claimed. The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate an embodiment of the invention and together with the general description, serve to explain the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The numerous advantages of the present invention may be better understood by those skilled in the art by reference to the accompanying figures in which:
FIGS. 1 and 2 are block diagrams illustrating an information display system in accordance with the present invention;
FIGS. 3A, 3 B, and 3 C are drawings of an information display system;
FIG. 4 is a drawings of an information display system wherein a control is placed on the information display system;
FIG. 5 is a drawings of an information display system wherein a plurality of controls are disposed on the information display system;
FIG. 6 is a drawings of an information display system wherein a keypad and cursor control device are connected to the information display system;
FIG. 7 is a diagram of an information display system capable of sending a reminder message;
FIG. 8 is a drawing of the placement of an information display system, connected to a locking mechanism, near an entryway;
FIG. 9 is a drawing of an information display system attached to a door;
FIG. 10 is a drawing of an information display system attached to a cubicle; and
FIG. 11 is a diagram of connections to a networked information display system.
DETAILED DESCRIPTION OF THE INVENTION
Reference will now be made in detail to the presently preferred embodiment of the invention, an example of which is illustrated in the accompanying drawings.
Referring now to FIG. 1, a hardware system in accordance with the present invention is shown. The hardware system shown in FIG. 1 is generally representative of the hardware architecture of an information display system of the present invention. A controller, for example, a processing system 102 , controls the information display system 100 . The processing system 102 includes a central processing unit such as a microprocessor or microcontroller for executing programs, performing data manipulations and controlling the tasks of the information display system 100 . Communication with the processing system 102 may be implemented through a system bus 110 for transferring information among the components of the information display system 100 . The system bus 110 may include a data channel for facilitating information transfer between storage and other peripheral components of the information display system 100 . The system bus 110 further provides the set of signals required for communication with processing system 102 including a data bus, address bus, and control bus. The system bus 110 may comprise any state of the art bus architecture according to promulgated standards, for example industry standard architecture (ISA), extended industry standard architecture (EISA), Micro Channel Architecture (MCA), peripheral component interconnect (PCI) local bus, standards promulgated by the Institute of Electrical and Electronics Engineers (IEEE) including IEEE 488 general-purpose interface bus (GPIB), IEEE 696/S-100, and so on. Furthermore, the system bus 110 may be compliant with any promulgated industry standard. For example, the system bus 110 may be designed in compliance with any of the following bus architectures: Industry Standard Architecture (ISA), Extended Industry Standard Architecture (EISA), Micro Channel Architecture, Peripheral Component Interconnect (PCI), Universal Serial Bus (USB), Access.bus, IEEE P1394, Apple Desktop Bus (ADB), Concentration Highway Interface (CHI), Fire Wire, Geo Port, or Small Computer Systems Interface (SCSI), for example.
The information display system 100 further includes a display system 112 for connecting to a display device 114 . The display system 112 may comprise a video display adapter having all of the components for driving the display device, including video random access memory (VRAM), buffer, and graphics engine as desired. The display device 114 may comprise a liquid-crystal display (LCD), or may comprise alternative type of display technologies, such as, a cathode-ray tube (CRT) type display such as a monitor or television, a light-emitting diode (LED) display, gas or plasma display, or employ flat-screen technology.
The information display system 100 further includes a network interface 106 . The network interface 106 communicates between the information display system 100 and a remote device, such as external devices, networks, information sources, or host systems that administer a plurality of information display systems. For example, host systems such as a server, may run software controlling the information display systems, serve as a storage for the information display systems, or coordinate software running separately on each information display system. The network interface 106 may provide or receive analog, digital, or radio frequency. The network interface system 106 preferably implements industry promulgated architecture standards, including Recommended Standard 232 (RS-232) promulgated by the Electrical Industries Association, Infrared Data Association (IrDA) standards, Ethernet IEEE 802 standards (e.g., IEEE 802.3 for broadband and baseband networks, IEEE 802.3z for Gigabit Ethernet, IEEE 802.4 for token passing bus networks, IEEE 802.5 for token ring networks, IEEE 802.6 for metropolitan area networks, 802.11 for wireless networks, and so on), Fibre Channel, digital subscriber line (DSL), asymmetric digital subscriber line (ASDL), frame relay, asynchronous transfer mode (ATM), integrated digital services network (ISDN), personal communications services (PCS), transmission control protocol/Internet protocol (TCP/IP), serial line Internet protocol/point to point protocol (SLIP/PPP), Universal Serial Bus (USB), and so on. For example, the network interface system 106 may comprise a network adapter, a serial port, parallel port, printer adapter, modem, universal asynchronous receiver-transmitter (UART) port, etc., or use various wireless technologies or links such as an infrared port, radio-frequency (RF) communications adapter, infrared transducers, or RF modem.
Referring now to FIG. 2, an information display system 100 may further include an input/output (I/O) system 116 for connecting to one or more I/O devices 118 , 120 up to N number of I/O devices 122 , as shown in FIG. 2 . Input/output system 116 may comprise one or more controllers or adapters for providing interface functions between one or more of I/O devices 118 - 122 . For example, input/output system 116 may comprise a serial port, parallel port, network adapter, printer adapter, radio-frequency (RF) communications adapter, universal asynchronous receiver-transmitter (UART) port, etc., for interfacing between corresponding I/O devices such as a door locking mechanism, door sensor to detect movement of a door, photo diode, sound detector, motion detector, thermostat, mouse, joystick, trackball, trackpad, trackstick, infrared transducers, printer, modem, RF modem, bar code reader, charge-coupled device (CCD) reader, scanner, compact disc (CD), compact disc read-only memory (CD-ROM), digital versatile disc (DVD), video capture device, touch screen, stylus, electroacoustic transducer, microphone, speaker, etc. It should be appreciated that modification or reconfiguration of the information display system 100 of FIGS. 1 and 2 by one having ordinary skill in the art would not depart from the scope or the spirit of the present invention.
Referring now to FIG. 3A, 3 B, and 3 C, exemplary embodiments of information display systems comprise a LCD screen 310 , contained in a housing 320 with a processing system 102 and network interface 106 positioned inside of the information display system (FIGS. 1 & 2 ). The LCD screen 310 is capable of presenting information processed by the controller to manage the room's usage. A person utilizing a remote device (for example, a computer) connected to the information display system through the network interface 106 may update or query the room's usage (FIGS. 1 & 2 ). The device may be connected through a server so that the device may be accessed over existing networks. In a preferred embodiment of the present invention, the display 310 may be a monochrome LCD with no back-lighting. Use of ambient light may be all that is necessary for the display and give the information display system low power requirements. Power requirements may be low enough so that the information display system may be powered, for example, by a powered network connection, onboard battery, solar cell, etc.
In FIG. 3A, an exemplary embodiment of the present invention is shown. In this embodiment, the information display system 300 is configured to be placed outside of an office. Information, in this instance the name of an office occupant 330 , is displayed on the screen 310 . The name of the occupant 330 may be changed through a network interface 106 (FIGS. 1 & 2 ). Graphic indicia may also be displayed by the information display system. In this example, the information display system is capable of switching between the name and title of an office occupant 330 to a graphic of a company logo 335 in a predetermined amount of time. Other examples, which include but are not limited to a company logo, a personalized screen saver, picture of the office occupant, art works, etc. may also be displayed on the screen 310 entered by either the administrator of the system or the office occupant. The time of day may also be displayed on the screen 310 . Furthermore, symbols may be displayed on the screen 310 indicating room usage. Any device contained in the room, such as video conferencing equipment, telephone conferencing equipment, overhead projectors, etc., may be monitored by the information display system, and resultant usage displayed accordingly. For example, if the lights of the room were on, detected by a photo diode or direct connection to the room lighting system, a lightbulb may be displayed on the screen. In another example, video conferencing equipment may be connected to the information display system so that when in use, the system displays that a video conferencing session is progressing. In this way, interruptions may be minimized. Additionally, motion and sound detectors may also be utilized so that room usage may be determined. The information display system may then display a message indicating the room usage, in this instance, that the room is occupied. By connection through the network interface, the usage of a large number of rooms may be monitored, for example, for security purposes, or to better manage the facility.
Referring now to FIG. 3B, a second exemplary embodiment of the present invention is shown. In this embodiment, an information display system 300 is configured to be used near an entryway to a conference room. Time management software is utilized by the information display system to process information regarding the rooms usage and present this information on the display 310 . Various types of information may be displayed, including the name of the group reserving the room 340 , the name of the room 350 , and contact information 360 . Information may be updated through a network interface 106 (FIGS. 1 & 2 ). In FIG. 3C, the information display system may provide a schedule 370 displayed on the screen 310 showing when the room 350 is reserved. In this example, the information display system 300 may display details of the next scheduled meeting. Various types of software may be utilized by the system. Preferred types of scheduling software include but are not limited to Microsoft® Outlook™, Microsoft®Schedule+™, and Lotus® Organizer.
Referring now to FIGS. 4-6, information may also be controlled and entered directly through the information display system. In FIG. 4, the information display system 400 includes one or more controls 420 as an input/output device to navigate through the information on the screen 410 . In FIG. 5, the information display system contains a plurality of controls 520 to access information contained in the information display system 500 . This information may include who reserved the room 530 , for what purpose the room is reserved 540 , and who to contact 550 if questions arise regarding the reservation. Controls 520 used to access the information may include, for example, a joystick, trackball, track-pad, track-stick, scanner, touch screen, stylus, microphone, speaker, etc. Hot keys may be mapped to various display screens, as shown in FIGS. 3A, 3 B, and 7 to access information contained in the unit or access other types of information contained in various devices connected through the network interface 106 (FIGS. 1 and 2 ).
Referring now to FIG. 6, the information display system contains a keypad 620 to enter information into the information display system 600 . In this exemplary embodiment, the information display system utilizes messaging software to process, retain, and display messages on the display 610 . For example, the messages may be entered on a computer through a network connected to the information display system by utilizing the network interface 106 (FIGS. 1 & 2 ), or through a keypad 620 , cursor control device 630 , or any other input device, such as a touch screen or voice recognition system. For example, if the information display system 600 was placed outside an office, visitors may access the message feature 640 through the keypad 620 or cursor control device 630 on the information display system 600 to leave a message for the occupant. Or, if the information display system 600 is placed outside a conference room, the room may be reserved by using an input/output device connected to the information display system utilizing time management software. Additionally, an individual may leave a phone message for a conference attendee. The phone message may be entered into the information display system 600 , for example, automatically through a voice mail system or a system operator.
Referring now to FIG. 7, an exemplary embodiment of the present invention is shown. In this embodiment, the information display system 700 utilizes messaging software to send a reminder message 740 or a series of reminder messages through the network 710 to the computer 720 of the person who reserved the room 750 . For example, this message may ask whether the person will keep the reservation or if the reservation should be deleted. Another type of message may serve as a reminder for a group of people to attend a meeting. For example, a list of names of all the people scheduled for a meeting may be entered into the unit, either directly or through a network, so that reminders are sent to the people on that list. These reminders may be sent as e-mail or any other type of message through the network connection. This embodiment increases room usage efficiency by verifying the schedule for the room.
Referring now to FIG. 8, an information display system 800 that includes a locking mechanism 810 is shown. The information display system 800 utilizes security software to control a lock mechanism 810 so as to allow access to the room at different prescheduled times, or to require a password, pass card, personal identification number, or other method of identification to gain access through the door 850 . Different periods of access may be controlled by the information display system 800 . For example, the information display system may restrict access to the room between certain hours, and lock the room at all other times to keep the room secure. The use of different codes linked to prescheduled times on the system would allow only certain people access to the room at specific times. For instance, instead of allowing general access between midnight and dawn, the information display system may be configured to allow only persons with a certain code to enter the room in that time period, such as cleaning personnel. Alternatively, the information display system may include a door sensor, so that entry into the room may be sensed. For example, when the information display system determines that a door is opened, the system may notify security, turn on the lights, start a computer, or perform any other action desired by the office occupant. These actions may be linked to scheduling software, so that the lights come on between certain hours. For example, the controller, sensing that someone has entered the room at 6:00 am, turns on the lights, but will not turn on the lights when someone enters the room at noon. This increases the room's safety by freeing people that enter the room from having to reach for light switches. It is also possible to connect a radio frequency 1 S ~identification reader for reading and identifying radio frequency transponders. For example, the information display system could detect a radio frequency identification transponder located on an employees badge. When the employee enters a conference room, the information display system may access the personal schedule for the employee through the network connection 106 (FIGS. 1 and 2) based on the identification tag so that the personal schedule of that employee may be displayed on the screen. This allows people trying to contact the employee to determine when he is next available. The door plate may also limit access to the room based on the radio frequency transponders contained in the employee badge.
There are many possible locations for the information display system. For example, in FIG. 8, the information display system 800 may be mounted next to a door 850 . In FIG. 9, the information display system 900 may be mounted on the door 910 itself. The information display system may utilize wireless technology (not shown) to communicate with a host system, central computer, etc. The information display system 1000 may also be mounted on the wall 1010 of a cubicle 1020 , as in FIG. 10 . There are many advantages to mounting the display on a cubicle. One advantage is that in many companies people change cubicles often, making it difficult to keep the name on the cubicle updated. This makes it difficult for both the person using the cubicle to find his new location and for people trying to find him. By using the information display system over a network, the name on the system may be changed easily, quickly, and more efficiently. The information display system may utilize a wireless connection, such as a radio frequency connection, so as to eliminate the need for extra wiring, which is especially important involving cubicles that tend to be reconfigured often. The information display system may also utilize mapping software so that a map displaying the names of the occupants is generated, and may be displayed on each information display system or computer connected to the network.
Referring now to FIG. 11, a network of information display systems 1100 is shown. A plurality of information display systems 1110 may be connected to a network 1120 . Each information display system may be accessed individually or as a group over the network 1120 through remote devices, such as computers 1130 , docking stations 1134 , local area networks 1124 , wide area networks 1126 , and remote phone access connections 1128 connected to the network 1120 through a server 1122 . The server 1122 may serve as a host system, for example, to run software controlling the information display systems, serve as a storage for the information display systems, or coordinate software running separately on each information display system, or coordinate information obtained from a wide variety of different networks, systems, or mechanisms. The information display system may operate in a distributed computing network wherein each information display system may handle its own workload. In contrast to a client/server architecture, a network may be implemented utilizing a “distributed computing” architecture. In a distributed computing architecture, a system of information display systems may be connected together for communicating. Each information handling system handles its local workload, and the network supports the system as a whole. The information display system may further utilize advanced wireless technologies 1132 to communicate with a central computer, host data terminal, or the like in an interactive or on-line mode via a data communications link established by a radio frequency (RF) transceiver assembly or radio. For example, the information display system may employ such radios as an internal 2.4 Gigahertz (GHz) RF radio (e.g., a Proxim radio) for communication with a 2.4 GHz local area network (LAN) system, an internal cellular digital packet data (CDPD) radio modem for communication with a cellular telephone system, an internal 400 MHz or 900 MHz radio (e.g., RAM radio) for communication with a 400 MHz or 900 MHz Wide Area Network (WAN) data system (e.g., US Mobitex), an internal 800 MHz radio (e.g., Ardis) for communication with a US Motorola Wide Area Network data system, or an internal 900 MHz radio (Motorola) for communication with a 900 MHz private radio network data system, one way paging radio, two way paging radio, GSM (global system for mobile communication) radio, or the like.
The network interface of the information display system enables people connected to the network to access the information contained in the information display system 1100 . For example, an office worker connected to the network could determine if a room is reserved, when it is reserved, and reserve a room if necessary. If an office worker no longer needs a room or needs to change his schedule, the information may be changed easily over the network. Emergency information 1110 may also be displayed through the network. This information may include the type of emergency and suggested routes for exit. Various types of entrances and rooms may be managed by using this system. For instance, the system may control access through an exit 1114 by utilizing a locking mechanism, the room usage of a conference room 1112 , the personal schedule of the occupant of a cubicle 1118 , etc. These various systems may be integrated, so that a wireless connection to a room 1118 , emergency information 1110 , and schedules may all be coordinated.
Although the invention has been described with a certain degree of particularity, it should be recognized that elements thereof may be altered by persons skilled in the art without departing from the spirit and scope of the invention. It is believed that the means and apparatus for an information display system of the present invention and many of its attendant advantages will be understood by the forgoing description, and it will be apparent that various changes may be made in the form, construction and arrangement of the components thereof without departing from the scope and spirit of the invention or without sacrificing all of its material advantages, the form herein before described being merely an explanatory embodiment thereof. It is the intention of the following claims to encompass and include such changes.
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An information display system is disclosed. The information display system includes a display connected to a controller and a network interface. The information display system is capable of changing the information processed by the system through a network interface or directly through an input/output device connected to the system. The present invention is directed to an information display system. An information display system for scheduling the utilization of a facility, comprising a controller connected to a display and a network interface.
A method for scheduling the utilization of a facility is also disclosed. The method comprises displaying scheduling information, controlling the information on the display, and interfacing the controller with a network interface for coupling the information display system to a network to a remote device.
A system for coordinating and displaying information regarding the utilization of a facility is also disclosed. The system comprising a server and an information display system connected to the server. The information display system comprising a display for displaying information a controller for controlling said display a network interface, coupled to said controller, for coupling the information display system to a network to a remote device and wherein the display is disposed proximal to the facility such that scheduling information for the facility transmitted from the remote device over the network to the information display system is capable of being displayed on the display.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method of preparing nanosized spherical vanadium oxide particles and, more particularly, to a method of preparing nanosized spherical vanadium oxide particles having an average particle size of tens of nanometers using a sol-gel method.
2. Description of the Related Art
Divanadium pentaoxide (V 2 O 5 ) particles are generally prepared using a solid phase method, a liquid phase method, or a vapor phase method. In the solid phase method, divanadium pentaoxide particles are derived from thermal decomposition of ammonium vanadate at a temperature of 400-600° C. This solid phase method is relatively easy to perform, but the resulting divanadium pentaoxide particles have irregular shapes and large particle size on the order of several micrometers.
When divanadium pentaoxide particles are prepared using the liquid phase method, there is an advantage of easy processing with efficient control of particle size, crystal phase, and specific surface area. However, the resulting divanadium pentaoxide particles are limited to planar or ribbon shapes, and thus spherical particles cannot be obtained using the liquid phase method.
The vapor phase method is divided according to the type of energy source, i.e., whether laser or plasma is used as an energy source. In preparing divanadium pentaoxide particles, the vapor phase method is difficult to control and is less economical than the liquid phase and solid phase methods.
Recently, there has been an increased interest in using nanosized particles in the development of new functional materials to improve the properties of existing active materials as well as to obtain new properties.
As electronic components have become smaller with increased performance requirements, the size of raw material particles for electronic components has also decreased to the order of submicrons or less. For a uniform and fine distribution of sintering additive particles in a green body, there is a need to reduce the size of the sintering additive particles to a fine level. Reportedly, performance of a sensor is improved by reducing the size of source particles with the effect of increasing active surface area.
Divanadium pentaoxide particles have great electrochemical activity. Thus, divanadium pentaoxide particles are used as catalysts, electrochromic devices, anti-static coating materials, and active materials for sensors and secondary cells. Discharge capacity of a secondary cell can be improved by using a nanosized, ribbon-shaped active material, compared to a secondary cell manufactured using a microsized active material. In additon to the application as active materials for secondary cells, nanosized divanadium pentaoxide particles are expected to show improved performance in applications of catalysts, electrochromic devices, anti-static coating materials, and active materials for sensors. In the above and other applications, spherical particles are needed for better mixing, dispersion, or forming processes. Accordingly, for commercial applications of nanosized divanadium pentaoxide particles, there exists a need for an economic and efficient method for preparing nanosized divanadium pentaoxide particles.
Up to now, however, an economic and efficient method of preparing nanosized divanadium pentaoxide particles having a spherical shape has not been developed.
SUMMARY OF THE INVENTION
According to a primary feature of the present invention, a method of preparing nanosized spherical divanadium pentaoxide particles comprises, preparing a vanadium ion-containing aqueous solution by dissolving a vanadium ion-containing material; adding at least one solvent selected from a non-protonic, polar organic solvent and a glycol solvent to the vanadium ion-containing aqueous solution and mixing the same; and aging the mixture.
In preparing the vanadium ion-containing aqueous solution, the vanadium ion-containing material is dissolved in a hydrogen peroxide aqueous solution or an acid aqueous solution. Although the type of the acid aqueous solution that may be used is not limited, a hydrochloric acid aqueous solution, a nitric acid aqueous solution, or a sulfuric acid aqueous solution is preferred.
Preferably, the amount of hydrogen peroxide in the hydrogen peroxide aqueous solution or the amount of acid in the acid aqueous solution is in the range of about 0.5 to 5 times the amount of vanadium ion-containing material in order to fully dissolve the vanadium ion-containing material. If the amount of hydrogen peroxide or the amount of acid exceeds the above stated range, it becomes uneconomical due to a relative low concentration of vanadium ions. If the amount of hydrogen peroxide or the amount of acid is less than the above stated range, it becomes difficult to fully dissolve the vanadium ion-containing material.
Preferably, the vanadium ion-containing aqueous solution contains between about 0.01 to 0.5 M vanadium ion.
In accordance with a preferred embodiment of the present invention, the non-protonic, polar organic solvent is at least one selected from the group consisting of N-methyl-2-pyrrolidone, N,N-dimethylacetamide, hexamethylphosphoamide, and pyridine, and the glycol solvent comprises at least one selected from the group consisting of ethyleneglycol, propyleneglycol, and butyleneglycol. The amount of the solvent is in a preferred range of about 60-98% by volume based on the total volume of the vanadium ion-containing aqueous solution and the solvent.
Aging of the mixture is performed preferably for about 0.5 to 100 hours at a temperature not less than 0° C. and not greater than the higher of the boiling point of the vanadium ion-containing aqueous solution and the boiling point of the solvent.
In the method for preparing vanadium oxide particles according to the present invention, any vanadium ion-containing material can be used without limitations, but divanadium pentaoxide is preferred.
These and other features and aspects of the present invention will be readily apparent to those of ordinary skill in the art upon review of the detailed description that follows.
BRIEF DESCRIPTION OF THE DRAWINGS
The above features and advantages of the present invention will become more apparent by describing in detail preferred embodiments thereof with reference to the attached drawings in which:
FIG. 1 is a scanning electron microscopic (SEM) photograph of divanadium pentaoxide (V 2 O 5 ) particles prepared in Example 1 in accordance with the present invention;
FIG. 2 is a graph illustrating an X-ray diffraction pattern of divanadium pentaoxide particles prepared in Example 1 in accordance with the present invention;
FIG. 3 is a SEM photograph of divanadium pentaoxide particles prepared in Example 5 in accordance with the present invention;
FIG. 4 is a SEM photograph of divanadium pentaoxide particles prepared in Example 6 in accordance with the present invention;
FIG. 5 is a SEM photograph of divanadium pentaoxide particles prepared in Example 7 in accordance with the present invention;
FIG. 6 is a SEM photograph of divanadium pentaoxide particles prepared in Example 8 in accordance with the present invention;
FIG. 7 is a SEM photograph of divanadium pentaoxide particles prepared in Comparative Example 1; and
FIG. 8 is a graph illustrating an X-ray diffraction pattern of divanadium pentaoxide particles prepared in Comparative Example 1.
DETAILED DESCRIPTION OF THE INVENTION
Korean Patent Application No. 2001-16325 filed Mar. 28, 2001, and entitled “Method of Preparing Nanosized Spherical Vanadium Oxide Particle,” and Korean Patent Application No. 2001-73735, filed Nov. 26, 2001, and entitled “Method of Preparing Nanosized Sperical Vanadium Oxide Particle,” are incorporated by reference herein in their entirety.
In a sol-gel method, formation of particles involves nucleation through hydrolysis and condensation and growth of the nuclei. The shape, particle size, and particle size distribution of the resulting particles are affected by reaction factors and conditions during nucleation and growth. Therefore, adjustment of the reaction conditions and factors is required to form particles having a desired shape, particle size, and particle size distribution.
It is known that formation of particles having a particular orientation on a crystal plane using the sol-gel method is greatly affected by growth. When a particular oriented crystal plane of a material has the lowest surface energy in a reaction solvent among other crystal planes in the growth step, the particular oriented crystal plane grows first to reduce the system energy such that growth of other crystal planes is suppressed. The resulting particles are surrounded by the particular oriented crystal plane having the lowest surface energy in the reaction solvent so that they have a non-spherical shape. In contrast, when all the crystal planes of a material have the same surface energy in a reaction solvent, nuclei growth occurs in every direction, and the resulting particles having a spherical shape. Therefore, to form spherical divanadium pentaoxide particles using a liquid phase method including a sol-gel method, the surface energy of all crystal planes of divanadium pentaoxide in a reaction solvent should be equal.
The surface energy of an oriented crystal plane of a material in a reaction solvent can be varied by adsorbing a surfactant to the oriented crystal plane or by changing the reaction solvent.
In the present invention, a mixed solvent of water and a non-protonic, polar organic solvent and/or a mixed solvent of water and glycol are used as the reaction solvent to obtain nanosized spherical divanadium pentaoxide particles. Suitable non-protonic, polar organic solvents include N-methyl-2-pyrrolidone, N,N-dimethylacetamide, hexamethylphosphoamide, pyridine, and mixtures of these solvents. Suitable glycols include ethyleneglycol, propyleneglycol, butyleneglycol, and mixtures of these materials. The amount of the reaction solvent is in a preferred range of about 60 to 98% by volume based on the total volume of a vanadium ion-containing aqueous solution and the reaction solvent.
A method of preparing nanosized spherical divanadium pentaoxide particles using a sol-gel method according to the present invention will now be described below.
First, a vanadium ion-containing aqueous solution is prepared by dissolving a vanadium ion-containing material in an aqueous solution. When divanadium pentaoxide is used as the vanadium ion-containing aqueous material, the vanadium ion-containing aqueous solution is prepared by dissolving divanadium pentaoxide in a hydrogen peroxide aqueous solution or an acid aqueous solution such as a hydrochloric acid aqueous solution, a nitric acid aqueous solution, or a sulfuric acid aqueous solution. Preferably, the vanadium ion-containing aqueous solution is prepared by dissolving divanadium pentaoxide in the hydrogen peroxide aqueous solution. Benefits of using the hydrogen peroxide aqueous solution include ease of use without residual ions.
Although the concentrations of the hydrogen peroxide aqueous solution and the acid aqueous solution are not limited, it is preferred that the concentration of the hydrogen peroxide aqueous solution is 30%, 30 to 32%, 35%, or 50% by weight, while it is preferred that the concentration of the acid aqueous solution is 20%, 37%, or 38% by weight for the hydrochloric acid aqueous solution, 70% or 90% by weight for the nitric acid aqueous solution, and 95 to 98% or 98% by weight for the sulfuric acid aqueous solution.
Preferably, the vanadium ion-containing aqueous solution contains about 0.01M to 0.5M vanadium ion. If the concentration of the vanadium ion is less than 0.01M, it is undesirable for economical reasons. If the concentration of the vanadium ion exceeds 0.5M, it is undesirable for the shape of divanadium pentaoxide particles in the vanadium ion-containing aqueous solution.
The prepared vanadium ion-containing aqueous solution is mixed with a non-protonic, polar organic solvent and/or a glycol solvent. Suitable non-protonic, polar organic solvents include N-methyl-2-pyrrolidone, N,N-dimethylacetamide, hexamethylphosphoamide, pyridine, and mixtures of these solvents. Suitable glycol solvents include ethyleneglycol, propyleneglycol, butyleneglycol, and mixtures of these materials.
The amount of the solvent is in a preferred range of 60-98% by volume based on the total volume of the vanadium ion-containing aqueous solution and the solvent. If the amount of the solvent is less than 60% by volume, it is undesirable from the standpoint of the shape of the resulting divanadium pentaoxide particles. If the amount of the solvent exceeds 98% by volume, it is uneconomical because of a too low of a vanadium ion concentration.
Next, the mixture of the vanadium ion-containing aqueous solution and the non-protonic, polar organic solvent, the mixture of the vanadium ion-containing aqueous solution and the glycol solvent, or the mixture of the vanadium ion-containing aqueous solution, the non-protonic, polar organic solvent, and the glycol solvent is aged at a temperature, preferably no less than 0° C. and no greater than the higher of the boiling point of the vanadium ion aqueous solution and the boiling point of the solvent. Preferably, aging is performed for 0.5-100 hours. If the aging time is less than 0.5 hours, divanadium pentaoxide particles cannot be formed. If the aging time exceeds 100 hours, it is undesirable for economical reasons. If the aging temperature is less than 0° C., the reaction rate is too slow or the divanadium pentaoxide generation reaction itself does not occur. If the aging temperature exceeds the upper limit, an additional hydrothermal reactor is needed to suppress excess evaporation of the solvent or water from the reaction mixture.
After the aging is completed, precipitates are filtered from the reaction product and dried to obtain divanadium pentaoxide particles according to the present invention.
According to the preparation method described above, spherical divanadium pentaoxide particles having an average particle size of tens of nanometers, and particularly 30-80 nm, can be prepared efficiently and economically.
EXAMPLE 1
4.5728 g of cystalline divanadium pentaoxide (V 2 O 5 ) granules (99.6% purity) was placed in a beaker containing 150 ml of distilled water. 25 ml of 30% (by weight) hydrogen peroxide (H 2 O 2 ) solution was added to the solution and thoroughly mixed to fully dissolve V 2 O 5 . Next, distilled water was added making the total volume of the reaction mixure 200 ml to prepare a vanadium ion-containing aqueous solution containing 0.5M vanadium ion.
40 ml of the vanadium ion-containing aqueous solution was added into a reaction container containing 160 ml of N-methyl-2-pyrrolidone and mixed. The reaction container was plugged and aged for 12 hours in a thermostatic bath at 80° C.
After aging, precipitants were filtered from the reaction product and dried in a dry chamber at 60° C. to prepare divanadium pentaoxide particles.
A scanning electron microscopic (SEM) photograph and a graph illustrating an X-ray diffraction pattern for the divanadium pentaoxide particles prepared in Example 1 are shown in FIGS. 1 and 2, respectively. FIG. 1 shows that the divanadium pentaoxide particles prepared in Example 1 are spherical with an average particle size of about 40 nm. The result of the X-ray diffraction analysis illustrated in FIG. 2 shows that the divanadium pentaoxide particles prepared in Example 1 are amorphous.
A vanadium-to-oxygen ratio was measured for the divanadium pentaoxide particles prepared in Example 1 using an inductively coupled plasma emission spectrometer. The divanadium pentaoxide particles prepared in Example 1 had a vanadium-oxygen ratio of 2:5 by mole.
EXAMPLE 2
Divanadium pentaoxide particles were prepared in the same manner as in Example 1, except that the concentration of vanadium ion was 0.2M. Physical properties of the divanadium pentaoxide particles were determined. As a result, the divanadium pentaoxide particles prepared in Example 2 were spherical and amorphous and had an average particle size of about 40 nm.
EXAMPLE 3
Divanadium pentaoxide particles were prepared in the same manner as in Example 1, except that the concentration of vanadium ion was 0.1M. Physical properties of the divanadium pentaoxide particles were determined. As a result, the divanadium pentaoxide particles prepared in Example 3 were spherical and amorphous and had an average particle size of about 35 nm.
EXAMPLE 4
Divanadium pentaoxide particles were prepared in the same manner as in Example 1, except that the concentration of vanadium ion was 0.01M. Physical properties of the divanadium pentaoxide particles were determined. As a result, the divanadium pentaoxide particles prepared in Example 4 were spherical and amorphous and had an average particle size of about 30 nm.
EXAMPLE 5
Divanadium pentaoxide particles were prepared in the same manner as in Example 1, except that N,N-dimethylacetamide instead of N-methyl-2-pyrrolidone was used. Physical properties of the divanadium pentaoxide particles were determined. A SEM photograph of the divanadium pentaoxide particles prepared in Example 5 is shown in FIG. 3 . As shown in FIG. 3, the divanadium pentaoxide particles prepared in Example 5 were spherical and crystalline and had an average particle size of about 80 nm.
EXAMPLE 6
Divanadium pentaoxide particles were prepared in the same manner as in Example 1, except that hexamethylphosphoamide instead of N-methyl-2-pyrrolidone was used. A SEM photograph of the divanadium pentaoxide particles prepared in Example 6 is shown in FIG. 4 . As shown in FIG. 4, the divanadium pentaoxide particles prepared in Example 6 were spherical and crystalline and had an average particle size of about 40 nm.
EXAMPLE 7
Divanadium pentaoxide particles were prepared in the same manner as in Example 1, except that pyridine instead of N-methyl-2-pyrrolidone was used. A SEM photograph of the divanadium pentaoxide particles prepared in Example 7 is shown in FIG. 5 . As shown in FIG. 5, the divanadium pentaoxide particles prepared in Example 7 were spherical and had an average particle size of about 40 nm. The divanadium pentaoxide particles prepared in Example 7 also included 50% or less needle-shaped or rod shaped particles having an average diameter size of about 40 nm.
EXAMPLE 8
Divanadium pentaoxide particles were prepared in the same manner as in Example 1, except that ethyleneglycol instead of N-methyl-2-pyrrolidone was used. A SEM photograph of the divanadium pentaoxide particles prepared in Example 8 is shown in FIG. 6 . As shown in FIG. 6, the divanadium pentaoxide particles prepared in Example 8 were spherical and amorphous and had an average particle size of about 80 nm.
EXAMPLE 9
Divanadium pentaoxide particles were prepared in the same manner as in Example 1, except that 4 ml of the vanadium ion-containing solution and 196 ml of N-methyl-2-pyrrolidone were used. Physical properties of the divanadium pentaoxide particles were determined. As a result, the divanadium pentaoxide particles prepared in Example 9 were spherical and amorphous and had an average particle size of about 30 nm.
EXAMPLE 10
Divanadium pentaoxide particles were prepared in the same manner as in Example 1, except that 60 ml of the vanadium ion-containing solution and 140 ml of N-methyl-2-pyrrolidone were used. Physical properties of the divanadium pentaoxide particles were determined. As a result, the divanadium pentaoxide particles prepared in Example 10 were spherical and amorphous and had an average particle size of about 40 nm.
EXAMPLE 11
Divanadium pentaoxide particles were prepared in the same manner as in Example 1, except that 80 ml of the vanadium ion-containing solution and 120 ml of N-methyl-2-pyrrolidone were used. Physical properties of the divanadium pentaoxide particles were determined. As a result, the divanadium pentaoxide particles prepared in Example 11 were spherical and amorphous and had an average particle size of about 40 nm.
EXAMPLE 12
Divanadium pentaoxide particles were prepared in the same manner as in Example 1, except that aging was performed at 20° C. Physical properties of the divanadium pentaoxide particles were determined. As a result, the divanadium pentaoxide particles prepared in Example 12 were spherical and amorphous and had an average particle size of about 40 nm.
EXAMPLE 13
Divanadium pentaoxide particles were prepared in the same manner as in Example 1, except that 25 ml of 98% (by weight) sulfuric acid aqueous solution instead of 25 ml of 30% (by weight) H 2 O 2 aqueous solution was used. The physical properties of the divanadium pentaoxide particles were determined. As a result, the divanadium pentaoxide particles prepared in Example 13 were spherical and amorphous and had an average particle size of about 40 nm.
EXAMPLE 14
Divanadium pentaoxide particles were prepared in the same manner as in Example 1, except that propyleneglycol instead of N-methyl-2-pyrrolidone was used. Physical properties of the divanadium pentaoxide particles were determined. As a result, the divanadium pentaoxide particles prepared in Example 14 were spherical and amorphous with an average particle size of about 40 nm.
Comparative Example 1
Divanadium pentaoxide particles were prepared in the same manner as in Example 1, except that water instead of the organic solvent (N-methyl-2-pyrrolidone) was used. Physical properties of the divanadium pentaoxide particles were determined.
A SEM photograph and a graph illustrating an X-ray diffraction pattern for the divanadium pentaoxide particles prepared in Comparative Example 1 are shown in FIGS. 7 and 8, respectively. FIG. 7 shows that the divanadium pentaoxide particles prepared in Comparative Example 1 have a ribbon shape. The result of the X-ray diffraction analysis illustrated in FIG. 8 shows that the divanadium pentaoxide particles prepared in Comparative Example 1 are crystalline.
Comparative Example 2
Divanadium pentaoxide particles were prepared in the same manner as in Example 1, except that aging was not performed. As a result, the particle generation reaction did not occur.
The experimental conditions for the preparation of divanadium pentaoxide particles in Examples 1 through 14 and Comparative Example 1 and 2 are summarized in Table 1. The result of the physical property determination for the divanadium pentaoxide particles prepared in Examples 1 through 14 and Comparative Examples 1 and 2 are summarized in Table 2.
TABLE 1
Vanadium ion
Amount of
concentration
Solvent (% by
Example
(M)
Reaction Solvent
volume)
Aging Conditions
Example 1
0.5
N-methyl-2-pyrrolidone
80
80° C. for 12 hours
Example 2
0.2
N-methyl-2-pyrrolidone
80
80° C. for 12 hours
Example 3
0.1
N-methyl-2-pyrrolidone
80
80° C. for 12 hours
Example 4
0.01
N-methyl-2-pyrrolidone
80
80° C. for 12 hours
Example 5
0.5
N,N-dimethylacetamide
80
80° C. for 12 hours
Example 6
0.5
Hexamethylphosphoamide
80
80° C. for 12 hours
Example 7
0.5
Pyridine
80
80° C. for 12 hours
Example 8
0.5
Ethyleneglycol
80
80° C. for 12 hours
Example 9
0.5
N-methyl-2-pyrrolidone
98
80° C. for 12 hours
Example 10
0.5
N-methyl-2-pyrrolidone
70
80° C. for 12 hours
Example 11
0.5
N-methyl-2-pyrrolidone
60
80° C. for 12 hours
Example 12
0.5
N-methyl-2-pyrrolidone
80
20° C. for 12 hours
Example 13
0.5
N-methyl-2-pyrrolidone
80
80° C. for 12 hours
Example 14
0.5
Propyleneglycol
80
80° C. for 12 hours
Comparative
0.5
H 2 O
80
80° C. for 12 hours
Example 1
Comparative
0.5
N-methyl-2-pyrrolidone
80
No aging
Example 2
TABLE 2
Average Particle
Example
Particle Shape
Size (nm)
Crystal Phase
Example 1
Spherical
40
Amorphous
Example 2
Spherical
40
Amorphous
Example 3
Spherical
35
Amorphous
Example 4
Spherical
30
Amorphous
Example 5
Spherical
80
Crystalline
Example 6
Spherical
40
Crystalline
Example 7
Spherical and
50
Crystalline
Needle-like
Example 8
Spherical
80
Amorphous
Example 9
Spherical
30
Amorphous
Example 10
Spherical
40
Amorphous
Example 11
Spherical
40
Amorphous
Example 12
Spherical
40
Amorphous
Example 13
Spherical
40
Amorphous
Example 14
Spherical
40
Amorphous
Comparative
Ribbon-like
—
Crystalline
Example 1
Comparative
No reaction
Example 2
As shown in Table 2, spherical vanadium pentaoxide particles having an average particle size of 30-80 nm were prepared in Examples 1 through 14. In contrast, divanadium pentaoxide particles prepared in Comparative Example 1 using water instead of the organic solvent had a ribbon shape. In Comparative Example 2 where aging was not performed, vanadium pertoxide particles could not be formed because no reaction took place.
As described above, in the preparation of divanadium pentaoxide particles by the sol-gel method according to the present invention, a mixed solvent of water and a non-protonic, polar organic solvent or a mixed solvent of water and a glycol are used as a reaction solvent so that spherical divanadium pentaoxide particles having an average particle size of tens of nanometers can be prepared efficiently and economically.
While this invention has been particularly shown and described with reference to preferred embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention as defined by the appended claims.
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A method of preparing nanosized spherical vanadium oxide particles, comprising preparing a vanadium ion-containing aqueous solution by dissolving a vanadium ion-containing material; adding at least one solvent selected from a non-protonic, polar organic solvent and a glycol solvent to the vanadium ion-containing aqueous solution and mixing the same; and aging the mixture.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention generally relates to exploration for hydrocarbons involving electrical investigations of a borehole penetrating an earth formation. More specifically, this invention relates to highly localized borehole investigations of multifrequency focusing of survey currents injected into the wall of a borehole by capacitive coupling of electrodes on a tool moved along the borehole with the earth formation.
[0003] 2. Background of the Art
[0004] Electrical earth borehole logging is well known and various devices and various techniques have been described for this purpose. Broadly speaking, there are two categories of devices used in electrical logging devices. In the first category, a measure electrode (current source or sink) are used in conjunction with a diffuse return electrode (such as the tool body). A measure current flows in a circuit that connects a current source to the measure electrode, through the earth formation to the return electrode and back to the current source in the tool. In inductive measuring tools, an antenna within the measuring instrument induces a current flow within the earth formation. The magnitude of the induced current is detected using either the same antenna or a separate receiver antenna. The present invention belongs to the first category.
[0005] There are several modes of operation. In one, the current at the measuring electrode is maintained constant and a voltage is measured, while in the second mode, the voltage of the electrode is fixed and the current flowing from the electrode is measured. Ideally, it is desirable that if the current is varied to maintain at a constant value the voltage between measure and return electrodes, the current is inversely proportional to the resistivity of the earth formation being investigated. Conversely, it is desirable that if this current is maintained constant, the voltage measured between monitor electrodes is proportional to the resistivity of the earth formation being investigated. Ohm's law teaches that if both current and voltage vary, the resistivity of the earth formation is proportional to the ratio of the voltage to the current.
[0006] Birdwell (U.S. Pat. No. 3,365,658) teaches the use of a focused electrode for determination of the resistivity of subsurface formations. A survey current is emitted from a central survey electrode into adjacent earth formations. This survey current is focused into a relatively narrow beam of current outwardly from the borehole by use of a focusing current emitted from nearby focusing electrodes located adjacent the survey electrode and on either side thereof. Ajam et al (U.S. Pat. No. 4,122,387) discloses an apparatus wherein simultaneous logs may be made at different lateral distances through a formation from a borehole by guard electrode systems located on a sonde which is lowered into the borehole by a logging cable. A single oscillator controls the frequency of two formation currents flowing through the formation at the desired different lateral depths from the borehole. The armor of the logging cable acts as the current return for one of the guard electrode systems, and a cable electrode in a cable electrode assembly immediately above the logging sonde acts as the current return for the second guard electrode system. Two embodiments are also disclosed for measuring reference voltages between electrodes in the cable electrode assembly and the guard electrode systems.
[0007] Techniques for investigating the earth formation with arrays of measuring electrodes have been proposed. See, for example, the U.S. Pat. No. 2,930,969 to Baker, Canadian Patent No. 685727 to Mann et al., U.S. Pat. No. 4,468,623 to Gianzero, and U.S. Pat. 5,502,686 to Dory et al. The Baker patent proposed a plurality of electrodes, each of which was formed of buttons which are electrically joined by flexible wires with buttons and wires embedded in the surface of a collapsible tube. The Mann patent proposes an array of small electrode buttons either mounted on a tool or a pad and each of which introduces in sequence a separately measurable survey current for an electrical investigation of the earth formation. The electrode buttons are placed in a horizontal plane with circumferential spacings between electrodes and a device for sequentially exciting and measuring a survey current from the electrodes is described.
[0008] The Gianzero patent discloses tool mounted pads, each with a plurality of small measure electrodes from which individually measurable survey currents are injected toward the wall of the borehole. The measure electrodes are arranged in an array in which the measure electrodes are so placed at intervals along at least a circumferential direction (about the borehole axis) as to inject survey currents into the borehole wall segments which overlap with each other to a predetermined extent as the tool is moved along the borehole. The measure electrodes are made small to enable a detailed electrical investigation over a circumferentially contiguous segment of the borehole so as to obtain indications of the stratigraphy of the formation near the borehole wall as well as fractures and their orientations. In one technique, a spatially closed loop array of measure electrodes is provided around a central electrode with the array used to detect the spatial pattern of electrical energy injected by the central electrode. In another embodiment, a linear array of measure electrodes is provided to inject a flow of current into the formation over a circumferentially effectively contiguous segment of the borehole. Discrete portions of the flow of current are separately measurable so as to obtain a plurality of survey signals representative of the current density from the array and from which a detailed electrical picture of a circumferentially continuous segment of the borehole wall can be derived as the tool is moved along the borehole. In another form of an array of measure electrodes, they are arranged in a closed loop, such as a circle, to enable direct measurements of orientations of resistivity of anomalies. U.S. Pat. No. 6,714,014 to Evans et al, having the same assignee as the present invention and the contents of which are incorporated herein by reference, teaches the use of capacitive coupling with the formation through both oil-based mud and water-based mud.
[0009] The Dory patent discloses the use of an acoustic sensor in combination with pad mounted electrodes, the use of the acoustic sensors making it possible to fill in the gaps in the image obtained by using pad mounted electrodes due to the fact that in large diameter boreholes, the pads will necessarily not provide a complete coverage of the borehole.
[0010] The prior art devices, being contact devices, are sensitive to the effects of borehole rugosity: the currents flowing from the electrodes depend upon good contact between the electrode and the borehole wall. If the borehole wall is irregular, the contact and the current from the electrodes are irregular, resulting in inaccurate imaging of the borehole. A second drawback is the relatively shallow depth of investigation caused by the use of measure electrodes at the same potential as the pad and the resulting divergence of the measure currents. U.S. Pat. No. 6,809,521 to Tabarovsky et al. discloses a multi-frequency method for determination of formation resistivity. The assumption made in Tabarovsky is that
[0000]
σ
1
ɛ
1
<<
ω
<<
σ
2
ɛ
2
[0000] where the σ's are conductivities, the ε's are dielectric constant, ω is the operating frequency, the subscript 1 refers to the mud and the subscript 2 refers to the formation. The first of the two inequalities is easily satisfied with oil based mud where the mud conductivity is extremely small. However, if the mud has a finite conductivity, the condition is hard to satisfy. It would be desirable to have an apparatus and method of determination of formation resistivity that is relatively insensitive to borehole rugosity and can be used with either water based or with oil-based muds for a wide range of formation resistivities. The present invention satisfies this need.
[0011] U.S. patent application Ser. No. 11/209,532 of Bespalov et al., having the same assignee as the present disclosure and the contents of which are incorporated herein by 5 reference, discloses a dual frequency apparatus and method for borehole resistivity imaging. There are a number of technically challenging issues that still remain. One of these is the elimination of “galvanic” cross-talk between sensor electrodes through non-conductive mud and a conductive formation. This error becomes more pronounced in the presence of borehole rugosity when the sensor experience uneven standoff from the formation. Another problem with multi-electrode imaging tools is the presence of mutual inductive coupling between circuits defined by the individual button electrodes. Most importantly, while prior art methods recognize the need for methods and hardware for maintaining the buttons at equipotential using, for example, focusing electrodes, this still remains a difficult technical problem at elevated frequencies (in the MHz range). In addition, multifrequency methods require that each of the amplifiers be maintained at proper tuning at a plurality of frequencies.
SUMMARY OF THE INVENTION
[0012] One embodiment of the disclosure is a method of imaging a resistivity property of a subsurface material. The method includes conveying a logging tool having a plurality of measure electrodes into a borehole and reducing a mutual coupling between at least one pair of the plurality of measure electrodes. A first measure current having a first frequency is conveyed through a first one of the at least one pair of measure electrodes and a second measure current at the first frequency is conveyed through a second one of the at least one pair of measure electrodes. A 2-D image of the resistivity property of the subsurface material is produced using a value of the first measure current and a value of the second measure current. The mutual coupling between the at least one pair of measure electrodes may be reduced introducing a series impedance with each of the at least one pair of measure electrodes. The series impedance may be a resistance, a capacitance, and/or an inductance. The mutual coupling may be reduced by increasing a spacing between the at least one pair of measure electrodes. The mutual coupling maybe reduced by floating the second one of the at least one pair of measure electrodes while conveying the measure current through the first one of the at least one pair of measure electrodes, and floating the first one of the at least one pair of measure electrodes while conveying the measure current through the second one of the at least one pair of measure electrodes. The method may include using a return electrode to return the first measure current and the second measure current. Floating any of the plurality of electrodes may be done by disconnecting an electrical connection, and/or disabling an input to an amplifier. The method may include conveying the logging tool on a bottomhole assembly on a drilling tubular, or a downhole logging string conveyed on a wireline.
[0013] Another embodiment is an apparatus for imaging a resistivity property of a subsurface material. The apparatus includes a logging tool having a plurality of measure electrodes configured to be into a borehole, the logging tool including circuitry configured to reduce a mutual coupling between at least one pair of the plurality of measure electrodes. The apparatus also includes at least one processor configured to convey a first measure current having a first frequency through a first, single one of the at least one pair of measure electrodes, convey a second measure current at the first frequency through a second, single one of the at least one pair of measure electrodes; and produce an image of the borehole wall of the resistivity property of the subsurface material using a value of the first measure current and a value of the second measure current. The circuitry may include a series impedance with each of the at least one pair of measure electrodes. The series impedance may be a resistance, a capacitance, and/or an inductance. The apparatus circuitry may further include a processor configured to float the second one of the at least one pair of measure electrodes while conveying the measure current through the first one of the at least one pair of measure electrodes, and a processor configured to float the first one of the at least one pair of measure electrodes while conveying the measure current through the second one of the at least one pair of measure electrodes. The apparatus may include a return electrode configured to return the first measure current and the second measure current. The processor may be further configured to float any of the plurality of electrodes by disconnecting an electrical connection, and/or disabling an input to an amplifier. The apparatus may include a conveyance device configured to convey the logging tool into the borehole, the conveyance device being a drilling tubular configured to convey a bottomhole assembly, or a wireline configured to convey a logging string.
[0014] Another embodiment is a computer-readable medium for use with an apparatus for imaging a resistivity property of a subsurface material. The apparatus includes a logging tool having a plurality of measure electrodes configured to be into a borehole the logging tool including circuitry configured to reduce a mutual coupling between at least one pair of the plurality of measure electrodes. The medium includes instructions that enable at least one processor to convey a first measure current having a first frequency through a first single one of the at least one pair of measure electrodes, convey a second measure current at the first frequency through a second single one of the plurality of measure electrodes produce an image of the borehole wall of the resistivity property of the subsurface material using a value of the first measure current and a value of the second measure current. The computer-readable medium may be a ROM, an EPROM, an EAROM, a flash memory, and/or an optical disk.
BRIEF DESCRIPTION OF THE FIGURES
[0015] The present invention is best understood with reference to the accompanying figures in which like numerals refer to like elements and in which:
[0016] FIG. 1 (prior art) shows an exemplary logging tool suspended in a borehole;
[0017] FIG. 2A (prior art) is a mechanical schematic view of an exemplary imaging tool;
[0018] FIG. 2B (prior art) is a detail view of an electrode pad of an exemplary logging tool;
[0019] FIG. 3 is a schematic circuit diagram corresponding to an ideal two-electrode imaging system;
[0020] FIG. 4 shows the mutual coupling between current flows in two electrodes;
[0021] FIG. 5 shows the equivalent circuit for the mutual coupling between current flows in the two electrodes;
[0022] FIG. 6 shows a phasor diagram of the currents in two electrodes, the induced EMF and the parasitic current;
[0023] FIG. 7 shows an equivalent Wheatstone bridge configuration of two button electrodes in combination with equivalent formation and mud electrical parameters to demonstrate the current imbalance due to uneven standoff;
[0024] FIG. 8 is schematic diagram of some aspects of the present disclosure; and
[0025] FIG. 9 is an exemplary image display of the Baker Hughes Earth Imager®.
DETAILED DESCRIPTION OF THE INVENTION
[0026] FIG. 1 shows an exemplary imaging tool 10 suspended in a borehole 12 , that penetrates earth formations such as 13 , from a suitable cable 14 that passes over a sheave 16 mounted on drilling rig 18 . By industry standard, the cable 14 includes a stress member and seven conductors for transmitting commands to the tool and for receiving data back from the tool as well as power for the tool. The tool 10 is raised and lowered by draw works 20 . Electronic module 22 , on the surface 23 , transmits the required operating commands downhole and in return, receives data back which may be recorded on an archival storage medium of any desired type for concurrent or later processing. The data may be transmitted in analog or digital form. Data processors such as a suitable computer 24 , may be provided for performing data analysis in the field in real time or the recorded data may be sent to a processing center or both for post processing of the data.
[0027] FIG. 2A is a schematic external view of a borehole sidewall imager system. The tool 10 comprising the imager system includes resistivity arrays 26 and, optionally, a mud cell 30 and a circumferential acoustic televiewer 32 . Electronics modules 28 and 38 may be located at suitable locations in the system and not necessarily in the locations indicated. The components may be mounted on a mandrel 34 in a conventional well-known manner. The outer diameter of the assembly is about 5 inches and about fifteen feet long. An orientation module 36 including a magnetometer and an accelerometer or inertial guidance system may be mounted above the imaging assemblies 26 and 32 . The upper portion 38 of the tool 10 may contain a telemetry module for sampling, digitizing and transmission of the data samples from the various components uphole to surface electronics 22 in a conventional manner. If acoustic data are acquired, they are preferably digitized, although in an alternate arrangement, the data may be retained in analog form for transmission to the surface where it is later digitized by surface electronics 22 .
[0028] Also shown in FIG. 2A are three resistivity arrays 26 (a fourth array is hidden in this view. Referring to FIGS. 2A and 2B , each array includes measure electrodes 41 a, 41 b, . . . 41 n for injecting electrical currents into the formation, focusing electrodes 43 a, 43 b for horizontal focusing of the electrical currents from the measure electrodes and focusing electrodes 45 a, 45 b for vertical focusing of the electrical currents from the measure electrodes. By convention, “vertical” refers to the direction along the axis of the borehole and “horizontal” refers to a plane perpendicular to the vertical.
[0029] The approximate imaging schematic circuit diagram for an ideal two-electrode case (single sensor electrode and return electrode) is presented in FIG. 3 . It shows that the measured effective impedance Z e depends on the internal impedance of the tool Z r , the impedance due to the gap between sensor electrode and formation Z G and effective formation resistance R f . With the measurement condition for operating frequency set per Tabarovsky the effective formation resistance R f is proportional to formation resistivity (or in converse with formation conductivity). The impedance appearing between the return electrode and the formation could be ignored as being very small compared to others. This is a reasonable assumption due to the large area of the return electrode. If U is the applied voltage and I is the measured current then the complex impedance Z e is
[0000]
Z
e
=
Z
T
+
Z
G
+
R
f
=
U
I
.
(
1
)
[0030] In case of a conductive formation (with a resistivity less than 10 Ω-m) and oil-based mud, the contribution of the formation into the effective impedance becomes small R f <<<Z T +Z G which results in a reduction of the sensitivity of the measured impedance to the resistivity of formation. The gap impedance Z G , which depends on the mud properties and the receiver standoff, becomes a major contributor to the effective impedance. Typically, Z T is negligible and could be excluded from considerations for on-pad oil-based imagers.
[0031] Notice that there the current flow through a button follows a path that typically includes transmitter (return) electrode—formation—mud—button—electronics and back to transmitter electrode. The path has complex impedance which is dominated by the gap capacitive reactance in oil-based mud. Some inductive reactance might also be present due to path length. However, the locality of measurements in the current disclosure makes it negligible. See, for example, U.S. Pat. No. 6,714,014 to Evans et al.
[0032] An effect that can not be ignored is the mutual magnetic coupling between these current paths and particularly in the areas where current paths become separated. This happens when currents leave a conductive formation and then flow through mud to buttons. This is illustrated in FIG. 4 where the pad is depicted by 401 , two button electrodes are denoted by 405 a, and 405 b, and the borehole wall by 403 .
[0033] The currents in the two electrodes are denoted by 407 a, 407 b. The current 407 b produces a magnetic field denoted by 409 that, in turn, crosses the conduction path of the neighboring electrode 405 a, thus inducing a current denoted by 411 in the first electrode 405 a.
[0034] The equivalent circuit for this is depicted in FIG. 5 . The currents in the two flow paths are depicted by 11 and 12 respectively and M is the mutual inductance. According to Faraday's Law the induced EMF would be proportional to the operating frequency and generates a compensation current in the neighboring conduction path. Upon a detailed analysis, it is found that in general case of oil-based mud imaging, the phase of these parasitic current would be almost 90° behind the phase of measured current.
[0035] Referring to FIG. 6 , the phasor diagram of the currents and voltages is shown. The currents in the two electrodes are denoted by 11 and 12 . The phase difference between the two may be due to differences in capacitances arising from standoff differences of the two electrodes from the borehole wall. The induced EMF is denoted by 605 . The parasitic current induced is indicated by 607 .
[0036] Generalizing the discussion to a plurality of electrodes, we conclude that:
there is a particular preferable conduction path associated with a particular sensor M from the total set of N buttons; every sensor current becomes a vector sum of the measure current I M and at least N−1 parasitic currents due to magnetic coupling with neighboring paths associated with sensors number 1 , 2 , . . . M−1, M+1, . . . N); the vector sum of parasitic currents would have a phase that is different from the phase of measure current. If mud reactance dominates in the overall impedance in front of the pad, the phase of vector sum would be close to 90° behind the phase of current I M .; and this effect could produce a significant error in post-processing estimation of Z G and R F , often resulting in obtaining both gap width and formation resistivity well above the actual values.
[0041] Another resistivity imaging problem associated with current re-distribution in the formation has been noted before in oil-based imagers. See, for example, U.S. Pat. No. 6,714,014 to Evans et al. Conventionally it has been called as a “defocusing” of the high frequency button current if a neighboring conductive pad structure is presented. See, for example, U.S. patent application Ser. No. 11/758,875 of Itskovich et al., filed on Jun. 6, 2007, having the same assignee as the present disclosure and the contents of which are incorporated herein by reference. As disclosed therein, the button and pad body are kept under the same potential as the sensor.
[0042] The simplified physics of this effect could be seen through example is based on equivalent Wheatstone bridge presentation and includes two neighboring buttons. As one can see from the FIG. 7 , even in case of homogeneous formation (R F1 =R F2 ) the high impedance mud and uneven button standoff (Z G1 >Z G2 ) create a potential distribution, primarily along the borehole wall (across resistor R bw ). In a first approximation this happens due to apparent differences in both magnitudes and phases of Z G , with a minor effect due to formation impedances. The bridge's legs become unbalanced (U 1 ≠U 2 ) and current appears in the diagonal. Following Ohm's Law, a significant portion of this current which would otherwise be going in the sensor # 1 with a bigger standoff will now flow in the sensor # 2 where the gap is smaller. As a result the image losses its fidelity, becomes distorted and smeared in details.
[0043] Providing for a high level of button equipotentiality has remained a challenge at higher frequencies. The sensor current has to be measured while entering the button and at elevated frequencies (10 MHz and above) mutual coupling of the button with associated electronics and rest of pad structure becomes an issue. Moreover, electronics itself could create unwanted biases coupled to the buttons and thus driving currents between them.
[0044] The principles of the present disclosure are illustrated by FIG. 8 . Shown therein is a logging tool with a nonconducting pad 803 and a rugose borehole 801 . Two exemplary electrodes 805 a, 805 b are shown, though in reality, there would usually be many more electrodes. An important difference between the electrode configuration here and in prior art devices is an absence of focusing electrodes and guard electrodes. Instead, each electrode ( 805 a , 805 b ) is coupled to its corresponding preamplifier ( 807 a , 807 b ) through a switch ( 809 a , 809 b ). In the example shown, the switch is depicted as a mechanical device, but any type of switching device could be used, including transistors, integrated circuits, etc. For the purposes of the present disclosure, we use the following definition of a switch: “a device for making, breaking, or changing the connections in an electrical circuit.” The preamplifiers 807 a , 807 b may be connected to a processor 821 .
[0045] An important aspect of the present disclosure is that only one of the electrodes ( 805 a , 805 b ) is connected to a power source at a time. This means that if a measure current is flowing through one of the electrodes, 805 a for example, there is no current flowing through any of the adjacent electrodes. The data are acquired sequentially by the individual electrodes rather than the prior art methods of simultaneous acquisition. Consequently, there is no need to use focusing or guard electrodes to prevent leakage current between the electrodes.
[0046] There are a number of ways by which the sequentially acquisition can be carried out. This could be done by sequentially connecting and disconnecting the switches 809 a , 809 b under control of the processor 821 , or by disabling input circuits of preamplifiers 807 a , 807 b under the control of the processor 821 .
[0047] Besides simplifying the hardware, the method disclosed above also eliminates the galvanic cross-talk between the channels. Based on the discussion above, when there is no current flowing through the other electrodes, the effect of mutual coupling is eliminated.
[0048] Referring now to FIG. 9 , an exemplary image obtained using the Earth Imager® is shown. This is an example of what should be obtainable using the method of the disclosure above. 901 shows the caliper log. 903 shows the gamma ray log. 905 shows a 2-D image of the borehole wall with a fixed gain display. 907 shows a 2-D image of the borehole wall with a dynamic gain applied to the display. 909 shows two isometric views of the borehole wall in cylindrical geometry.
[0049] The disclosure above was directed towards a method and apparatus for eliminating the effects of mutual magnetic coupling between currents flowing through different electrodes. In an alternate embodiment of the disclosure, instead of completely eliminating the mutual magnetic coupling, the coupling is mitigated by introducing series impedance at each and every sense electrode. This acts to suppress the differences between the signals at each electrode, thereby reducing the relative magnitude of the cross-coupling. The series impedance can be achieved using a resistor, capacitor or inductor, or by adding an ‘impeding material’ in the current path, such as an insulator in front of the electrodes. While it is obviously not desirable to have a soft material in contact with the borehole wall, such a configuration might be acceptable for imaging a fluid. Mitigation can also be achieved by attempting to calibrate the response in an environment that is substantially similar to the measurement environment, although this is generally much less practical. Reduction of mutual coupling can also be accomplished by increasing the spacing between the electrodes.
[0050] A point to note with the present disclosure is that many of the prior art processing methods may also be applied to data acquired using the method of the present invention. This includes, for example, dual frequency focusing (U.S. patent application Ser. No. 11/209,531 of Bespalov et al.).
[0051] The invention has further been described by reference to logging tools that are intended to be conveyed on a wireline. However, the method of the present invention may also be used with measurement-while-drilling (MWD) tools, or logging while drilling (LWD) tools, either of which may be conveyed on a drillstring or on coiled tubing. An example of a resistivity imaging tool for MWD use is discloses in U.S. Pat. No. 6,600,321 to Evans, having the same assignee as the present invention and the contents of which are incorporated herein by reference.
[0052] Implicit in the processing of the data is the use of a computer program implemented on a suitable machine readable medium that enables the processor to perform the control and processing. The term processor as used in this application is intended to include such devices as field programmable gate arrays (FPGAs). The machine readable medium may include ROMs, EPROMs, EAROMs, Flash Memories and Optical disks. As noted above, the processing may be done downhole or at the surface, by using one or more processors. In addition, results of the processing, such as an image of a resistivity property, can be stored on a suitable medium.
[0053] While the foregoing disclosure is directed to the preferred embodiments of the invention, various modifications will be apparent to those skilled in the art. It is intended that all variations within the scope and spirit of the appended claims be embraced by the foregoing disclosure.
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Sequential measurements are made using a two terminal resistivity imaging device wherein the measure electrodes are activated sequentially with the remaining electrodes in a floating mode. This eliminates the hardware requirements for focusing electrodes, prevents galvanic leakage between proximal electrodes and the effects of mutual coupling between circuits including proximal electrodes.
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BACKGROUND OF THE INVENTION
This invention relates to a process for hydrolyzing an acrylamide polymer, that is, a process for producing a partially hydrolyzed acrylamide polymer.
Acrylamide polymers, namely, homopolymers and copolymers of acrylamide have been widely used as flocculants or thickeners for paper making and more recently for secondary recovery of petroleum. Although the performance required of the polymer may differ depending on the respective purposes of uses, the common desirable features for these uses are most probably high molecular weight and good solubility of these polymers.
One group of such acrylamide polymers are copolymers of acrylamide with acrylic acid (or its salt) (comonomers are not necessarily limited to acrylic acid alone). One method for obtaining such a copolymer comprises hydrolyzing with an alkali agent a part of the amide groups by contacting an acrylamide polymer in the state of an aquagel obtained from the polymerization step. For example, the following proposals have been made: (1) a gel-like polymer is kneaded with an alkali agent by means of a rotary screw type extruder, and the kneaded mixture is dried according to necessity. (reference: Japanese Patent Publication No. 17668/1974); (2) granules of a gel-like polymer are contacted with an aqueous alkali, further subjected to regranulation by means of a granulating extruder and then dried. (reference: Japanese Laid-open Patent Publication No. 167705/1981); and (3) hydrous polymer particles are contacted with an alkali agent under agitation in a device equipped with a stirring mechanism with a ribbon type blade or a gate type blade whose surface to be in contact with the polymer particles is made of a synthetic resin, which step is followed subsequently by drying under heating (reference: Japanese Patent Publication No. 15793/1979).
All of these methods provide methods for mixing a gel-like polymer with an alkali agent and have successfully achieved their respective objects. To the best of our knowledge, however, these methods involve problems. That is, the methods (1) and (2) may be considered to be superior to the method (3) in the aspect of achieving uniform hydrolysis, but a lowering of the molecular weight of the polymer is unavoidable because of a great shearing force acting on the polymer in the presence of an alkali agent. On the other hand, according to the method of (3), while deterioration of the polymer is suppressed to some extent, it is not yet satisfactory with respect to carrying out hydrolysis uniformly. When uniform hydrolysis is not accomplished, various problems arise depending on the uses of the polymers obtained, even though the polymer may have a high molecular weight and good solubility. For example, when applied as a thickener for paper making, the pulp may undergo partial agglomeration to cause poor formation of the paper, sometimes resulting in failure of paper making in extreme cases. Also, when applied as an agent for secondary recovery of petroleum, white turbidity may be generated in water containing polyvalent metal ions to lower the function of the agent.
Still another disadvantage of the method for hydrolysis of the aquagel of an acrylamide polymer as described above is that, since a considerable part of the hydrolysis reaction is accomplished in the drying step, the by-produced ammonia is occluded in dried polymer particles, which ammonia is in turn released upon dissolution of the dried particles, whereby the working environment is impaired as a consequence of the generation of the odor of ammonia. In view of such a drawback, various proposals have also been made to use various additives (reference: Japanese Laid-open Patent Publication Nos. 102390-102392/1979).
SUMMARY OF THE INVENTION
An object of the present invention is to overcome the drawbacks of the prior art as described above, and the present invention seeks to accomplish this object by carrying out hydrolysis of an aquagel polymer according to a specific mode and at the same time completing the hydrolysis before the drying step.
More specifically, the process for producing a partially hydrolyzed acrylamide polymer according to this invention comprises mixing small pieces of the aquagel of an acrylamide polymer with an alkali agent and then drying the mixture thereby to produce a partially hydrolyzed acrylamide polymer, wherein the small pieces of the aquagel are mixed with the alkali agent and maintained at a temperature of 50° to 95° C. for a time until hydrolysis is accomplished to a degree of 1.1 to 3 times the theoretical hydrolysis percentage corresponding to the amount of the alkali agent mixed, hydrolysis being substantially completed, and thereafter the small pieces of the aquagel are dried.
The present invention has been attained as the result of our various investigations on various parameters such as the quantity of the alkali agent adhering to the aquagel surface, the rate of diffusion of the alkali agent into the aquagel, the secondary hydrolysis caused by the ammonia which is a by-product, etc.
According to the present invention as specified above, hydrolysis can be accomplished uniformly under application of substantially no shearing force on the aquagel of the polymer, whereby the solubility of the resultant polymer can be markedly improved as compared with the products obtained by the methods of the prior art. As another advantage, substantially no occlusion of ammonia within the dried polymer particles is observed.
DETAILED DESCRIPTION OF THE INVENTION
Aquagel of acrylamide polymer
The aquagel of the acrylamide polymer to be subjected to hydrolysis is essentially not different from those used in the prior art as described above.
Thus, first, as the acrylamide polymer, in addition to typical acrylamide homopolymers, there can be copolymers of a major proportion, preferably 80 mole %, of acrylamide and a minor proportion of a comonomer copolymerizable therewith. Since this polymer should be soluble in water, the comonomer employed should be chosen so that the resultant copolymer at a given composition will be soluble in water. Examples of such comonomers are (meth)acrylic acid or esters and salts thereof, acrylonitrile, hydroxyethyl (meth)acrylate, 2-acrylamido-2-methylpropane sulfonic acid and salts thereof. Here, "(meth)acrylic acid" means both acrylic acid and methacrylic acid.
From the requirement as stated above that the acrylamide polymer should have a high molecular weight, the aquagel has almost no fluidity but has a certain extent of "solidness". The "solidness" of the aquagel of course depends on the molecular weight and the concentration of the polymer dissolved therein. In view of its ease in handling, it is desired that the aquagel have ample solidness, and, specifically, for example, in the case of an acrylamide homopolymer having an average molecular weight of about 5,000,000, the "solidness" of the aquagel when containing the polymer at a concentration of at least 15% by weight is suitable.
Such an acrylamide aquagel is ordinarily prepared by polymerization of a required monomer in an aqueous solution. Since it is the common practice to utilize the polymer solution formed with 100% of polymerization conversion directly as it is for the aquagel, the monomer concentration during the polymerization in an aqueous solution is substantially the same as the polymer concentration in the aquagel. More specifically, the monomer concentration is of the order of from 15 to 40%, preferably 20 to 35%, by weight. The kind and quantity of the catalyst should be appropriately selected with due consideration of the nature of the polymerization system wherein a high molecular weight polymer is produced with a conversion of 100%, whereby it is impossible to agitate the system, and, therefore, the rise in temperature of the system due to the heat of polymerization must be unpreventably left to occur. Specific examples are redox initiators and azo initiators.
The present invention is directed toward the preparation of small pieces of such an acrylamide polymer aquagel. Such small pieces can be obtained by roughly crushing the mass of the aquagel and further grinding the crushed product into pieces. For grinding into small pieces, it is convenient to use an extruder like a meat grinder, that is, a meat grinder having a rotary cutter in contact with the inner side of a perforated plate. The perforated plate to be used in this case has orifices of a diameter of the order of 3 to 20 mm, preferably of the order of 5 to 10 mm. The small pieces of aquagel are obtained as pellets or stubs with diameters of the same order or deformations thereof.
Hydrolysis step
The small pieces of the acrylamide polymer aquagel thus obtained are mixed with an alkali agent and hydrolyzed under specific conditions.
The alkali agent may be any compound which can cause the desired hydrolysis in the acrylamide polymer, but most typically a hydroxide of an alkali metal, particularly sodium hydroxide.
The alkali agent is ordinarily in the form of an aqueous solution so as to be contacted evenly with the small pieces of aquagel, and mixing of the alkali agent with the small pieces of aquagel is generally practiced by spraying of the aqueous solution over the small pieces. This aqueous solution may also contain auxiliary materials such as antioxidants and others dissolved therein depending on the necessity. The aqueous solution of an alkali agent desirably has a high concentration from the standpoint of drying load, while a low concentration is desirable from the standpoint of homogeneous dispersion and spraying load. Generally, however, it is of the order of 20 to 40%. It is preferable to use an aqueous solution at such a concentration and warmed to about 50° to 70° C.
One specific feature of the present invention resides in the use of an alkali agent in an amount within a specific range and also substantially completing hydrolysis before drying with the use of such an amount of the alkali agent.
More specifically, the theoretical hydrolysis percentage in the case of hydrolysis of an acrylamide polymer with an alkali agent [namely, {(moles of amide groups hydrolyzed)/(moles of amide groups before hydrolysis)}(×100)] is the same as the quantity in mole percentage of the alkali agent employed [namely, {(moles of the alkali agent employed/(moles of amide groups before hydrolysis)}(×100)]. In actual practice, however, the hydrolysis percentage attained is generally smaller than the theoretical hydrolysis percentage corresponding to the amount of the alkali agent employed. The present invention has been attained, in the first place, as a result of our perceptively observing this hydrolysis behavior and thereupon carrying out the various investigations as mentioned hereinbefore. The hydrolysis step is carried out so that the hydrolysis percentage will be 1.1 to 3 times, preferably 1.5 to 2.0 times the theoretical hydrolysis percentage corresponding to the amount of the alkali agent employed. To attain a hydrolysis percentage 1.1 to 3 times the theoretical hydrolysis percentage corresponding to the amount of the alkali agent employed means to use an alkali agent in an amount corresponding to 1/1.1 to 1/3 of the desired hydrolysis percentage, which desired hydrolysis percentage is that desired in the final product since hydrolysis is substantially completed in the hydrolysis step in the present invention.
In the present invention, moreover, this hydrolysis step is substantially completed prior to the drying step. For this purpose, the small pieces of aquagel and the alkali agent are mixed together and maintained at a temperature within a specified range, namely, from 50° to 95° C., preferably from 60° to 80° C., for a certain period of time. The maintenance time in this case is the time until the state wherein hydrolysis is substantially completed is attained. The "state where hydrolysis is substantially completed" as herein mentioned means that the increase in the hydrolysis percentage after drying is not greater by about 5%, preferably about 2% based on that before drying.
The maintenance time differs depending on the temperature employed. For example, at the same level of the alkali agent, 8 hours are necessary at 70° C., while about 15 hours of maintenance time are required at 60° C. Since the temperature of the polymer aquagel to be prepared in this invention is permitted to rise freely during adiabatic polymerization in an aqueous solution, it is sometimes found that the aquagel produced has a temperature of 90° C. or higher upon completion of polymerization. Even after this gel is disintegrated into pieces, the temperature of the pieces is still at approximately 70°-80° C. and therefore it is advantageous with respect to energy saving to carry out the hydrolysis step with addition of an alkali agent at a temperature of the order of 60° to 80° C. At a temperature higher than 95° C., the hydrolysis rate is so great that hydrolysis will proceed under the state where the alkali agent is insufficiently diffused in the small pieces of gel to give locally ununiform hydrolysis percentages within the given piece of gel.
Drying step
Except for carrying out the hydrolysis step under the controlled conditions as described above, the drying step in the present invention is substantially the same as that employed in the prior art as described above.
Thus, it is possible to use any of box type drier, rotary drier and belt type drier conventionally used, and the small pieces of the polymer after drying is pulverized in a conventional manner into powder.
EXPERIMENTAL EXAMPLES
Example 1
After an aqueous solution containing 25% by weight of acrylamide was thoroughly purged with nitrogen, polymerization was carried out in a conventional manner by the use of a redox initiator at 10° C. to obtain a rubbery polymer gel.
Twenty kilograms (20 kg) of this gel was minced into small pieces by means of an extruder resembling a meat grinder having a perforated plate with orifice size of 6 mm equipped internally with a cutter. The temperature of the small pieces of gel was 78° C. on the average. These pieces were charged into a drum granulator of a ca. 250 liter capacity, and 1,020 g of an aqueous 30% caustic soda solution (10 mole % of the acrylamide units in the gel) heated to 50° C. was sprayed thereover while the drum was rotated. The small pieces were then transferred into a vessel traced with hot water, and the temperature thereof was measured and found to be 65° C. on the average. The same temperature was maintained with the lid kept closed for 12 hours. A part of the treated small pieces of gel was sampled, and the remainder was dried in a 100-liter hot air rotary drier at 120° C. for 20 minutes, and then at 60° C. for 5 hours. The polymer pellets obtained were crushed and measured for solubility (Note 1), microgel (Note 2) and uniformity of hydrolysis (Note 3). A part of the 1% solution was sampled for measurement of hydrolysis percentage. The results were as shown below.
Hydrolysis percentage: 20.5 mole %
Solubility: 0%
Microgel: ±
Uniformity of hydrolysis: Slight white turbidity
pH of 1% solution: 7.1
The hydrolysis percentage of the small pieces of gel sampled before drying was found to be 20.3%, the increase in the hydrolysis percentage by drying being thus 0.98%.
Comparative Example 1
The aqueous caustic soda solution was sprayed in the same manner as in Example 1 and the mass was thereafter maintained as it was for 30 minutes. A part of the mass was sampled and the remainder was dried according to the same method as in Example 1. This polymer was evaluated similarly as in Example 1. The results were as shown below.
Hydrolysis percentage: 9.8 mole %
Solubility: 0.2%
Microgel: ++
Uniformity of hydrolysis: Slight white turbidity (with transparency)
pH: 10.0
Hydrolysis percentage of the gel before drying: 7.5 mole % (hydrolysis percentage is increased by 31% by drying)
Comparative Example 2
Comparative Example 1 was repeated except that the amount of the caustic soda added was changed to 2,040 g (20 mole % of the acrylamide units in the gel), and the polymer was evaluated similarly. The results are as shown below.
Hydrolysis percentage: 20.1 mole %
Solubility: 0.2%
Microgel: +++
Uniformity of hydrolysis: White turbidity (with no transparency whatsoever)
pH: 10.5
Hydrolysis percentage of the gel before drying: 16 mole % (hydrolysis percentage is increased by 26% by drying)
As is apparent from Example 1, Comparative Example 1 and Comparative Example 2, the process of the present invention can provide a product which is superior in both solubility and uniformity of hydrolysis as compared with the products of the hydrolysis methods proposed in the prior art, and which, in a 1.0-% solution, exhibits a pH which is not high, there being no existence whatsoever of unreacted alkali, ammonia, etc.
Examples 2-6 and Comparative Examples 3-5
After small pieces of gel were obtained according to the procedure of Example 1, about 200 g of the small pieces of gel were accurately weighed in a polyethylene bag, and hydrolysis was conducted with various amounts of alkali added and for various periods of maintenance time to obtain various hydrolyzed polymer powders. The polymers were evaluated similarly as in Example 1 to obtain the results as shown in the following Table.
__________________________________________________________________________ Hydrolysis Hydrolysis Conditions Percentage (%) Alkali added Temperature Maintenance Before After Solubility (Note 4) (mol %) (°C.) time drying drying (%) Microgel pH Uniformity__________________________________________________________________________Example2 5 80 8 hrs. 9.5 9.7 0 + 7.1 Substantially no turbidity3 15 70 16 26.0 26.2 0 ± 7.2 Slight white turbidity (with transparency)4 20 70 15 29.6 30.0 0 ± 7.3 --5 20 80 8 30.8 30.7 0 ± 7.3 --6 10 75 8 19.2 19.6 0 ± 7.3 Slight white turbidity (with transparency)ComparativeExample3 20 70 30 min. 14.0 20.0 0.2 ++ 10.8 Great white turbidity (with no transparency)4 20 98 15 min. 15.2 20.0 0.3 +++ 9.8 Great white turbidity (with no transparency)5 30 70 15 min. 19.5 29.5 0.1 ++ 11.0 --__________________________________________________________________________ (Note 1) Solubility: The test was conducted at a water temperature of 23 ± 1° C. Solubility was measured as follows. One half (0.5) gram of polymer powder was weighed into a glass beaker containing 500 ml of tap water and stirre for 4 hours. The mixture was transferred onto a 100mesh screen and left t stand thereon for about 5 minutes. The residue on the screen was collecte and dried, and its proportion was represented in terms of percentage. (Note 2) Microgel: Even in the above method, some microgels which can pass through the 100mesh screen may sometimes exist. This was measured by observing a piec of glass plate (25.sup.mm × 75.sup.mm × 1.sup.mm) dipped in and withdrawn from the polymer solution, its quantity (numbers of swollen microgel particles) observed being rated according to the following ranking. +++: markedly much ++: much +: slight ±: almost none (Note 3) Irregularity of hydrolysis (uniformity): Five (5) grams of powder polymer was transferred into a beaker containing 500 ml of deionized water, and, after stirring for 4 hours, 2N--H.sub.2 SO.sub.4 was added thereinto to adjust pH to 2.2. After additional stirring for 60 minutes, the white turbid state is observed. The degree o white turbidity depends greatly on the temperature and the hydrolysis percentage, and therefore particular caution is necessary for samples to be compared. When hydrolysis proceeds to 35 mole % or higher on an averag or when hydrolysis irregularity becomes greater, precipitates of a polyme may sometimes be formed. In such a case, comparison should be made by changing the measuring conditions such as elevation of temperature. (Note 4) pH of 1.0% solution: Determination of the pH of the above 1.0% solution shows the presence of unreacted alkali or NH.sub.3 formed during drying.
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Polyacrylamide in the form of aquagel is partially hydrolyzed in such a manner that small pieces of the aquagel are mixed with an alkali agent in a specified quantity and maintained at a temperature of 50° to 95° C. until the hydrolysis reaches substantial completion. The quantity of the alkali agent is that corresponding to 1/1.1 to 1/3 of the hydrolysis percentage desired of the final partially hydrolyzed polyacrylamide. The partially hydrolyzed polyacrylamide thus produced is characterized by uniform hydrolysis evidenced by its improved solubility in water and a pH around 7 of its aqueous solution. The term "aquagel" is herein used interchangeably with a term "hydrogel".
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[0001] The application claims the priority of Chinese patent application with application No. 201020158149.X, titled as “WALL HANGING AIR CONDITIONER”, and filed on Apr. 9, 2010, and all disclosed contents thereof should be incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to the field of indoor air conditioners, in particular, to a wall hanging air conditioner.
BACKGROUND OF THE INVENTION
[0003] Swing blades of the wall hanging air conditioner in prior art are generally mounted at an upper portion of the air outlet. Since the air outlet of the air conditioner has a lamer air output at the lower portion than at the upper portion, if the swing blades are mounted at the upper portion of the air outlet, the adjustment of the air discharging angle of the air conditioner and the comfort level would he limited to some extent. Thus, the air blowing out of the air conditioner can not flow adequately indoors, and the comfortable feeling of the people in rooms can be reduced.
SUMMARY OF THE INVENTION
[0004] The purpose of the present invention is to provide a wall hanging air conditioner which can solve technical problems that the limited air discharging angle of the air conditioner and the low comfort level.
[0005] Therefore, the present invention provides a wall hanging air conditioner comprising: a panel provided with an air outlet, and a swing blade mechanism mounted at a lower portion of the air outlet.
[0006] Further, the swing blade mechanism may comprise: a base mounted on an air outlet seat of the lower portion of the air outlet; a plurality of swing blades provided on the base in sequence; and a transmission mechanism connected transmittingly to a driving output end of a swing, motor of the wall Naming air conditioner and connected respectively to each of the plurality of swing blades.
[0007] Further, each of the plurality of the swing blades may comprise: a blade body connected to the transmission mechanism; a blade seat provided at a bottom portion of the blade body and fixedly connected to the base; and an elastic connecting part connecting between the blade body and the blade seat.
[0008] Further, the elastic connecting part may be of an elongated shape, an upper end of which may be connected to an inner edge of the blade body.
[0009] Further, the transmission mechanism may be a connecting rod The connecting rod may be provided with a plurality of grooves, and a blade notch may be provided at an outer side of each of the blade body. The blade notch of each of the blade bodies may be fitted with the corresponding groove of the connecting rod.
[0010] Further, in the case that the transmission mechanism is a connecting rod, the connecting rod may be provided with a plurality of ring-shaped friction parts, and a blade notch may be provided at one side of the blade body. The blade notch of each of the blade bodies is closely fitted with the corresponding friction part of the connecting rod.
[0011] Further, the blade notch may be provided at a middle portion of an outer edge of the corresponding blade body.
[0012] Further, the swing blade mechanism may include a manual adjusting device. The manual adjusting device may comprise: a rotatable shaft rotatablely provided on the base and including a manual force exerting portion and a pinion portion; and a rack portion provided on the connecting rod and engaged with the pinion portion.
[0013] Further, the manual force exerting portion is a polyhedral prism portion provided at a middle portion of the rotatable shaft, and the pinion portion is provided at an upper end of the rotatable shaft.
[0014] Further, the base of the swing blade mechanism may comprise: a sinking step portion provided at least at a longitudinal edge portion of the base; a recess portion which may be provided therein with a counter bore penetrating the base; and protrusions fitted with an edge portion of the sinking step portion and the counter bore of the recess portion may be provided on the air outlet seat of the air conditioner.
[0015] The present invention has the following technical effects.
[0016] Since the air outlet has a larger air output at the lower portion than at the upper portion, the swing blade mechanism is provided at the lower portion of the air outlet and can efficiently guide the direction of the air, improve the swing angle, and increase the comfortable level of people.
[0017] The base, the transmission mechanism and the swing blades are combined to form the swing blade mechanism, which not only can ensure the flexible swing of the blade bodies, but also can facilitate detaching and mounting of the mechanism. When the components of the swing blade mechanism are failed or need to be cleaned, these components can be detached quickly and easily, thereby the operating efficiency is increased.
[0018] With the manual adjusting device connected transmissively to the transmission mechanism, the swing angle of the swing blades can be adjusted manually, thereby the flexibility of the swing blade mechanism is further improved.
[0019] By providing the locating notch in the rectangular recesses fitted with the locating protrusions and providing the locating pins fitted with the locating holes, the swing blade mechanism is mounted on the seat of the lower portion of the air outlet, thereby the detaching and mounting efficiency of the swing blade mechanism is increased.
[0020] Besides purposes, features and advantages described above, the present invention also has other purposes, features and advantages. Other purposes, features and advantages of the present invention will be further described in details below as shown in drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] Drawings, which form a part of the description and are provided for further understanding of the present invention, show the preferred embodiments of the present invention, and explain the principle of the present invention together with the description. In the drawings:
[0022] FIG. 1 is a structural schematic view of the assembly of a preferred embodiment of the present invention;
[0023] FIG. 2 is a structural schematic view of a swing blade mechanism of a preferred embodiment of the present invention;
[0024] FIG. 3 is a structural schematic view of a swing blade of a preferred embodiment the present invention; and
[0025] FIG. 4 is an enlarged structural schematic view of part 1 in FIG. 1 indicating a manual rotary device.
DETAILED DESCRIPTION
[0026] The embodiments of the present invention will be described in detail below as shown in drawings, however the present invention may he implemented by various different ways defined and covered by the claims. In the drawings, identical components are indicated by identical reference number.
[0027] As shown in FIG. 1 , the wall hanging air conditioner of the present invention includes a panel 1 . An air outlet 10 is provided, in the panel 1 , and a swing blade mechanism 3 is provided at a lower portion 102 of the air outlet.
[0028] In the prior art, the swing device for is generally mounted at the upper portion 101 of the air outlet 10 . However, since the air outlet has a larger air output at the lower portion 102 than at the upper portion, it is difficult for the swing device located at the upper portion of the air outlet 10 to perform an effective sweep for the air outgoing from the lower portion 102 of the air outlet, and the air discharging angle of the air conditioner is also limited. In the present invention, the swing blade mechanism 3 is provided at the lower portion 102 of the air outlet, which can efficiently change the air discharging direction, and can improve the air discharging angle under a relatively large air force, thereby increasing the flowing range of the air discharged from the air conditioner indoors and increase the comfortable feeling of people.
[0029] As shown in FIGS. 2 and 3 , in order to make the swing blade mechanism 3 achieve a better swing angle and be detached or mounted flexibly, preferably, the swing blade mechanism 3 may include a base 31 , a transmission mechanism 33 , and a plurality of swing blades 35 connected in a transmission manner to the transmission mechanism 33 . One end of the transmission mechanism 33 is connected in a transmission manner to a driving output end of a swine motor of the wall hanging air conditioner. The swing blades 35 are driven to swing left or right under the driving of the swing motor. The plurality of swing blades 35 may be provided on the base 31 in sequence and at an equal interval.
[0030] In order that the swing blades 35 can be detached or mounted more flexibly, each swing blade 35 may include a blade body 351 , a blade seat 353 , and an elastic connecting part 355 connecting the blade body 351 and the blade seat 353 . The blade seat 353 fixedly connected to an air outlet seat of the lower portion 102 of the air outlet 10 .
[0031] In order that the swing blade 35 can be easily deformed to better change the air guide angle, the blade body 351 can swing at a larger angle and the swing resistance can be reduced, the elastic connecting part 355 may be of an elongated shape, and an upper end of the elastic connecting part 355 may be connected to an inner edge of the blade body 351 .
[0032] Preferably, in the present embodiment, the upper end of the elastic connecting part 355 may be connected to an upper end of the inner edge of the blade body 351 , to efficiently reduce the connection portion between the elastic connecting part 355 and the blade body 351 and increase the swing flexibility of the blade body 351 .
[0033] The blade body 351 may be fixedly connected to the base 31 via the elastic connecting part 355 and the blade seat 353 . The elastic connecting part 355 and the blade body 351 may be made integrally, or be formed separately. The elastic connecting part 355 and the blade seat 353 may be made integrally, or be formed separately. The blade seat 353 may be fixedly connected to the base 31 in an inserted coupling manner, and accordingly, the base 31 may be provided with the corresponding number of grooves. Generally, the blade body 351 may be made of an elastic material that can be bent, and the blade body 351 can be driven by the transmission mechanism 33 to swing left of right under the elastic force.
[0034] In order that the swing blade mechanism 3 can be detached for cleaning or maintaining, each blade body 351 may be connected to the transmission mechanism 33 in a snap-fit coupling manner. The transmission mechanism 33 may be a connecting rod, and each swing blade 35 may be connected to the connecting rod in a snap-fit coupling manner. The connecting rod may be provided with a plurality of grooves, and each blade body 351 may be correspondingly provided at a side thereof with a blade notch 352 , and the blade notch 352 of each blade body 351 is fitted with corresponding groove of the connecting rod.
[0035] The connecting rod may also be provided with a plurality of ring-shaped friction parts, and the blade notch 352 of each blade body 351 may be closely engaged with the corresponding friction part of the connecting rod. So that the blade body 351 may be driven by the connecting rod to swing left or right under the friction force.
[0036] The blade notch 352 may be provided at a middle portion of an outer edge of each blade body 351 and is located at the opposite side of the elastic connecting part 355 .
[0037] When the swing blade mechanism 3 is operated, the connecting rod is rotated under the drive of the driving output end of the swing motor, and thus drives the blade body 351 of each swing blade 35 to swing left or right to perform the air sweep, thereby achieving the adjustment of a relatively large air discharging angle.
[0038] As shown in FIG. 4 , in order to further facilitate the adjustment of the swing angle of the swing blades 35 , and also to avoid the circumstance in which the direction of the air can not be adjusted due to the breakdown of the swing motor, the swing blade mechanism 3 may further includes a manual adjusting device. The manual adjusting device includes a rotatable shaft 32 and a rack portion. The rotatable shaft 32 which includes a manual force exerting portion 321 and a pinion portion 322 , is rotatablely provided on the base 31 The rack portion is provided on the connecting rod and engages with the pinion portion 322 .
[0039] In order to facilitate applying a force to the manual adjusting device, the manual force exerting portion 321 may be a polyhedral prism portion provided at a middle portion of the rotatable shaft 32 , and the pinion portion 322 may be provided at an upper end of the rotatable shaft 32 .
[0040] When it needs to adjust the swing angle of the swing blade 35 manually, the polyhedral prism portion may be rotated manually such that the pinion portion 322 is rotated accordingly, so as to drive the connecting rod to move left or right through the engagement between the pinion of an upper end of the pinion portion and the rack of the connecting rod, thereby achieving the leftward or rightward swing of the swing, blade 35 .
[0041] The manual force, exerting portion 321 may also be configured as a handle mounted on the rotatable shaft 32 . The rotatable shaft 32 may he rotated at an angle by operating the handle, such that the connecting rod moves by a distance in a longitudinal direction, thereby achieving the adjustment of the air direction via the swing blades 35 connected to the connecting rod.
[0042] In order that the swing blade mechanism 3 can be stably mounted on the air outlet seat of the lower portion 102 of the air outlet 10 and can be easily detached, preferably, the swing blade mechanism 3 may further include a sinking step portion 37 which is at least provided at a longitudinal edge portion of the base 3 . 1 . A lower side of the sinking step portion 37 may be detachably fixed on the air outlet seat of the lower portion of the air outlet 10 .
[0043] The sinking step portion 37 may be of a semicircular shape or a rectangular shape, or any other shape adapted to snap lit with the air outlet seat. Preferably, in the present embodiment, the sinking step portion is of a rectangular shape.
[0044] In order that the swing blade mechanism 3 may be detached, a top surface of the base 31 may be provided with several rectangular recesses 38 . In the present embodiment, a rectangular recess 38 may be provided at each end portion as well as a middle position of the base 31 . An edge counter bore 382 penetrating the base 31 may be provided in each of the rectangular recesses 38 at the two end portions of the base 31 , and protrusions fitted with the edge counter bores 382 may be provided at corresponding positions of the air outlet seat of the lower portion 102 of the air outlet 10 . Two middle counter bores 381 may be provided in the rectangular recess 38 at the middle position of the base 31 . Accordingly, two protrusions corresponding to the two middle counter bores 381 may be provided at corresponding positions of the air outlet seat of the lower portion 102 of the air outlet 10 .
[0045] The rectangular recesses 38 may also he of a circular shape or any other suitable shape.
[0046] When the swing blade mechanism 3 is to be mounted in whole to the lower portion 102 of the air outlet 10 of the wall hanging air conditioner according to the present invention, the protrusions on the air outlet seat of the lower portion 102 of the air outlet 10 may be inserted into the edge counter bores 382 , thereby achieving the reliable mounting of the swing blade mechanism 3 . With this kind of mounting structure, when the swing, blade mechanism 3 is failure or needs to be cleaned, the swing blade mechanism 3 may be easily detached from the wall hanging air conditioner, which is convenient and flexible.
[0047] Above contents only describe the preferred. embodiments of the present invention and are not intended to limit the present invention; for one skilled in the art, the present invention may have various modifications and changes. Any modifications, equivalent replacements and improvements made within the spirit and principle of the present invention should be included within the protection scope of the present invention.
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A wall hanging air conditioner comprises a panel ( 1 ) provided with an air outlet ( 10 ) and an air sweep blade mechanism ( 3 ). The swing blade mechanism ( 3 ) is mounted at a lower portion ( 102 ) of the air outlet ( 10 ). The invention has advantages of buffering wind power, improving the swing angle, and increasing the comfortable level of people.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to the fields of computer systems and computer conferencing. More specifically, the present invention relates to heterogeneous multimedia conferencing.
2. Background Information
Today, many computer conferencing systems support simultaneous exchanges of "natural" data (i.e. video, audio, etc.) as well as "conventional" data (i.e. file transfer, email, remote login, etc.) among the conference participants. Exchanges of these data are typically made in either an one-to-all or a selective point-to-point basis. In the case of one-to-all, data are broadcast to all participants, whereas in the case of point-to-point, data are sent to particularized recipients, one a time.
As telecommunication and computing continue to merge, both users and system integrators desire closer modeling of participant behaviors in a face-to-face conference. For example, in a face-to-face conference, in addition to the main conference, typically there are side conversations among some of the participants. As a further illustration, a listener of a presentation may ask another listener to clarify certain information that was just "broadcast" to the listeners by the presenter. Furthermore, there may be sub group discussions among subsets of the participants on the exchanges that are taking place in the main conference. The prior art approach of exchanging data has the disadvantage in that for a large conference, conducting these sub group discussions may require sending the subgroup discussion data along with the specific recipient's address, as many time as there are participants to receive it.
Thus, it is desirable if conference participants can engage in these side conversations or subgroup discussions in a more friendly and efficient manner. As will be described in more detail below, the method and apparatus of the present invention achieves these and other desirable results.
SUMMARY OF THE INVENTION
The desired results are advantageously achieved by providing a plurality of specially equipped personal conference managers (PCMs), one each, to a plurality of personal conference systems (PCSs), and a plurality of specially equipped multi-point conference managers (MCMs), also one each, to a plurality of multi-point control units (MCUs) interconnecting the PCSs.
Each PCM is equipped with a first plurality of data routing matrix management functions for creating, updating, and deleting a plurality of data routing matrices specifying a plurality of data routing patterns for the PCSs, thereby allowing a conference to be viewed as a collection of these data routing matrices, and data routing among the PCSs to be specified in a transport network independent manner. The first plurality of data routing matrix management functions are also used for creating, updating, and deleting a plurality of data routing matrix employment rules specifying the conditions governing the runtime employment of the data routing matrices, thereby allowing data routing to be dynamically altered during runtime in an efficient manner with very low switching latency. The conditions are specified in terms of multi-point references. In some embodiments, the multi-point references are implemented using character tokens, and the employment rules are expressed in terms of these character tokens.
Additionally, each PCM as well as each MCM is equipped with a second plurality of data routing matrix management functions for enrolling these routing matrices and their employment rules with the MCMs, and canceling their enrollments. Furthermore, each PCM as well as each MCM is equipped with a data transmission function for sending data. The PCM's data transmission functions specify the destinations in terms of the multi-point references. In some embodiments, the multi-point references are specified in the header of each data frame. The MCM's data transmission functions ascertain the destinations from the proper routing matrices as governed by the employment rules, and route the data accordingly. In some embodiments, for certain data types, the data transmission functions of the MCMs are further equipped to infer from the routing matrices whether certain intermediate processing are to be applied before routing the data, and cause the necessary processing to be performed.
Thus, by enrolling and canceling data routing matrices for audio/video data and their employment rules, a conference participant may engage in side conversations or subgroup discussions with selected subgroups of conference participants, without having to particularize the recipients of each data transmission, one at a time.
BRIEF DESCRIPTION OF DRAWINGS
The present invention will be described by way of exemplary embodiments, but not limitations, illustrated in the accompanying drawings in which like references denote similar elements, and in which:
FIGS. 1 & 2 illustrate two exemplary networks of personal conferencing systems incorporating the teachings of the present invention;
FIG. 3 illustrates one embodiment of the personal conferencing systems of FIGS. 1 & 2;
FIG. 4 illustrates one embodiment of the multi-point control units of FIGS. 1 & 2;
FIG. 5 illustrates the key software components of the personal conferencing systems and the multi-point control units of FIGS. 1 & 2;
FIGS. 6 & 7 illustrate one embodiment of the data routing matrix management functions and the data transmission functions of FIG. 5;
FIGS. 8 & 9 illustrate one embodiment of the data routing matrices and the data routing matrices employment rules of FIG. 5; and
FIG. 10 illustrates one embodiment of a frame of data.
DETAILED DESCRIPTION OF THE INVENTION
In the following description, for purposes of explanation, specific numbers, materials and configurations are set forth in order to provide a thorough understanding of the present invention. However, it will be apparent to one skilled in the art that the present invention may be practiced without the specific details. In other instances, well known features are omitted or simplified in order not to obscure the present invention.
Referring now to FIGS. 1 & 2, wherein two exemplary networks of personal conferencing systems incorporated with the teachings of the present invention are illustrated. Exemplary network 10 comprises a plurality of personal conferencing systems (PCSs) 14a-14i and a plurality of multi-point control units (MCUs) 12a-12c. MCUs 12a-12c interconnect PCSs 14a-14i to each other. In some cases, the interconnections are made through another MCU 12a-2c. For example, MCU -- 1 12a interconnects PCS -- A 14a to PCS -- D 14d directly, but to PCS -- H 14h indirectly through MCU -- 3 12c. Exemplary network 10' is a simpler network having only one MCU, i.e. MCU -- i interconnecting all conference participants PCS -- X, PCS -- Y and PCS -- Z 14x-14z to each other directly. The two exemplary networks 10 and 10' are intended to represent complex networks having multiple PCSs and MCUs, and simple networks having a small number of PCSs and a single MCU respectively. Furthermore, PCSs 14a-14i and 14x-14z need not be systems of like kind, provided they all employ communication software that are compatible with the communication software of the interconnecting MCUs 12a-12c and 12i. As will be obvious from the description to follow, the present invention may be practiced on networks of any complexity having any heterogeneous mix of PCSs.
FIG. 3 illustrates one embodiment of a PCS 14a-14i and 14x-14z (collectively represented by 14* in FIG. 3). PCS 14* includes CPU 20, cache memory 24, main memory 28, memory controller 26, and processor bus 22 coupled to each other as shown. PCS 14* further includes I/O bus controller 30, video display 34, audio interface 36, telephony 38, communication interface 40 and I/O bus 32 coupled to each other as shown. The I/O and memory controllers 30 and 26 are also coupled to each other, whereas audio interface 36 also has headset 42 and microphone 44 coupled to it.
FIG. 4 illustrates one embodiment of a MCU 12a-12i and 12x-12y (collectively represented by 12* in FIG. 4). MCU 12i is similarly constituted as PCS 14*, except MCU 12i includes multiple CPUs 50a-50b, and multiple levels of cache memory 52a-52b and 56 for improved performance. Additionally, MCU 12i typically does not include headset 42 and microphone 44.
Except for the manner the elements in FIGS. 3 & 4 are used, they are intended to represent a broad category of similar elements found in many computer systems whose constitutions and functions are well known and will not be otherwise further described. The manner these elements are used under the present invention will be described in detail below with additional references to the remaining figures.
FIG. 5 illustrates the key software elements of exemplary PCS 14* and MCU 12*. As shown, PCS 14* and MCU 12* include operating system 70 and 70' having device drivers 74 and 74' respectively. Preferably, operating system 70 further includes windowing subsystem 72. Any number of operating systems well known in the art may be used for operating systems 70 and 70'. PCS 14* and MCU 12'further include applications 76 and 76' respectively. Application 76 includes personal conferencing manager (PCM) 78 having data routing matrix management functions and data transmission function, whereas application 76' includes multi-point conferencing manager (MCM) 80 having complementary data routing matrix management functions and data transmission function, which will be described in more detail below. As will be described also in more detail below, the various data routing matrix management functions and data transmission functions create data routing matrices and data routing matrix employment rules, and employ them to transmit data among the conference participants, thereby allowing a conference to be viewed simply as a collection of these data routing matrices, as well as data routing to be specified in a transport network independent manner and dynamically altered at runtime with very low switching latency. Thus, side conversations and subgroup discussions may be conducted in a more friendly and efficient manner.
FIGS. 6-7 illustrate one embodiment of the data routing matrix management functions and data transmission functions of PCM 78 and MCM 80. Data routing matrix management functions of PCM 78 include a PCM -- CREATE, a PCM -- UPDATE, a PCM -- DELETE, a PCM -- ENROLL, and a PCM -- CANCEL function 102-110, whereas data transmission function of PCM 78 includes a PCM -- SEND function 112. Complementary data routing matrix management functions of MCM 80 include a MCM -- ENROLL and a MCM -- CANCEL function 114-116, whereas complementary data transmission function of MCM 80 includes a MCM -- SEND function 120. Preferably, complementary data routing matrix functions of MCM 80 further include a MCM -- GET function 118.
PCM -- CREATE, PCM -- UPDATE, and PCM -- DELETE functions 102-106 are used by the conference participant of the particular PCS 14* to create, update and delete data routing matrices specifying a plurality of data routing patterns for the PCSs. In other words, a conference may be advantageously viewed as a collection of these data routing matrices. Furthermore, data routing among the PCSs may be specified in a transport network independent manner, i.e. regardless whether the underlying transport network uses point-to-point connections, as is used for ITU H.320 compliant ISDN video conferencing, or if the underlying transport network supports multi-casting, such as IP Multicast. Preferably, PCM -- UPDATE 103 includes automatically retrieving a copy of a data routing matrix from MCU 12* for update. (The reason for such preference will be obvious from the descriptions to follow.)
PCM -- CREATE, PCM -- UPDATE, and PCM -- DELETE functions 102-106 are also used by the conference participant of the particular PCS 14* to create, update and delete data routing matrix employment rules specifying the conditions governing the runtime employment of the data routing matrices. In other words, data routing may be dynamically altered during runtime in an efficient manner with very low switching latency. Preferably, PCM -- UPDATE 103 also includes automatically retrieving a copy of a data routing matrix employment rule from MCU 12* for update. (The reason for such preference will also be obvious from the descriptions to follow.)
As will be obvious from the descriptions to follow, the implementation of these functions 102-106 are well within the ability of those skilled in the art, thus will not be further described.
Skipping now to FIG. 8, wherein couple of embodiments of data routing matrices, i.e. video routing matrices 84 and audio routing matrices 86 are illustrated. While for ease of explanation, the present invention is being illustrated with video and audio routing matrices, based on the descriptions to follow, it will be appreciated that the present invention may be practiced with other types of data routing matrices, including numeric data routing matrices, character data routing matrices, file routing matrices etc.
As shown, each A/V routing matrix 86 or 84 comprises a plurality of pair-wise A/V routing specifications, with each specification specifying whether A/V data are routed from one conference participant to another. For examples, conference participant A's A/V signals are routed to conference participants B and C, whereas conference participants B & C's A/V signals are routed to conference participant A only. A specification may specify conditional routing. For example, conference participants A, B & C's audio signals are sent if the signal levels exceed threshold values "a", "b" and "c" respectively.
Thus, a conference participant may create one or more A/V routing matrices that specify routing to selective conference participants only to facilitate side conversations or subgroup discussions from time to time. For examples, conference participant A may have an additional A/V routing matrix that routes A/V data to conference participant B only, and another additional A/V routing matrix that routes A/V data to conference participant C only, to facilitate side-conversations with B and C respectively, from time to time.
Skipping further now to FIGS. 9-10, wherein one embodiment of the data routing matrix employment rules and a data frame, i.e. an A/V routing matrix rule 88 and an A/V data frame 90 are illustrated. Similarly, while for ease of explanation, the present invention is being illustrated with A/V routing matrix employment rules and A/V data frame, based on the descriptions to follow, it will be appreciated that the present invention may be practiced with other types of data routing matrix employment rules and data frames, including numeric data routing matrix employment rules and numeric data frame, character data routing matrix employment rules and character data frame, files routing matrix employment rules and file data frames etc.
Each A/V routing matrix employment rule 88 comprises one or more conditions governing the employment of the various A/V routing matrices 84 and 86 for routing A/V data. The governing conditions are expressed in terms one or more multi-point references. A multi-point reference is a reference from which recipients may be dynamically inferred. The multi-point references are specified at the time of data transmission. In some embodiments, for A/V data, the multi-point references are specified in each A/V data frame 90.
In some embodiments, the multi-point references are implemented using character tokens. Therefore, the governing conditions of the data routing matrix employment rules are expressed in terms of character tokens, and the character tokens are included as part of the header 92 of a data frame 90.
Referring now back to FIGS. 6-7, the PCM -- ENROLL, PCM -- CANCEL, MCM -- ENROLL and MCM -- CANCEL functions 108-110 and 114-116 are used to enroll and cancel the PCS' created data routing matrices 84 and 86 and data routing matrices employment rules 88, such as the A/V routing matrices and their associated employment rules described earlier, with MCM 80 of the interconnected MCU 12*. PCM -- ENROLL 108 provides the desired data routing matrices 84 and 86 and/or data routing matrix employment rules 88 to be enrolled with MCM 80 responsive to user inputs. MCM -- ENROLL 114 logs the enrollments accordingly. Conversely, PCM -- CANCEL 110 informs MCM 80 of the desired data routing matrices 84 and 86 and/or data routing matrix employment rules 88 to be canceled responsive also to user inputs. MCM -- CANCEL 116 deletes the enrollments accordingly. Additionally, MCM -- GET 118 is used to support automatic retrieval of a copy of a data routing matrix 84 or 86 or a data routing matrix employment rule by PCM -- UPDATE 104 of PCS 14*. The implementation of these functions 108-110 and 114-118 are also well within the ability of those skilled in the art, thus will not be further described.
Continuing to refer to FIGS. 6-7, PCM -- SEND and MCM -- SEND 112 and 130 are used to send data, including A/V data described earlier. PCM -- SEND 112 sends data from a PCS 14* to the interconnected MCU 12* specifying the destination(s) in terms of a multi-point reference, as described earlier. In response, MCM -- SEND 120 determines which enrolled data routing matrix 84 and 86 should govern the routing, applying the enrolled data routing matrix employment rules 88, based on the specified multi-point reference.
Thus, by enrolling data routing matrices 84 and 86 desired, a conference participant of a PCS 14* may initiate and engage in side conversations or subgroup discussions with selected subgroups of conference participants in other PCSs 14*, without having to particularize the recipients of each data transmission, one at a time. In like manner, by canceling data routing matrices 84 and 86 no longer desired, a conference participant of a PCS 14* may disengage from these side conversations or subgroup discussions.
Thus, a method and apparatus for heterogeneous multimedia conferencing using multi-point references has been described. While the method and apparatus of the present invention has been described in terms of the above illustrated embodiments, those skilled in the art will recognize that the invention is not limited to the embodiments described. The present invention can be practiced with modification and alteration within the spirit and scope of the appended claims. The description is thus to be regarded as illustrative instead of restrictive on the present invention.
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A plurality of specially equipped personal conference managers (PCMs), one each, are provided to a plurality of personal conference systems (PCSs), and a plurality of specially equipped multi-point conference managers (MCMs), also one each, are provided to a plurality of multi-point control units (MCUs) interconnecting the PCSs. Each PCM is equipped with a first plurality of data routing matrix management functions for creating, updating, and deleting a plurality of data routing matrices specifying a plurality of data routing patterns for the PCSs. The first plurality of data routing matrix management functions are also used for creating, updating, and deleting a plurality of data routing matrix employment rules specifying the conditions governing the runtime employment of the data routing matrices. The conditions are specified in terms of multi-point references. Additionally, each PCM as well as each MCM is equipped with a second plurality of data routing matrix management functions for enrolling these routing matrices and their employment rules with the MCMs, and canceling their enrollments. Furthermore, each PCM as well as each MCM is equipped with a data transmission function for sending data utilizing these data routing matrices and their employment rules.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates, in general, to garment storage and, more particularly, to portable laundry storage containers and sorters for storing and pre-sorting of garments prior to laundering them.
[0003] 2. General Background of the Invention
[0004] Laundry hampers or bags providing a compartment or interior for receiving soiled or used garments have been known for some time. It has also been known to use multiple removable or portable laundry bags or hampers to facilitate pre-sorting of garments by type prior to washing, such as separating white, light color, and dark color fabrics, so that each pre-sorted group of garments may be loaded directly into a washing machine. The use of removable laundry bags permits individual loads of pre-sorted laundry to be separately transported for placement within a washing machine.
[0005] Prior art laundry sorters having removable laundry bags, such as the one disclosed in U.S. Pub. No. 2006/0157358 A1, are commonly top loading in construction, meaning that removal and replacement of each supported laundry bag requires that the bag must be vertically lifted above the frame, in order to clear, among other structures, a top front horizontal bar or similar structure of the frame. Particularly during removal of the laundry bags, when they may be relatively heavily loaded with garments, vertically raising the bag above the frame may be cumbersome or difficult, particularly if the user is not physically strong, is relatively short in height, or is suffering from lower back pain or other physical ailment.
[0006] Other prior art hanging laundry bags, such as the one disclosed in U.S. Pat. No. 8,714,350 B2, include separate handles or areas for grasping the laundry bag for removal of the bag from its hanging position and transporting during the washing process.
BRIEF SUMMARY OF THE INVENTION
[0007] The present invention provides laundry storage containers such as bag or hampers and sorters for the laundry storage containers that overcome many of the shortcomings of certain prior art laundry bags and sorters. In particular, hanging laundry storage containers are disclosed that include handles that are designed and shaped to both support the laundry storage containers on a horizontal support and permit a user to remove and transport the laundry storage containers without the need for separate handles or grasping surfaces.
[0008] In one embodiment of the present invention, removable laundry bags include a pair of substantially C-shaped handles extending upwards from opposites sides of the top of the bag. The C-shaped handles define interior regions for receiving a horizontal support to hang the bag thereon. The curved end of the handles prevent the hampers from sliding off the horizontal support. A grasping surface located on the opposite side of the handle end allows the handle to be grasped when the bag is positioned on the horizontal support to facilitate the lifting of the handle and bag off the support. As a result, the requirement of a separate component for removing and transporting the hamper is eliminated. The bag may have cut-away sections corresponding to the interior of the handles to provide an open area to facilitate the bag's placement on and removal from the support.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0009] FIG. 1 is an elevated, front perspective view of an embodiment of a laundry sorter including a plurality of hanging laundry bags of the present invention;
[0010] FIG. 2 is an elevated, front perspective view of the frame portion of the laundry sorter of FIG. 1 ;
[0011] FIG. 3 is an elevated front view of the top of one of the laundry bags of FIG. 1 illustrating one embodiment of the handles of the present invention;
[0012] FIG. 4 is a top plan view of one of the handles of FIG. 3 .
[0013] FIG. 5 is an elevated front view of the top of a laundry bag showing a second embodiment of the handles of the present invention;
[0014] FIG. 6 is a top plan view of one of the handles of FIG. 5 ; and
[0015] FIG. 7 is a front perspective view of another embodiment of a laundry sorter including a pair of hanging laundry bags vertically positioned relative to one another on a frame.
DETAILED DESCRIPTION OF THE INVENTION
[0016] While the present invention is susceptible of embodiment in many different forms, there is shown in the drawings and will herein be described in detail, several specific embodiments, with the understanding that the present disclosure is intended as an exemplification of the principles of the present invention and is not intended to limit the invention to the embodiments illustrated.
[0017] FIGS. 1 and 2 illustrate one embodiment of a laundry sorter 10 having a plurality of hanging laundry storage containers 200 of the present invention. The sorter 10 comprises a frame 20 supporting a plurality of substantially adjacent removable hanging laundry storage containers in the form of bags 200 . Frame 20 may be constructed primarily of tubular steel or aluminum components and comprises a pair of two parallel horizontal bottom tubes 22 connecting a pair of side members 24 and a horizontal top tube 26 extending between the side members 24 to form a horizontal support such as a bar or rod. Clips or other elements 42 may protrude upwards from the horizontal support 26 to help retain the bags 200 on the horizontal support 26 when in use.
[0018] As shown in FIG. 2 , at least one of the bottom tubes 22 and the top tube 26 may have curved ends that matingly connect or attach to the ends of the side members 24 through a press fit, detents, bolts or other known means. The bottom 30 of each of the side members 24 may have a pair of spaced apart holes or openings 32 to attach a pair of casters 36 to the frame 20 . In particular, bolts from the casters may extend therethrough and be secured in place through nuts or other fasteners 34 . Alternatively, feet or other friction members may be attached to the bottom of the frame 20 to inhibit inadvertent movement of the frame 20 . Side frames 24 may also include reinforcing members 38 extending between the bottom members 30 and the vertically rising member 40 to provide strength and rigidity to the frame 20 .
[0019] While the figures show a frame having side members in the shape similar to an inverted question mark, it is appreciated that the frame may take any number of shapes and sizes and not depart from the scope of the present invention. Among other things, the side members may take the shape of an inverted “Y”, an “A” frame, or an inverted “U” with a horizontal bar at the bottom.
[0020] As best seen in FIG. 1 , laundry sorter 10 includes three removable laundry bags 200 , each comprising a fabric body 210 for receiving soiled laundry. While three bags are shown, it is appreciated that a different number of bags, hampers or other laundry storage containers may be used and not depart from the scope of the present invention. The fabric body includes a bottom 212 and at least one wall 214 extending from the bottom 212 to an upper edge 216 at the top 218 that defines an opening for receiving the laundry. Referring to FIG. 1 , fabric body 210 may be generally cylindrically shaped with a substantially rectangular cross section, and may include internal stiffeners such as, but not limited to, flat wires, about its vertical, top and bottom edges to inhibit folding or collapsing of the fabric, such that laundry bag 200 substantially retains its general configuration. It is appreciated that collapsible/foldable metals or other materials may be used along the seams to allow the walls to fold into one another and then snap back into place to form the laundry bag. The front side of the upper edge 216 of the laundry bag may be curved downwardly to facilitate placement of garments into the laundry bag 200 . Referring to FIG. 3 , the sides of the top 218 of the laundry bag 200 may include curved cut away section or recess 220 therein.
[0021] FIG. 4 illustrates one embodiment of a pair of handles 250 for use with the laundry storage bag 200 . The handles 250 are substantially circular in shape with an opening sized to permit the handles 250 to be placed over and removed from the horizontal support 26 . Each of the handles includes an upper curved portion 252 and a lower curved portion 254 for directly or indirectly attaching the handle to the bag 200 . In one embodiment, the curvature of handle 250 extends about 320 degrees, wherein the interior of the handle 250 defines a receiving area for placement of the handles 250 and laundry bag 200 on a horizontal support 26 . The upper curved member preferably has a radius of curvature that is greater than the radius of curvature of the horizontal support, which allows each of the handles to engage the top of the horizontal support. The curvature of the upper portion 252 of the handle 250 allows part of the handle 250 to project outwardly away from the plane defined by the horizontal support 26 and provides for an area 274 on the handle 250 that may be grasped by a user to lift the handle 250 off of the horizontal support 26 and maneuver the horizontal support 26 through the opening to remove the bag 200 from engagement with the horizontal support 26 , thereby allowing the bag to be transported (e.g., to the laundry room or washing machine).
[0022] A pair of spaced apart seams 222 , 224 may be used with a piece of fabric 226 to form a channel 280 extending through the top of each side of the laundry bag 200 for receiving the lower portion 254 of handles 250 . Referring to FIG. 4 , the channels may extend underneath the recess 220 in the top 218 of the laundry bag 200 . In one embodiment, the opening in the C-shaped handle's lower portion corresponds to the shape and size of the recess 220 to provide a large opening in the bag 200 to facilitate its removal from the horizontal support 26 . Each handle 250 may be constructed of a relatively rigid material such as steel or aluminum. The end 270 of handle 250 may include a hook or curved end 256 that extends back over the channel thereon or be folded back toward itself to help secure handle 250 relative to the laundry bag 200 . A slot 262 may be used proximate to the upper or lower seam 222 , 224 to receive part of the end of the hook 256 .
[0023] A sleeve or coating 272 may be placed over the upper portion 252 of the handle 250 to provide a slip-resistant surface for grasping the handle 250 and for interacting with the horizontal support 26 . The surface may be cushioned for comfort. Examples of materials for the sleeve or coating may include, but are not limited to foam, thermoplastic elastomers, synthetics or polymers. The sleeve 272 may be attached or applied to the handle 250 in any known way, including, but not limited to, over-molding the sleeve onto the handle, or fastened using adhesives, welding or screws or other fasteners. By providing a cushioned material on the handle, a user can more easily grasp the area 274 of the handle on the side opposite the end 276 to facilitate placement and removal of the laundry bag 200 on the horizontal support 26 . Accordingly, each laundry bag does not need a separate handle or grasping area to place or remove the laundry bag on or from the horizontal support.
[0024] Referring to FIGS. 5 and 6 , a second embodiment of a handle of the present invention is disclosed. Each of the pair of handles 350 for a laundry bag 200 a is substantially D-shaped with a curved upper portion 352 and a lower straight portion 354 . Straight portion 354 is sized to fit within channel 380 formed at the top 218 a of the sides of the laundry bag 200 a by a piece of material attached along its length by a pair of seams 364 , 366 . The end 370 of the straight portion 354 may include a hook or curved end 356 that extends back over the channel 380 when the straight portion 354 is positioned within the channel 380 to help retain the handle 350 in place. A slot may be used proximate to the upper or lower seam 364 , 366 to receive part of the end of the hook 356 .
[0025] The upper portion of the handle may be curved in the shape of a partial circle. Referring to FIG. 4 , in one embodiment, the curvature of upper portion extends about 140 degrees, wherein the interior of the handle defines a receiving area for placement of the handles and laundry bag on a horizontal support.
[0026] A sleeve or coating 372 may be placed over the upper portion 352 of the handle 350 to provide a slip-resistant surface for grasping the handle 350 and for interacting with the horizontal support 26 . The surface may be cushioned for comfort. Examples of materials for the sleeve or coating may include, but are not limited to foam, thermoplastic elastomers, synthetics or polymers. The sleeve 372 may be attached or applied to the handle 350 in any known way, including, but not limited to, over-molding the sleeve onto the handle, or fastened using adhesives, welding or screws or other fasteners. By providing a cushioned material on the handle, a user can more easily grasp the area 374 of the handle on the side opposite the end 376 to facilitate placement and removal of the laundry bag 200 a on the horizontal support 26 . Accordingly, each laundry bag does not need a separate handle or grasping area to place or remove the laundry bag on or from the horizontal support.
[0027] Although the previously described embodiment discloses a laundry sorter consisting of three laundry bags 200 , different sized laundry sorts having different numbers of supported bags are also contemplated by the present invention. For example, referring to FIG. 7 , the frame may include a pair of horizontal supports 26 , 26 a extending between elongated side members 24 a to allow a pair of laundry bags 200 b to be placed in a vertically spaced position relative to one another. It is appreciated that any of the laundry bags disclosed or taught herein may be used in connection with the sorters.
[0028] Many modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims, the invention may be practiced other than as specifically described. Various modifications, changes and variations may be made in the arrangement, operation and details of performing the various steps of the invention disclosed herein without departing from the spirit and scope of the invention. The present disclosure is intended to exemplify and not limit the invention.
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A removable hanging laundry storage container such as a bag or hamper including a pair of substantially C-shaped handles extending upwards from opposites sides of the top of the hamper or bag. The C-shaped handles define interior regions for receiving a horizontal support to hang the hamper or bag thereon. The handles are sized and shaped to provide for a grasping surface on the opposite side of the handle end to allow the handle to be readily grasped when the storage container is hanging from a horizontal support to facilitate the lifting of the handle and hamper off the horizontal support. The hamper or bag may have cut-away sections matching the interior of the handles to provide an open area to facilitate placement and removal of the hampers on the horizontal support.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part part of U.S. patent application Ser. No. 10/248,064.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention is a flashlight that has an attachment means for fitting on a shirt pocket.
[0004] 2. Description of Related Art
[0005] The use of flashlights is imperative to security guards and police for patrolling and checking identification and documentation. Often the police officer or security guard carries the flashlight on his belt in a holster or clip. However in this situation the user must unhook the flashlight, and position the flashlight in a proper position to see the documentation. Often this includes tucking the flashlight in the fold of the arm at the armpit against the body. The inherent problem with this situation includes lack of use of the hand on the arm holding the flashlight, or trying to juggle documentation and the flashlight in the same hand, or having no hands free while holding the documentation in one hand and the flashlight in the other hand.
[0006] U.S. Pat. No. 3,953,722 issued to Stick on Apr. 27, 1976 shows a flashlight support means. Stick's invention is unlike the present invention because it is attached to the wearer by a safety pin, it is larger than the present invention, and the light would not fit under a shirt pocket flap.
[0007] U.S. Pat. No. 4,605,990 issued to Wilder, et al. on Aug. 12, 1986 shows a surgical clip-on light pipe illumination assembly. Wilder's invention is unlike the present invention because the clip is a hinged mechanism that is not as discreet or hidden as the present invention, and the light mechanism cannot be hidden under a shirt pocket flap.
[0008] U.S. Design Pat. No. D292,616 issued to Sexton on Nov. 3, 1987 shows a disposable clip light. Sexton's invention is unlike the present invention because when clipped it could not light in a downward direction as is needed to read documentation, and cannot fit underneath a shirt pocket flap.
[0009] U.S. Pat. No. 5,029,055 issued to Lindh on Jul. 2, 1991 shows a portable light. Lindh's invention is unlike the present invention because it is intended to be mounted on a bicycle, would not clip onto a shirt pocket, and would not be covered by the flap on a shirt pocket.
[0010] U.S. Design Pat. No. D340, 777 issued to Choi, et al. on Oct. 26, 1993 shows a personal safety light. U.S. Design Pat. No. D362,312 issued to Chen on Sep. 12, 1995 shows a clip-on flashlight. Choi and Chen's inventions are unlike the present invention because they are bulkier, and cannot be easily hidden by a pocket flap as the present invention.
[0011] U.S. Pat. No. 4,953,892 issued to Adkins on Sep. 4, 1990 shows a ski pole clip. Adkins' invention is unlike the present invention because it does not have a light mechanism, and it would not fit in a pocket to light identification or documentation.
[0012] U.S. Pat. No. 5,541,816 issued to Miserendino on Jul. 30, 1996 shows a clip light source. Miserendino's invention is unlike the present invention because it is a flashlight intended to be attached to a helmet as for a miner or fireman, it cannot be covered by a shirt pocket flap, and it has a hinged mechanism for the light that is bulkier than the present invention.
[0013] U.S. Pat. No. 6,027,223 issued to Lackey, et al. on Feb. 22, 2000 shows a writing instrument pocket clip light. Lackey's invention is unlike the present invention because it is a writing instrument, and the light needs to be activated by unfolding the pen clip requiring additional hand coordination.
[0014] Therefore, a need has been established for a flashlight that can be hidden by a shirt pocket flap, which can assist policemen or security officers in viewing documents.
INVENTION SUMMARY
[0015] The present invention is a light that an officer or security guard could wear on his shirt pocket that projects a light in a downward direction. The light is compact and fits in a shirt pocket with a clip mechanism. The main body of the pocket light will fit inside a shirt pocket and there is a 1⅜ inch overlap from the front of the pocket that holds the light source. The pocket light mechanism is completely concealed within the user's pocket and cannot be seen on the wearer until the light source is turned on, which is advantageous because it allows an officer to conform his appearance to the approved regulation appearance of his department. The main body of the light source encases the power source for the light and a push switch for turning the light on or off. The push button is sensitive enough to be pushed through the fabric of a shirt pocket and turn the light on or off. In this manner the user can turn on the light and view any documents or light his way in a dark area, such as a theater isle. The present invention is useful to police officers, security guards, ushers, and bouncers at nightclubs or the like.
[0016] The light projects at an approximate 30 degree outward and downward angle. Due to the approximate 30 degree angle the user can hold the documents that need to be read or viewed in his hand at a natural angle without having to place the documents directly underneath the light. Additionally, a hinged member allows the user to move the light up to a 90 degree angle or even up to a 180 degree angle from the main body of the pocket light, allowing for different angles of viewing capacity for the user. Although the light bulb is small and compact, the projection ray of the light is wide enough to project onto a letter sized document easily, and concentrated to make small print reading easier.
[0017] Advantages to the present invention include hands free use and quick access to a light source. The user can turn on the light through his shirt pocket with the push of a finger and the light can project easily from the underside of the shirt pocket flap allowing the user to have both hands free for handling documents. Currently, with conventional flashlights the user must keep one hand free to operate the flashlight and to hold the flashlight during use.
[0018] Exemplary embodiments of the invention will be further described below with reference to the drawings, in which like numbers refer to like parts.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] FIG. 1 shows an environmental view of a first embodiment of the present invention.
[0020] FIG. 2 shows a side view of a first embodiment of present invention.
[0021] FIG. 3 shows a side view of a first embodiment of the present invention with the exterior casing extended.
[0022] FIG. 4 shows a back view of a first embodiment of the present invention.
[0023] FIG. 5 is another illustration of the first embodiment of the present invention.
[0024] FIG. 6 is an environmental view of a second embodiment of the present invention having two LED lamps, showing the device positioned underneath a shirt pocket flap.
[0025] FIG. 7 is a perspective view of the second embodiment of the present invention with an optional clip.
[0026] FIG. 8 is a side elevation view of the second embodiment of the present invention, with phantom lines used to illustrate the lamp portion being rotated up and away from the main body of the flashlight.
[0027] FIG. 9 is a perspective view of the second embodiment, showing the flashlight separated from the optional clip.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0028] The present invention is a pocket light for viewing documents or merely lighting one's way without having to use a hand held flashlight. The pocket light is small and thin in size to easily fit in any shirt pocket and still leave room for other items. An exemplary embodiment of the present invention is preferably made of a high-density or composite type plastic shell casing; a pair of batteries; a power button; a Light Emitting Diode (LED) lamp emitting red, blue or white light; and a flap mechanism for securing the present invention to a pocket in a secure yet removable fashion.
[0029] FIG. 1 shows an environmental view of the pocket light ( 10 ) according to a first exemplary embodiment having a single LED lamp. The LED light display ( 20 ) is located on the outer casing ( 70 ) facing in an approximate 30 degree angle from the elongated back casing ( 50 ). That is, the LED light emitting member ( 20 ) is angled relative to elongated outer member ( 130 ) such that the light from the LED projects at an outward angel of approximately 30 degrees when the outer member ( 130 ) is rotated fully downward. The angling of LED ( 20 ) relative to the outer member ( 130 ) is additionally illustrated in FIG. 8 . The power switch ( 30 ) is activated by depressing the switch to activate or deactivate the LED light display ( 20 ). The power switch ( 30 ) is attached via a wiring system ( FIG. 4, 120 ) connect to a circuit board ( FIG. 4, 110 ) and to a pair of batteries ( 40 ). The batteries ( 40 ) are long life lithium batteries that can easily be changed through the rear protective door ( 100 ) back casing ( 50 ), as shown in FIG. 4 . In this embodiment the batteries ( 40 ) are 3 volts each that supply the LED light with a total of six volts.
[0030] The back casing ( 50 ) is fixedly connected to the outer casing ( 70 ) by a clip member ( 60 ). The clip member ( 60 ) fastens across the top of a shirt pocket and can easily be concealed by a pocket flap. The clip member ( 60 ) communicates with a hinged member ( 90 ) to allow the user to move the LED light display ( 20 ) up to a 90 degree angle ( FIG. 3 ) from the shirt pocket (not shown). The hinged member ( 90 ) can be of a conventional receptor and screw mechanism as in the arm of a pair of glasses. The clip member top ( 60 ) is fastened to the back casing ( 50 ) and is non-adjustable, and is 1/16 inch thick where it communicates with the outer casing ( 70 ). The LED light display ( 20 ) is situated, in FIG. 1 , at an approximate 30 degree angle from the shirt pocket and the outer casing ( 70 ), and is therefore at the correct front facing and downward angle to view documents without additional adjustment of the light. The movable pocket light ( 10 ) could also be used in alternate embodiments from a car dashboard or at a crime scene investigation to light pieces of evidence. The LED light display ( 20 ) is designed to last thousands of hours before total burn out, allowing the wearer to have long-term use of the pocket light ( 10 ).
[0031] The outer member ( 130 ) that holds the LED lamp ( 20 ) or other type of lamp is connected to the main body ( 50 ) by the hinged member ( 90 ) that rotates about hinge ( 94 ). The area where outer member ( 130 ) connects to main body ( 50 ) defines a connection zone ( 92 ), connection zone ( 92 ) being located at the respective top portions of each of main body ( 50 ) and outer member ( 130 ). An elongated clip ( 80 ), which is more clearly visible in FIG. 3 , includes two clip arms ( 81 and 82 ). As seen in FIG. 1 outer member ( 130 ), when rotated downward so as to be folded toward main body ( 50 ) as shown in the figure, rests partially between clip arms ( 81 , 82 ) of clip ( 80 ), contributing to the overall thinness of the design. The overall thinness of the design, including the combined thicknesses of the respective top portions of main body ( 50 ) and outer member ( 130 ), allows pocket light ( 10 ) to be easily worn in a shirt pocket with the outer member ( 130 ) concealed by the shirt pocket flap. As can be further seen in the figure, outer member ( 130 ) has a bottom end ( 131 ) that is thick enough to hold LED lamp ( 20 ), and has an upper end ( 132 ) that is thinner than the bottom end ( 131 ). The thinner top end ( 132 ) contributes to the ability of a shirt pocket flap to hang generally flat and downward over outer member ( 130 ). As can also be seen in the figure, main body ( 50 ) also has a tapered, chisel shaped bottom end ( 52 ). The chisel shaped bottom end allows main body ( 50 ) to easily be inserted into a shirt pocket. As can be further seen in the figure, power switch ( 30 ) is located on the outward facing surface of main body ( 50 ) when the pocket light is inserted into a pocket. The power switch ( 30 ) is located lower on main body ( 50 ) than a lowermost extension of the outer member ( 130 ), which allows the user to active power switch ( 30 ) even when the outer member ( 130 ) is rotated downward so as to be in close proximity to main body ( 50 ) as shown in the figure. That is, the lamp holding outer member ( 130 ) does not block a user's access to power switch ( 30 ).
[0032] As can be seen in the FIG. 1 , main body ( 50 ) is generally planer, includes at least one flat surface, and is substantially thinner than it is long and wide. That is, the thickness dimension is substantially smaller than the length and width dimension. Similarly, the rotatable outer member ( 130 ) that holds the LED lamp ( 20 ) at its distal end ( 131 ) is generally planar, and is substantially thinner than it is long and wide. The distal end of LED lamp ( 20 ) defines the distal most extension of outer member ( 130 ).
[0033] Turning to FIG. 2 we have a clear view of the side of the pocket light ( 10 ). FIG. 2 shows the sleek design of the pocket light and the separate members as described above. The outer casing ( 70 ), clip member top ( 60 ), back casing ( 50 ), rear protective plate ( 100 ), LED display light ( 20 ) and power switch ( 30 ) of the pocket light are each shown in FIG. 2 . The rear protective plate ( 100 ) protects the batteries ( 40 ) and circuit board ( 110 ) from moisture or dust. The rear protective plate ( 100 ) is easily removable to replace the batteries ( 40 ) or wiring (not shown) as necessary. The outer casing ( 70 ), back casing ( 50 ), rear protective plate ( 100 ) and clip member ( 80 ) are made of a high density plastic composite, or an aluminum alloy which is water resistant and durable for extended use of the pocket light ( 10 ). In separate embodiments of the pocket light ( 10 ) the back casing ( 50 ), exterior casing ( 70 ), clip member ( 60 ) and rear protective plate ( 100 ) could be constructed in a waterproof manner.
[0034] FIG. 3 shows a side view of the pocket light ( 10 ) with the exterior casing ( 70 ) fully extended at an approximate 90 degree angle from the rear casing ( 50 ) and level with the clipping member top ( 60 ). The hinged member ( 90 ) allows the user to lock the exterior casing ( 70 ) in this position, or at any angle between the closed angle ( FIG. 2 ) and the fully extended angle ( FIG. 3 ), to allow a user to point the light at a desired angle relative to the user's body while the main body ( 50 ) of the pocket light remains within the shirt pocket. Also shown in FIG. 3 are the power switch ( 30 ), LED light display ( 20 ), rear casing ( 50 ) and rear protective plate ( 100 ) previously detailed. Clip ( 80 ) connects to main body ( 50 ) and outer member ( 130 ) at connection zone ( 92 ), such that the top portions of each of main body ( 50 ), clip ( 80 ), and outer member ( 130 ) all connect together at connection zone ( 92 ) and all extend therefrom. As can be readily inferred from FIGS. 2 and 3 , when pocket light ( 10 ) is placed within a shirt pocket main body ( 50 ) and clip ( 80 ) cooperate to hold pocket light ( 10 ) to the shirt pocket, main body ( 50 ) is disposed primarily within the pocket; outer member ( 130 ) and clip ( 80 ) are disposed primarily outside of the pocket, and connection zone ( 92 ) is disposed at the top edge of the pocket. The connection zone ( 92 ) could rest on the top of the pocket or, if clip ( 80 ) and main body ( 50 ) are sufficiently close together or the shirt fabric is sufficiently thick such that the shirt fabric is held tightly, connection zone ( 92 ) could be held slightly above the top edge of the shirt pocket fabric.
[0035] FIG. 4 shows a rear view of the pocket light ( 10 ). As is shown the batteries ( 40 ) are covered by a rear protective plate ( FIG. 2, 100 ), which can be removed to replace the batteries ( 40 ) as necessary. The batteries ( 40 ) are connected via wiring ( 120 ) to the power switch via circuit board assembly ( 110 ) to activate the LED display ( 20 ). The power switch ( 30 ) is touch sensitive and the user can easily activate the light through the material of a shirt pocket with a push of a finger. The wiring ( 120 ) will act as negative and positive charge connectors from each functioning component to the batteries ( 40 ) and circuit board ( 110 ). The wiring ( 120 ) also feeds power source from the batteries ( 40 ) to the LED light display ( 20 ). The series of wiring ( 120 ) are easily manipulated without damage of the circuit board ( 110 ) or other interior components of the pocket light ( 10 ). The pocket light ( 20 ) has an automatic shut off so the LED light display ( 20 ) will burn 5 minutes and shut off to minimize depletion of the batteries ( 40 ). Alternatively, the automatic turn-off time can be adjusted by the user.
[0036] FIG. 5 shows the basic embodiment of FIG. 1 with minor shape changes and all solid lines for clarity of illustration.
[0037] FIG. 6 shows a second embodiment of the invention ( 10 ′) placed within a shirt pocket, with the flap of the shirt pocket partially lifted at its corner to partially reveal the device. In this embodiment there are two separate LED lamps provided on pocket light ( 10 ′). Pressing the power switch once causes one lamp to be illuminated; pressing the power switch a second time causes both lamps to be illuminated; and pressing the power switch a third time causes both lamps to turn off. As with both embodiments, the thinness of the overall design, particularly when combined with the tapered shape of outer member ( 130 ), allows the shirt pocket flap to hang over the portion of pocket light ( 10 ′) that hangs outside the pocket while concealing that portion, but still allowing light from the LEDs to shine downward and slightly outward to illuminate the area immediately in front of the user such as a driver's license that a police officer is examining.
[0038] FIG. 7 shows the embodiment of FIG. 6 with an optional detachable clip ( 150 ). As illustrated more clearly in FIG. 9 , detachable clip ( 150 ) has a pair of holding arms ( 152 and 154 ) that define a receiving channel ( 156 ) for holding main body ( 50 ), preferably in a friction fit, therebetween. Detachable clip ( 150 ) further includes a spring biased hinge ( 158 ) and a clip arm ( 160 ) which is spring biased toward pocket light ( 10 ′). Detachable clip ( 150 ) allows pocket light ( 10 ′) to be firmly mounted to a wide variety of objects.
[0039] FIG. 8 is a side elevation view of either the pocket light ( 10 ) of FIG. 5 or the pocket light ( 10 ′) of FIG. 6 . The phantom lines illustrate outer member ( 130 ) rotated upward and away from main body ( 50 ).
[0040] For most consumer uses, the lamp or lamps will preferably be white LEDs. In other embodiments, however, the light source can emit other than visible light. For example, the single lamp can be a white LED, a red LED in order to help preserve a user's night vision, an infrared ( 1 R) LED for police and military night vision purposes, or an ultraviolet (UV) LED. A UV LED can be useful for a bouncer to view hands stamped with UV visible ink, for a police officer to view the UV visible ink used in driver's licenses, and many other purposes in which UV light is desired. The dual LED embodiment can use any combination of the foregoing types of lamps, with the sequential activation feature allowing the user to cycle between the different types of lights. In such a sequential activation of different types of lights, in most cases it would be desirable to cycle through the sequence of one type of lamp being on, the other type of lamp being on, and neither lamp being on, and would probably be undesirable in most cases, although not necessarily all cases, to include a state in which lamps of different types are turned on simultaneously. The invention is not limited to use of only one or two lamps, but could include any combination of lamps being sequentially activated, such as a white LED, a red LED, an IR LED, and then a UV LED in any sequence, or activated by two or more switches. Of course, the lamps need not be LEDs, and could be other types of light emitting members including light emitting members that have not yet been invented or have not yet come into widespread use.
[0041] It will be appreciated that the term “present invention” as used herein should not be construed to mean that only a single invention having a single essential element or group of elements is presented. Similarly, it will also be appreciated that the term “present invention” encompasses a number of separate innovations which can each be considered separate inventions. Although the present invention has thus been described in detail with regard to the preferred embodiments and drawings thereof, it should be apparent to those skilled in the art that various adaptations and modifications of the present invention may be accomplished without departing from the spirit and the scope of the invention. For example, the lamp could be another type of light emitting member other than an LED, different types of batteries could be used, different materials could be used, and other modifications may be made that would be within the skill of a mechanical designer and/or electrical designer. Accordingly, it is to be understood that the detailed description and the accompanying drawings as set forth hereinabove are not intended to limit the breadth of the present invention, which should be inferred only from the following claims and their appropriately construed legal equivalents.
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A pocket light that allows a user to view documents in a dark situation without having to hold a flashlight. The pocket light fits easily over the top of the pocket and can be covered by a conventional pocket flap. The light is an LED display device that produces a significant amount of light so a user can check identification or documentation, as in a license check, or registration verification for police. The pocket light has a push button power switch that can be activated by the user through the fabric of their shirt.
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BACKGROUND OF THE INVENTION
This invention relates to the distribution of a plastic of the butyl rubber type, particularly for the extrusion of the bead intended to serve as a seal and interlayer in multilayer glass sheets, hereinafter referred to as multiple glazings, and it relates more particularly to the preparation of said plastic and its routing from a tank where it is hard, viscous and at a relatively low temperature to an extrusion nozzle, optionally mobile in relation to the tank, where it should have a viscosity and hardness much lower than it had initially in the tank, and a higher temperature.
It is known from French Pat. No. 2 211 413 how to prepare a plastic of the butyl rubber type for the extrusion of a bead intended to be deposited on a glass sheet to make a multiple glazing, to work from small amounts of material, that can be easily and quickly heated, to obtain satisfactory characteristics of viscosity and hardness, on the one hand for the extrusion of the bead, on the other hand for the bonding of the bead thus extruded to a glass sheet. In addition, according to this prior patent, the extrusion unit is stationary and the glass sheets move to receive the extruded bead successively along all their edges.
This prior technique is satisfactory. However to increase the rates of production on the one hand, and to increase the dimensions of the extruded beads on the other hand, it has been known to avoid working from small amounts of material, which would necessitate too-frequent stops for refeeding, but from large amounts of material, particularly directly from the drums of raw material delivered by the supplier.
These large amounts are more difficult to heat than small amounts, which restricts the deliveries and the rates while, on the contrary, it is desired to increase said deliveries and said rates.
To obtain at the output of the extrusion nozzle a suitable material, with the desired delivery, at the suitable temperature, different stages for preparing the material therefore have to be created, which necessitates circuits to feed these various stages.
Further, it has also been considered to use a technique for placing the bead on the glass sheets in which the nozzle supplying the bead would no longer be stationary, but would move, at least in one direction. Therefore, the circuits conducting raw material up to the nozzle necessarily have a relatively great length and cannot be stationary. To convey the material along these circuits, it is, on the one hand, as already stated, difficult to heat it sufficiently to lower its viscosity, on the other hand neither is it desirable to overheat it, so as not to degrade it. It is therefore, necessary during the various stages for preparing the plastic to combine a moderate heating and a pressurizing.
It is known how to convey plastics in hoses, optionally cladded, but such material is, at certain times in its path, at pressures greater than 300 bars and at temperatures greater than 100° C. and the known holes are incapable of resisting this temperature and this pressure at the same time.
SUMMARY OF THE INVENTION
This invention aims to avoid the drawbacks of the prior techniques, i.e., a stationary nozzle and frequent stops for refeeding due to the use of small amounts of basic material.
The invention contemplates making possible the distribution of a plastic at a high delivery and continuously when necessary, through at least one mobile nozzle, said plastic coming from a large-sized tank where it is available with a high viscosity and a high hardness, much higher than it must have at its output through the nozzle.
For this purpose, the invention proposes a process for preparing a plastic of the type having a butyl rubber base, from a mass of said material in the raw state, having in particular a high viscosity and a high hardness, for its extrusion through an output nozzle, particularly in the form of a gaged bead having a viscosity and a hardness lower than those of the material in the raw state. According to the invention, small volume of the material mass is heated, material from this volume is continuously removed by subjecting it to a pressure, this removed material is put under a higher pressure to propel it up to the output nozzle, this material is continuously introduced into a variable volume magazine that can expand when the amount of material that it receives is greater than the amount of material that it delivers and, on the other hand, that can shrink under the opposite conditions, necessary amounts of material are removed from this variable volume magazine, at the desired delivery, limited however by the volume of material stored in the variable volume magazine and by the continuous delivery which feeds said magazine.
The invention also proposes an installation for preparing a plastic of the butyl rubber type including a tank of said material having a wall, particularly the cover, applied with pressure against the material, wall or this cover bored with an outlet orifice, having such a shape that the section of the volume of material that it encloses is smaller the closer it is to the output orifice, and being equipped on its face oriented toward the material with heating appendages which plunge into said material.
A pump is located at the output of the tank for supplying a continuous delivery of plastic under a high pressure while a variable volume magazine consists of a cylinder and a piston returned to the inside of the cylinder with a constant force less than the force exerted by the material supplying said magazine and an output nozzle is fixed to the variable volume magazine.
According to a particular embodiment, the cover of the tank has a conical shape.
According to the invention, the variable volume magazine and the output nozzle are able to move, said magazine and the pump then being connected by rigid conduits joined by rotating connections.
Advantageously, a positive-displacement pump is located at the output of the variable volume magazine upstream from the output nozzle.
BRIEF DESCRIPTION OF THE DRAWINGS
Various other objects, features and attendant advantages of the present invention will be more fully appreciated as the same becomes better understood from the following detailed description when considered in connection with the accompanying drawings in which like reference characters designated like or corresponding parts throughout the several views and wherein:
FIG. 1A is a top view of the entire plastic distribution installation.
FIG. 1B is a profile view of the installation of FIG. 1A.
FIG. 2 is a more detailed view of the tank with a cone-shaped cover applied on the material.
FIG. 3 is a view of the detail of a seal of the cover applied on the material.
FIG. 4 is a detailed top view of an internal gear pump located at the output of the tank.
FIG. 5 is a detailed view of the variable volume magazine placed downstream from the pump according to FIG. 4, and
FIG. 6 is a section at the rotating connections that equip the transfer means connecting the pump of FIG. 4 to the magazine of FIG. 5.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIGS. 1A and 1B provide an overall view of the installation for preparing a plastic for supplying a bead intended to be used as a seal and an interlayer in a multiple glazing.
This bead 1 is intended to be deposited on a glass sheet 2, arranged vertically or approximately vertically against a wall 3, particularly with insertion of a gas cushion between said wall 3 and glass sheet 2, and resting on rollers 4 of a vertical conveyor.
The installation for preparing the plastic is mounted on a frame including a base 5 and a vertical panel 6 on which the various elements of the installation rest or are fastened.
This installation includes a tank 7 of raw material 8 to be prepared and to be distributed in the form of bead 1, equipped with a heated cover 9, of a particular shape detailed below, a pump 10 at the output of this tank 7, a variable volume magazine 11, a positive-displacement pump 12, a nozzle 13 that can be oriented, means 14 for translation of nozzle 13 and for magazine 11 in a direction different from that of the movement of glass sheets 2, and in this case in a vertical direction, at right angles to the direction of movement of glass sheets 2 and parallel to the plane of said glass sheets and of wall 3, and means 15 for transferring the raw material from pump 10 to variable volume magazine 11.
Tank 7 has a broadened base 16 by which it is attached to base 5 thanks to a clamp 17. This tank 7 generally consists of the drum in which the plastic, for example having a butyl rubber base, is delivered by the supplier. As can be seen more particularly in FIG. 2, it is covered with a cover 9 able to plunge into it like a piston, under the pressure of two lateral jacks 18 and 19 (that also can be seen in FIG. 1A) acting on it by a gantry 20. This piston-forming cover 9 is equipped with at least two ring seals 21 and 22 that rub against the walls of the drum so as to achieve fluid-tightness despite the annular corrugations that are generally provided on the drums. These seals 21 and 22 have an outside diameter slightly greater than that of the inside of the drum; they are solid, bulky, hard (Shore hardness on the order of 70°), of a continuous rubber type material, and as shown in detail in FIG. 3, they are each fitted in a groove 23, 24 of cover 9.
Advantageously, to enable the centering of cover 9 on tank 7 and its progress inside said tank, both in the direction of plunging and in the opposite direction, each seal 21, 22 has a profile provided with two cants 25, 26 along an angle on the order of 20° with respect the direction parallel to the lateral wall of tank 7 against which they rest, separated by a flat piston face 27 whose surface is at least 1/3 of the total surface outside groove 23, 24 oriented toward the lateral wall of tank 7.
This piston-forming cover 9 has such a shape that it delimits a volume whose section is smaller the closer it is to an outlet 28 of the cover.
It can have the shape of a conical surface, in particular either a cone or a pyramid depending on whether tank 7 is cylindrical or prismatic, outlet 28 being located at the tip of the cone or of the pyramid.
Generally, tanks 7 are cylindrical drums and cover 9 than has a conical shape and in particular a right circular cone.
The surface of this piston cover 9 is equipped with heating means such as electric resistors 29.
The face directed to the inside of tank 7 is further provided with appendages 30, also heated.
These appendages 30 can be of variable lengths. Preferably, they are longer the closer they are to the axis of the cone or of the pyramid that constitutes cover 9.
Advantageously, to facilitate the housing of piston cover 9 in tank 7, particularly when it arrives at the end of travel, these appendages 30 are contained inside the volume delimited by said piston cover 9.
To make it possible to use all of the material contained in the drum, the bottom of said drum opposite conical cover 9, equipped with heating appendages 30, can have a shape complementary to that of cover 9 with its appendages 30.
According to an advantageous variant, the bottom of drum 7 is flat, but it is provided with a nonadhering coating. This coating of the teflon, silicone, graphite, talc, etc. type, can be deposited directly on the bottom, or better on an intermediate bottom, for example of paper or cardboard.
Advantageously, this intermediate bottom, for example of siliconed paper, is in the shape of a crown, and in the place of the hollowed part of the center of the crown, the nonstick coating is deposited directly on the bottom of drum 7.
Outlet 28 through piston cover 9 of tank 7 feeds pump 10 directly.
Advantageously, considering the considerable viscosity and considerable hardness of the material having a butyl rubber base, even after the removal from tank 7, considering the continuity of required delivery, and of the size of the necessary delivery, a rotary internal gear pump 10 is involved.
Preferably, to avoid the drawbacks due to a resistance that is too great for functioning, in particular at the time of starting, this pump 10 is hydraulically actuated. This pump is represented diagrammatically in FIG. 1A and shown more in detail in top view in FIG. 4.
This rotary internal gear pump 10 has a pump body 31 enclosing a toothed circular crown 32, and a rotor 33 also toothed, whose teeth have a shape complementary to the shape of those of crown 32. This rotor 32 is off-center in relation to crown 32 due to an off-centering core 34. This rotor 33 is bored in its center with a housing 35 with a keying groove 36 to receive a drive shaft and a locking key, not shown here, intended to drive rotor 33 in rotation.
Teeth 37 of rotor 33 and corresponding teeth 38 of crown 32 are distant from one another in zone 39 which surrounds off-centering core 34 thus forming large spaces 40 between them.
Going away from this zone 39, teeth 37 and 38 are increasingly better fitted into one another, which leads to a gradual restriction of spaces 40.
Spaces 40 are almost nonexistent and teeth 37 and 38 completely fitted into one another in zone 41 that is diametrically opposed to off-centering core 34.
Advantageously, as can be seen in FIG. 4, teeth 37 and 38 have a trapezoidal shape, which increases their mechanical strength and makes it possible to have larger spaces 40 than with another shape of teeth, particularly triangular.
Advantageously, to make a better supercharging of spaces 40 possible by the material removed from tank 7, the material is brought opposite aid spaces 40, in region 39 where they are the largest, from above and below at the same time by a double pipe not shown in the figures, resulting from the division of a pipe 42 connected to outlet 28 through cover 9. A pump output pipe 43, that can be seen only in FIG. 1A is provided approximately perpendicular to zone 41 where spaces 40 are the smallest. This pipe 43 goes through pump body 31 in a direction approximately perpendicular to the plane of crown 32 and of rotor 33. Advantageously, the mouths of the supply pipes and of evacuation pipe 43 cover several spaces 40.
As can be seen in FIGS. 1A and 1B, the material coming from pump 10 is transmitted to the elements of the installation located downstream, by transfer means 15 consisting of a multiplicity of rigid conduits 44, 45, 46 resistant to pressure and heat, connected to one another and to the upstream and downstream devices by rotating connections 47, 48, 49, 50 an example of which is shown in section in FIG. 6.
This rotating connection, for example 49 (FIG. 6), comprises a male element 51 fitted into a female element 52, each of these two elements 51 and 52 being connected by welding to upstream conduit 45 and downstream conduit 46. The fluid-tightness between these two elements 51 and 52 is obtained through annular seals 53 and 54 and the rotation of the male part 51 in the female part 52 is facilitated by a series of balls 55 and 56 that roll in annular grooves 57 and 58 bore paratially in male element 51, partially in female element 52.
Advantageously, to facilitate the rolling of balls 55 and 56 on the one hand and their exchange when they are worn out on the other hand, these balls are mounted elastically inside cavities 59, 60, on bearings 61, 62 that can be removed from the outside of female element 52.
These connections with a single axis of rotation are, with regard to fluid-tightness at high pressure, preferable to ball and socket revolving systems with multiple axes of rotation.
The movements in all the directions of the space are made possible by the juxtaposition of a multiplicity of these connections having a single degree of freedom, these connections being joined by bent rigid conduits.
Transfer means 15 described above are advantageously heated. They are intended to connect output pipe 43 of pump 10, which can progress in height since it is fixed to piston cover 9 which plunges into tank 7, to variable volume magazine 11 fixed to nozzle 13, which is capable of movements of translation in a vertical direction to be able to deposit a bead 1 over the entire height of glass sheet 2. To avoid blocking conduits 45 and 46 in aligned position when piston cover 9 is in the highest position and nozzle 13 is in lowest position or vice versa, said conduits 45 and 46 have a length such that there always exists between them an angle less than 180°.
The plastic material conveyed by transfer means 15 is introduced continuously at a steady delivery rate to the inside of variable volume magazine 11. This magazine 11 can be seen in top veiw in FIG. 1A, inside view in FIG. 1B and in more detailed view in FIG. 5. It comprises a cylinder 63 equipped with an input opening 64 and an output 65 feeding positive-displacement pump 12. Inside this cylinder 63 can move a piston 66 through whose entire length passes a plastic intake channel 67 which opens inside cylinder 63, this channel 67 being connected on the side of its upstream end to the last rotating connection 50 of transfer means 15.
Piston 66 is returned to the inside of cylinder 63 by a system exerting a constant force, particularly one or more jacks, and as in the example shown, two jacks 68 and 69 each connected on the one hand to cylinder 63 by a flange 70, and on the other hand to piston 66 by a plate 71. The return force of jacks 68 and 69 is less than the force exerted by the plastic entering into magazine 11 to avoid any delivery counter to the normal direction of advance. The end of piston 66 plunged into cylinder 63 is equipped with annular scraping segments. End of travel stops 72, 73 of piston 66 inside cylinder 63, in each of the two possible directions of movement of said piston 66, also provided. These stops are pulled by contact elements 74, 75 belonging to piston 66, one element 74 determining the maximum penetration position, on the rear part of the piston, the other element 75 determining the maximum withdrawal position, therefore the maximum volume inside of cylinder 63, on the front end of the piston. An intermediate element 90 intended to come in contact with stop 72 is provided on the body of piston 66, this element determining the low level for refilling cylinder 63 and triggering the actuation of the upstream means for supplying plastic.
Contact between stops 72 and 73 and corresponding elements 74, 75 control stop the injection of plastic through output 65 and respectively stopping the supply of material to cylinder 63.
Advantageously, to avoid cooling of the plastic and optionally to complete its heating so that it reaches the desired consistency, the walls of cylinder 63 and of channel 67 are heated.
This variable volume magazine 11 delivers its plastic with a constant pressure to standard positive-displacement pump 12 whose speed of rotation can vary on demand.
At the output of pump 12, the plastic is supplied to an extrusion head 76 comprising nozzle 13. This extrusion head 76 is mounted on a carriage 77 pulled by means such as jacks and an endless screw activated by an electric motor, not shown, making it possible to move nozzle 13 close to or away from glass sheet 2. The electric motor and the endless screw make it possible to finely adjust the advance of carriage 77 carrying nozzle 13, particularly as a function of the thickness of the glass sheets 2, while the jacks make movements of a predetermined magnitude possible.
This extrusion head is mounted on a crown 78 that revolves around an axis perpendicular to the plane of vertical, or approximately vertical, wall 3 so as to correctly orient nozzle 13 with regard to the glass sheets as a function of the relative direction of movement of said nozzle and of said glass sheets. Actually, as taught in French Pat. No. 2,294,313 or U.S. Pat. No. 4,205,104 the nozzle should make an angle between 15° and 45° and preferably between 25° and 35°, with the glass sheet.
To lock crown 78 in predetermined positions, a locking punch 79 engages in notches provided for this purpose in crown 78 the, notches not shown in the figures.
The unit of variable volume magazine 11, positive-displacement pump 12, extrusion head 76, carriage 77 can move in translation in relation to glass sheets 2 under the action of means 14 detailed below. For this purpose, this unit is mounted on a plate 80 that can move along two slides 81, 82 parallel to wall 3 and therefore to the plane of glass sheets 2, in a direction different from that of the movement caused by the vertical roller conveyor 4 and in particular in a direction at right angles to the one imparted to glass sheets 2 by this roller conveyor 4. The movement along these two slides 81, 82 is caused by a motor 83 which drives in rotation an endless crew 84 parallel to slides 81 and 82, this endless screw 84 being engaged in ball sockets not shown, fixed to plate 80. Slides 81 and 82 and endless screw 84 are fastened along vertical panel 6.
As known in the art, nozzle 13 is also equipped with a system for adjusting the height of extruded bead 1, and with a bead cutter, not shown.
Also as is known in the art according to the French Pat. No. 2,207,799, a system known in the art able to create a partial vacuum in the circuit for supplying plastic has a bypass connection immediately upstream from nozzle 13. This system is also not shown in the figures.
The previously described installation operates in the following manner:
Plastic 8, for example, having a butyl rubber base, is provided in a drum 7. This drum is fastened on base 5 by clamp 17 which grips its base 16. Cone-shaped cover 9 is placed on this drum, then pressed against the material which is contained thereby jacks 18 and 19. Under the action of this pressure and also the heating produced by heating appendages 30 and by the wall of this conical piston, the material covered by piston cover 9 is gradually softened and removed from drum 7 through output 28. The pressure under which the plastic is removed, however, is insufficient to convey it through the entire distribution circuit to output nozzle 13. However, this pressure is sufficient to supercharge pump 10, especially as the supercharging can be done on both faces of pump 10 by the two supply pipes. Because of this double supply, because of the particular shape of its teeth, this pump can deliver into its output pipe 43 a steady delivery of plastic under a pressure much higher than that upstream of said pump.
This pressure in the output pipe can be on the order of 300 or 350 bars. Thanks to this high pressure, it is not necessary to overheat the material to convey it up to nozzle 13, and therefore it is not likely to be degraded.
At the output of this pump 10, the plastic under high pressure, however at a temperature on the order of 100° C. is introduced into the conduits and the rotating connections of the transfer system 15. Thanks to this transfer system 15, generally of steel, the high pressures, and the relatively high temperature, can be supported without leaks.
The multiplicity of rigid conduits 44, 45, 56 and of rotating connections 47, 48, 49, 50, despite the single degree of freedom of each of said connections, makes it possible to transfer the plastic from pump 10, which descends strictly vertically into drum 7, to variable volume magazine 11 which also progresses, along slides 81, 82 in a slightly different direction, i.e., generally inclined about 5° in relation to the vertical. Thus, thanks to these possible movements, conduit 46 and rotating connection 50 can take the position indicated in broken lines in FIG. 1B, to feed nozzle 13 located toward the top of glass sheet 2 as shown in broken lines in this same figure.
Regardless of the relative positions of piston cover 9 and of nozzle 13 or of variable volume magazine 11, the routing of material 8 always takes place and under the same conditions.
Magazine 11 is therefore continuous fed with a delivery, sometimes however too small to extrude continously certain very large beads 1, on the order of 15 mm and more, on large-sized glass sheets 2, that can have perimeters of close to 15 m. Thanks to magazine 11, an intermedite reserve of material can be constituted in particular by taking advantage of breaks in extrusion through nozzle 13, between two glass sheets 2 or further at the corners of said glass sheets. During these breaks, piston 66 moves out of cylinder 63 thus increasing the capacity of magazine 11.
On the other hand, during the extrusion of a bead of great height and in general of great section, if the continuous delivery provided by conical heating piston 9 and rotary internal gear pump 10 is less than the delivery coming out through nozzle 13, the necessary additional delivery is obtained by gradually emptying the reserve in magazine 11. In this case, piston 66 advances, on the contrary, to the inside of cylinder 63. Thus, for example, when making a bead 1 of considerable heat, 2.8 kg of material per minute is needed, thanks to the reserve accumulated in the variable volume magazine, it is possible to get by with a supply of material by conical heating piston 9 and gear pump 10, continuously, of 1.3 kg per minute. This variable volume magazine 11 also makes possible, by the action of lateral jacks 68 and 69 to control the pressure of the plastic, a control which is particularly important for the feeding of positive-displacement pump 12.
Positive-displacement pump 12 whose output delivery is regulated by acting on the motor which controls it, supplies the plastic at the desired delivery for the extrusion of a bead of determined section. Extrusion nozzle 13 is positioned directly opposite glass sheets 2, at a distance therefrom and oriented in the direction of the relative movement of nozzle 13 and of glass sheet 2. Once nozzle 13 is correctly oriented by rotation of crown 78 which carries it, punch 79 locks said crown.
If bead 1 must be deposited along a line parallel to the direction of movement provided by roller conveyor 4, nozzle 13 remains stationary, and extrudes the bead while the glass sheet passes before it.
If, on the other hand, bead 1 must be deposited along a line parallel to slides 81, 82, roller conveyor 4 remains at the stop and plate 80 moves steadily, under the action of motor 83 acting on endless screw 84 and on the ball sockets. The nozzle is thus driven with a steady movement of translation and its deposits bead 1 on immobile glass sheet 2.
By simultaneously guiding the movement of plate 80 and that of roller conveyor 4, a depositing of the bead along lines other than vertical and horizontal can also be obtained.
Therefore, thanks to this installation for preparing a plastic, there can be continuously obtained using several combined stages, at the output of an optionally mobile nozzle 13, a bead 1 of said plastic at a desired temperature, delivery, pressure, viscosity and hardness while at the beginning of the installation the material is at a much lower temperature, the viscosity and the hardness are much higher, whereas a single heating would be much too long to soften the initial material according to the desired consistency and, moreover, would even be likely to degrade said material.
When the material contained in drum 7 is used up, conical cover 9 equipped with heating appendages 30 is withdrawn from drum 7. In the case of a drum bottom provided with a nonstick coating, a certain amount of plastic, that is to be superposed on the material in the new drum, is withdrawn of the same time inside the conical cover, which makes it possible to restart the injection immediately and which avoids purging.
Obviously, numerous modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that within the scope of the apprended claims, the invention may be practiced otherwise than as specifically described herein.
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The invention relates to the distribution of a plastic of the butyl rubber type, and more particularly to its preparation and its routing from a tank where it is hard, viscous and at a relatively low temperature, to an extrusion nozzle where it must have a viscosity and a hardness much lower than those that it had initially. The invention proposes a preparation in several stages combining heating and pressurizing so as to feed, at the desired delivery and with the desired quality of plastic, an optionally mobile nozzle. The invention applies to the production of a bead that is used as a seal and as an interlayer in multiple glazings.
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CROSS REFERENCE TO RELATED APPLICATION
This application is a continuation-in-part of our copending application Ser. No. 521,637, filed Nov. 7, 1974 and now U.S. Pat. No. 3,967,909 dated July 6, 1976.
BACKGROUND OF THE INVENTION
This invention relates to latching devices for securing shank-and-socket type couplings, such as for connecting auger sections used in auger mining machines to rotate a cutting head and progressively drive an auger assembly forward into a mineral deposit while removing the mined material with the auger strings. More particularly, the invention relates to a latching device of small radial dimension relative to the auger section to fit within the cross sectional limits of the hole being cut by the auger machine.
The invention has particular utility in connection with auger machines for mining lateral seams or veins of mineral, such as coal, and especially to a machine, usually located adjacent an open wall, that advances a rotary cutting head progressively laterally into the seam of coal while conveying the dislodged coal rearwardly from the cutting head with helical auger flights according to conventional practice. Additional auger sections are added as needed depending upon the extent of the advance of the cutting head into the coal seam, to form a string of endwise coupled auger sections corresponding to the depth of the hole.
Many such auger mining machines have multiple rotary cutting heads journaled in a rigid frame with their respective axes parallel and generally coplanar. The resulting assembly is advanced as a unit into the earth to cut a relatively wide hole as the mining progresses. Where multiple cutting heads are used, normally two or more separate strings of auger sections extend from the main body of the machine to the cutting head assembly to rotate the plurality of cutting heads simultaneously and to exert a thrust to advance the cutting heads into the mineral deposit to be mined.
New developments in the economics of coal mining have created conditions where it is now feasible to mine coal from relatively thin seams that in the past would have been bypassed as being economically unfeasible to mine. The relatively small diameters of the cutting heads and auger flights for mining such thin seams have necessitated the provision of associated equipment that will fit within the cross section of the hole through which the auger strings are advanced. This associated equipment includes the devices for latching the couplings between axially aligned endwise coupled auger sections in the auger strings.
Normally the interconnected auger sections have a socket portion on one end of each section and a cooperating mating shank on the opposite end. The shank fits into the socket recess of the next section, and a latch pin extending transversely of the auger axis extends through the wall of socket portion and into a recess formed in the shank. Such a connection is disclosed in U.S. Pat. No. 3,278,236. A lever is usually provided for retracting the latch pin from the shank to permit uncoupling of the section, as when the cutting head is being withdrawn from the hole at completion of the mining of the seam. As the auger string is withdrawn, the auger sections of each string must be sequentially removed from the machine by uncoupling the sections and lifting the rearmost section from the machine.
Prior art latching devices, however have not been sufficiently compact to permit their use in holes of smaller cross section that are now common.
Moreover, prior art latching devices are susceptible to being rendered inoperative by debris that enters the latching device and impairs operative movement of the latch pin.
The present invention resolves the difficulties indicated above and affords other features and advantages heretofore not obtainable.
SUMMARY OF THE INVENTION
An object of the invention is to reduce the space occupied by a latching device for connecting a socket to a mating shank, as in longitudinally connected auger sections, to permit the latching device to be effective even though its pin is moved a relatively small distance.
Another object is to provide a latching device, for endwise coupled auger sections, that extends radially a substantially lesser distance than prior unlatching devices to fit within the cross section of the hole through which such sections pass, even though the hole is of relatively small diameter.
Another object is to provide a latching device having recess means permitting removal of debris that could impair operative movement of the latch pin.
As many as desired of these and other objects may be accomplished by the present invention.
The latching device of the invention is located on a socket portion that has a socket recess adapted to receive a mating shank, and has means defining a passage extending transversely through the wall of the socket portion. The means defining the passage has retainer means at one end that defines an opening. A latch pin extends through the passage and has an actuating end portion projecting outwardly through the opening of the retainer means, and a latching end portion adapted to extend beyond the other end of the passage. The latch pin is reciprocable between an extended position in latching engagement with a latch recess in the shank, and a retracted unlatching position. The latch pin is biased by means, preferably a spring, located in the passage that bears against the retainer means and the pin to urge the latching end of the pin towards its extended latching position. Externally of the passage, the pin has retractor means.
The pin is retracted by pin actuating means, preferably a lever, mounted on the socket with a pin-engaging arm end located between the retractor means on the pin and the retainer means. The pin-actuating means is adapted to cause its pin-engaging arm to move to a retracting position whenever it lifts the pin, by pressure against the retractor means, to the pin's retracted unlatching position, and a retaining position wherein the pin-engaging arm engages both the retractor means and the retainer means and prevents further movement of the retractor means so as to prevent movement of the latching end portion of the pin beyond its extended latching position. This arrangement minimizes the outward projection of the latch pin so that the entire device occupies a minimum amount of space.
Preferably, the means defining the passage has recess means permitting removal of debris that may enter the passage and could otherwise impair operative movement of the latch pin.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a broken plan view to a greatly reduced scale of an auger mining machine embodying the invention, useful for mining coal and having three auger strings connected to a single driving carriage;
FIG. 2 is a fragmentary plan view on a larger scale illustrating a latching device embodying the invention;
FIG. 3 is a fragmentary sectional view taken on the line 3--3 of FIG. 2 and to the same scale;
FIG. 4 is a fragmentary elevational view on an enlarged scale with parts broken away and shown in section, illustrating a modification of the latching device of FIG. 3;
FIG. 5 is a fragmentary sectional view taken on the line 5--5 of FIG. 4;
FIG. 6 is a fragmentary plan view of another modified form of the latching device of the invention with parts broken away and shown in section for the purpose of illustration;
FIG. 7 is a fragmentary side elevation of the device of FIG. 6 with parts broken away and shown in section for the purpose of illustration;
FIG. 8 is a fragmentary sectional view taken on the line 8--8 of FIG. 7; and
FIG. 9 is a cross sectional view of a modification of the latching device of FIGS. 6-8, along a section similar to that of FIG. 5 for FIG. 4.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In the drawings, (FIGS. 1, 2 and 3) there is shown an auger-mining machine A for mining minerals such as coal from an open pit. The machine A has a multiple cutting head assembly B which is advanced laterally into a seam of coal by a reciprocable carriage C. The machine A has a main frame 10 of known construction with a pair of parallel ways or rails 11 and 12 thereon along which the carriage C travels on wheels 13.
An internal combustion engine 15, constituting a power source for rotating the augers, is mounted on the carriage C and drives the below-discussed augers through a power train including a clutch 16, a flexible coupling 17 and a shiftable transmission 18. The output shaft of the coupling 17 is operatively connected to the transmission 18 and a gear box 19 adapted to drive three driving heads 21, 22 and 23 forming part of carriage C and rotatable about parallel coplanar axes.
The driving heads are each connected to one of three parallel auxiliary auger sections 25, 26 and 27 which are axially coupled to another three parallel auger sections 28, 29 and 30 forming part of three auger strings extending to the three individual cutting heads 31, 32 and 33 of the cutting head assembly B, which may be known construction. The assembly B has a rigid frame 34 in which the three cutting heads 31, 32 and 33 are journaled for rotation about parallel axes in a generally common plane.
Each of the auxiliary auger sections 25, 26, 27, 28, 29 and 30 comprises (FIGS. 2 and 3) an elongated body 35 with external helically vaned flights 36 secured thereon as by welding, a socket portion 37 having a cross-section recess 38 that is polygonal, preferably square, at the forward end of body 35, and at the rearward end of body 35 a shank 39 that is of matching-mating cross section and adapted to slidably but non-rotatably fit into recess 38. Thus, pairs of axially aligned auger sections may be interconnected or coupled to one another end-to-end by inserting the shank 39 of one section into the mating socket recess 38 of the other section and securing the shank and socket against substantial relative axial movement.
At the start of the mining operation as shown in FIG. 1, the cutting head units 31, 32 and 33 of cutting head assembly B are respectively coaxially aligned end-to-end and coupled directly to the three auger sections 25, 26, 27 that are connected to the driving heads 21, 22 and 23. However, after the assembly B and its cutting head units 31, 32 and 33 have advanced sufficiently into the vein of mineral to be mined, the driving heads are disconnected, the carriage C is retracted and three new auger sections are inserted and connected to the sockets of the former rearmost auger sections in the string. As this progressive adding of additional auger sections continues, a relatively long string of auger sections is constructed. On withdrawal of the cutting head assembly B from the hole, the rearmost auger sections are sequentially unlatched and removed from each strip.
A novel latching device embodying the invention is provided to hold the auger sections together. In the mining machine illustrated in FIGS. 1-3, the cutting head assemblies 31, 32 and 33 cut three circular holes of about 16 inch diameter. For this reason the space available for each latching device is somewhat limited, as it must be capable of advancing forward with the auger sections through a hole having only such diameter. The unique construction of the latching device in accordance with the invention minimizes the space required for effective latching and thus is capable of meeting the requirements of relatively small diameter mining equipment.
Each latching device 40 of FIGS. 2 and 3 comprises a housing 41, defining a cylindrical passage 42, fixed in a radial hole in wall 43, of socket portion 37 at the forward end of an auger section, which in FIGS. 3 and 4 is section 27. The socket 38, shown of square cross section, is adapted to receive the square cross section shank 39 of an adjacent auger section, shown as section 30 in FIGS. 2 and 3. Shank 39 has a cross section that matches but is slightly smaller than that of socket 38. Passage 42 opens into one of the flat sides of socket 38.
The housing 41 has a retainer 44 fixed, as by threads 45, to the outer end of housing 41 defining a central opening 46 adapted to receive a latch pin 47 that can reciprocate in passage 42 of housing 41. Pin 47 has an actuating end portion 48 that extends through the opening in the retainer 44 radially outwardly away from the exterior of socket portion 37. Latch pin 47 has at its other end a latching end portion 50 having an outer surface tapered inwardly toward the outer end of the pin, and adapted to extend into a latch hole 51 in the shank 39 of connected auger section 30, which hole 51 is alignable with passage 42. Hole 51 has its inner surface tapered inward toward the outer end of the hole to cooperate with the tapered surface of the latch pin portion 50 to prevent any accidental unlatching that might occur from the forces involved during the mining operation or on withdrawal of the auger strings. Preferably, hole 51 is formed in a sleeve 52 of hard metal inset into and secured in shank 39. A coil spring 53 located in passage 42 of housing 41 and compressed between a shoulder 54 on the latch pin adjacent the latch pin portion 50 and the interior of the retainer 44 biases the latch pin 47 to its extended latching position wherein its portion 50 extends into the hole 51 in shank 39.
It will be noted that the shank 39 has a tapered outer end 55 and that during the coupling operation the movement of the shank 39 into the socket 38 results in engagement between the tapered end of the shank 39 and the end of latch pin 47 and moves it upwardly against the force of the spring 53 until the pin 47 becomes aligned with the latch pin hole 51 at which time the spring forces the latching end portion 50 of pin 47 into hole 51 to cause latching engagement with the shank 39. Accordingly, the coupling operation results in an automatic latching of the aligned auger sections in the particular auger string.
The latch pin 47 has a laterally extending retractor pin 56 secured in its actuating end portion 48 to permit retraction of the latch pin 47 when the sections are to be uncoupled. Retraction of the pin against the force of the spring 53 is accomplished by a lever 57 having an operating arm 58 at one end and connected by a pivot pin 59 to a clevis 60 welded to the socket portion 37. The lever has another pin-engaging arm 62 with a bifurcated end.
As indicated in FIGS. 2 and 3 the bifurcated pin engaging arm 62 extends on each side of the upper actuating end portion 48 of latch pin 47 between the opposite ends of the retractor pin 56 and the outer face of the retainer 44. Therefore, when the lever 57 and its retractor arm 62 are in its normal retaining position shown in full lines in FIG. 3, arm 62 blocks further extension of the latch pin 47 into the hole 51 in shank 39 and thus serves as a positive stop to prevent the force of the spring 53 from moving the latch pin 47 into further extension. When the operating arm 58 is depressed by latch releasing means 64, as by the means disclosed in U.S. Pat. No. 3,278,236 or in applicants' copending U.S. Pat. No. 3,967,909 the pin engaging arm 62 lifts the retractor pin 56 together with the latch pin 47 to retract portion 50 of the latch pin 47 from the hole 51 in the shank 39 and permit the shank 39 to be moved axially out of the socket to unlatch the two interconnected auger sections so that they may be axially separated, thus uncoupling them.
FIGS. 4 and 5 illustrate on a larger scale a slightly modified version of the latching device of FIGS. 1 to 3. In these figures, parts like those of FIGS. 1-3 have like reference characters, but a latch pin 65 of an alternative construction is utilized instead of the latch pin 47 of the preceding Figures. The latch pin 65 has a latching end portion 66 adapted to be moved into latching engagement in the latch pin hole 51 of the shank 39 by spring 53, and to be lifted out of latching engagement by lever 58 having pin-engaging arm 62 located between retractor pin 56 on actuating end portion 67 of pin 65, and retainer 44. Pin 65 has a fixed flange portion 68 adjacent to, and of equal diameter to the latching end portion 66 of the pin 65. As in the previous embodiment, the diameter of flange portion 68 is somewhat smaller than the inner diameter of passage 42 in housing 41 and approximates it in cross section; and the flange portion serves to guide the pin on housing 41 and also serves as a seat 69 against which bears one end of the coil compression spring 53; the other end of the spring bears against and is located by retainer 44.
Flange portion 68 has two oppositely located indented or recessed portions 70 and 71. These portions permit finely divided debris, such as dirt, rock, or material being mined such as coal, which may have entered the passage 42, to pass the flange portion when the pin 65 is forced upward to the unlatched position. Such debris could enter passage 42 through retainer opening 46 or between the surfaces of the socket 38 and shank 39.
While this modification will be helpful in some cases, it may not be desirable in others since it does not make possible ready removal of the debris from passage 42, and may cause debris to pack in passage 42 sufficiently to prevent satisfactory unlatching.
FIGS. 6, 7 and 8 illustrate still another modified form of the invention having provision for permitting the removal and escape of finely divided debris that could clog the passage in the interior of the housing in which the latch pin 43 is intended to reciprocate. The latching device of FIGS. 6-8 is similar to that of FIGS. 1-3 except that it has a modified housing 73 illustrated as having fixed to its outer end a modified retainer 74 that differs from the threadedly attached retainer of the previous embodiment in that it is welded to the outer end of the housing. The housing 73 has a passage 75 through which pin 43 extends and in which it is biased toward latching position by compression spring 53 bearing against retainer 74 and shoulder 54 on the pin 43. Housing 73 also has a pair of diametrically opposed openings 76 and 77, of substantial area, located at the upper end of the housing 73 inwardly of retainer 74 and externally of the socket portion 37. The slots 76 and 77 permit debris that may enter the housing passage 75 through opening 78 of the retainer or between the socket and shank to be ejected by the pin 43 when it is moved radially outwardly to unlatching position by pin engaging arm 62 which is fixed about the pivot 59 of lever 57 by latch releasing means 64. When the pin is raised by the pin engaging lever arm 62 the shoulder 54 of the pin 43 moves upward, forcing along with it any debris that has entered the passage 75 of housing 73. Raising of the pin 43 can be repeated to cause a pumping action. Raising of the pin forces the debris out through the openings 76 and 77, and thus reduces the possibility of interference with the operation of the latching device that might otherwise be caused by the debris since attaching the retainer 74 to the end of the housing as by welding, rather than by threaded portions, permits more space for openings 76 and 77, and thus facilitates removal of debris.
This arrangement is particularly advantageous in auger-type mining operations where considerable amounts of dirt and dust are generated.
FIG. 9 illustrates a modification of the latching apparatus of FIGS. 6-8. In this embodiment, all parts are the same as in FIGS. 6-8, except that the latch pin is like that of FIGS. 4 and 5, having a flange portion 68 with recesses 70 and 71. Under certain conditions the combination of the recesses 76 and 77 in the housing 73, and recesses 71 and 72 in the pin flange portion 68, can provide special benefits in clearing the latching device of harmful debris that could impair operation of the device.
While the invention has been shown and described in respect to specific embodiments thereof, this is intended for the purpose of illustration rather than limitation and other variations and modifications of the specific devices herein shown and described will be apparent to those skilled in the art all within the intended spirit and scope of the invention. Accordingly, the patent is not to be limited to the specific devices herein shown and described nor any other way that is inconsistent with the extent to which the progress in the art has been advanced by the invention.
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A lever-operated latching device for securing in endwise coupled relation a socket portion and mating shank of axially aligned auger sections of an auger mining machine. The latching device is designed to be of minimum radial dimension so as to fit in a hole of limited radial cross section bored by the auger machine, and includes a latch pin that reciprocates in a passage formed in the socket portion between an extended position in latching engagement with the shank and a retracted unlatching position. The pin is biased by a spring toward its extended position and is retractable by a lever that engages a retractor element on the pin and that also acts as limit means that prevents the pin from extending beyond its extended latching position against the force of the spring. Openings are provided to permit removal by the latch pin of debris that could impair operative movement of the latch pin.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates to an ultrasonic motor and a method for operating the same.
[0003] 2. Description of Related Art
[0004] Recently, ultrasonic motors have been drawing attention as a new type of motor replacing electromagnetic motors. Ultrasonic motors have the following advantages over known electromagnetic motors:
[0005] 1) Ultrasonic motors are capable of high torque without using gears;
[0006] 2) Ultrasonic motors have holding force when powered off;
[0007] 3) Ultrasonic motors have high resolution;
[0008] 4) Ultrasonic motors are quiet; and
[0009] 5) Ultrasonic motors do not generate magnetic noise and are unaffected by noise.
[0010] A known ultrasonic motor is described in Japanese Unexamined Patent Application Publication No. 9-224385. The ultrasonic motor disclosed in this publication is configured so that an ultrasonic vibrator is pressed against a driven body by a pressure spring with a predetermined pressing force. In the known ultrasonic motor according to this publication, the pressing force is set at a value smaller than the pressing force at which a longitudinal-vibration resonant frequency and a flexural-vibration resonant frequency match each other, and the driving frequency is set at a value between the longitudinal-vibration resonant frequency and the flexural-vibration resonant frequency. Under such conditions, the ultrasonic vibrator is excited so as to generate longitudinal vibrations and flexural vibrations, causing the driven body to be driven leftward or rightward.
[0011] However, since the longitudinal-vibration resonant frequency and the flexural-vibration resonant frequency of a known ultrasonic motor, such as the one disclosed in Japanese Unexamined Patent Application Publication No. 9-224385, do not match each other because the pressing force of the ultrasonic motor is set at a value smaller than that at which the longitudinal-vibration resonant frequency and the flexural-vibration resonant frequency match each other, the maximum vibration amplitudes of the longitudinal and flexural vibration modes cannot be used. Thus, the ultrasonic motor cannot achieve a sufficient motor output. Moreover, since the driving frequency is set to a value between the longitudinal-vibration resonant frequency and the flexural-vibration resonant frequency, the maximum vibration amplitudes of the longitudinal and flexural vibration modes cannot be used. Thus, in this case too, the ultrasonic motor cannot achieve a sufficient motor output.
BRIEF SUMMARY OF THE INVENTION
[0012] The present invention has been conceived in light of the above-described problems, and an object thereof is to provide an ultrasonic motor and operating method thereof in which it is possible to simultaneously generate a plurality of vibration modes and to efficiently generate each vibration mode to stably obtain high motor power.
[0013] In order to achieve the objects described above, the present invention provides the following solutions.
[0014] An ultrasonic motor according to a first aspect of the present invention includes an ultrasonic vibrator and a pressing unit. The ultrasonic vibrator includes an electromechanical converting element that generates a substantially elliptic vibration at an output end of the ultrasonic vibrator by simultaneously generating two different vibration modes by applying a first alternating-current voltage of a first phase and a second alternating-current voltage of a second phase to the electromechanical converting element, wherein the first and second alternating-current voltages have a predetermined phase difference and predetermined driving frequencies. The pressing unit presses the output end of the ultrasonic vibrator against a driven body. The pressing force against the driven body on the output end of the ultrasonic vibrator by the pressing unit is set to a value which allows the mechanical resonant frequencies of the two different vibration modes to substantially match each other. In other words, the output end of the ultrasonic vibrator is pressed against the driven body by a pressing force that causes mechanical resonant frequencies in the two different vibration modes to substantially match each other.
[0015] In the ultrasonic motor according to the first aspect of the present invention, by applying the alternating-current voltages having a predetermined phase difference and predetermined driving frequencies to the electromechanical converting element of the ultrasonic vibrator, two different vibration modes are generated simultaneously and a substantially elliptic vibration is generated at the output end of the ultrasonic vibrator. By pressing the output end against the driven body by the movement of the pressing unit, the frictional force generated between the output end and the driven body causes the driven body to be driven in a tangential direction of the substantially elliptic motion of the output end.
[0016] In this case, the pressing force applied by the pressing unit is adjusted so that the mechanical resonant frequencies of the two different modes substantially match each other. Thus, it is possible to simultaneously use substantially the maximum vibration amplitudes of the two vibration modes when driving the driven body. As a result, high motor power can be obtained and the driven body can be driven efficiently.
[0017] In the ultrasonic motor according to the first aspect of the present invention, the pressing force may be set to a value substantially in the center of a predetermined range corresponding to a range of pressing forces that cause the mechanical resonant frequencies in the two different vibration modes to substantially match each other.
[0018] In this way, even when the value of the pressing force changes slightly for some reason, the ultrasonic motor can be operated with a pressing force within the range in which the mechanical resonant frequencies of the two different modes match each other. Thus, substantially the maximum vibration amplitudes of the two difference vibration modes can be stably utilized.
[0019] In the ultrasonic motor according to the first aspect of the present invention, the driving frequencies may be higher than the mechanical resonant frequencies in the two different vibration modes.
[0020] In this way, the ultrasonic vibrator can be driven in a range where the change in the vibration velocity is relatively gentle with respect to the change in the driving frequency. Thus, the ultrasonic motor can be stably controlled.
[0021] In the ultrasonic motor according to the first aspect of the present invention, the vibration direction of one of the two vibration modes at the output end of the ultrasonic vibrator may be the same as the pressing direction of the pressing unit, and the vibration direction of the other vibration mode at the output end of the ultrasonic vibrator may be a direction substantially orthogonal to the pressing direction.
[0022] As the pressing force of the pressing unit increases, the mechanical resonant frequencies of the two different vibration modes change. In the vibration mode in which the vibration direction is the same as the pressing direction of the pressing unit, the change in the mechanical resonant frequencies with respect to the change in the pressing force is great, whereas, in the vibration mode in which the vibration direction is substantially orthogonal to the pressing direction, the change in the mechanical resonant frequencies with respect to the change in the pressing force is relatively small. Accordingly, by using the difference in the changes of the mechanical resonant frequencies in the two different vibration modes with respect to the pressing force, the mechanical resonant frequencies in the two different vibration modes can be easily matched with each other by changing the pressing force generated by the operation of the pressing unit.
[0023] In the ultrasonic motor according to the first aspect of the present invention, the two different vibration modes may be a flexural vibration mode and a longitudinal vibration mode.
[0024] By using a flexural vibration mode and a longitudinal vibration mode as the vibration modes, the output end of the ultrasonic vibrator can be vibrated in two directions orthogonal to each other so as to easily generate a substantially elliptic vibration. The mechanical resonant frequencies in the two different vibration modes can be matched with each other by the operation of the pressing unit so as to drive the ultrasonic motor with substantially the maximum amplitudes of the two orthogonal vibrations. Thus, high motor power can be obtained.
[0025] In the ultrasonic motor according to the first aspect of the present invention, the driven body may be moved linearly.
[0026] In this way, an ultrasonic linear motor having a high motor power can be provided.
[0027] In the ultrasonic motor according to the first aspect of the present invention, the driven body may be moved rotatively.
[0028] In this way, an ultrasonic rotary motor having a high motor power can be provided.
[0029] A method according to a second aspect of the present invention method for operating an ultrasonic motor having an ultrasonic vibrator includes the step of setting a pressing force against the driven body on the output end of the ultrasonic vibrator to a value which allows the mechanical resonant frequencies of the two different vibration modes to substantially match each other. The ultrasonic vibrator includes an electromechanical converting element that generates a substantially elliptic vibration at an output end of the ultrasonic vibrator by simultaneously generating two different vibration modes by applying a first alternating-current voltage of a first phase and a second alternating-current voltage of a second phase to the electromechanical converting elements, wherein the first and second alternating-current voltages have a predetermined phase difference and predetermined driving frequencies.
[0030] In the method according to the second aspect of the present invention, by applying the alternating-current voltages having a predetermined phase difference and predetermined driving frequencies to the electromechanical converting element of the ultrasonic vibrator, two different vibration modes are generated simultaneously and a substantially elliptic vibration is generated at the output end of the ultrasonic vibrator. By pressing the output end of the ultrasonic vibrator against the driven body by the movement of the pressing unit, the frictional force generated between the output end and the driven body causes the driven body to be driven in a tangential direction of the substantially elliptic motion of the output end.
[0031] In this case, by adjusting the pressing force, the mechanical resonant frequencies of the two different modes can be substantially matched with each other. Thus, it is possible to simultaneously use substantially the maximum vibration amplitudes of the two vibration modes when driving the driven body. As a result, high motor power can be obtained and the driven body can be driven efficiently.
[0032] In the method according to the second aspect of the present invention, the pressing force may be set to a value substantially in the center of a predetermined range. The predetermined range corresponds to a range of pressing forces that cause the mechanical resonant frequencies in the two different vibration modes to substantially match each other.
[0033] In this way, even when the value of the pressing force changes slightly for some reason, the ultrasonic motor can be operated with a pressing force within the range in which the mechanical resonant frequencies of the two different modes match each other. Thus, the substantially maximum vibration amplitudes of the two different vibration modes can be stably utilized.
[0034] In the method according to the second aspect of the present invention, the driving frequencies may be higher than the mechanical resonant frequencies in the two different vibration modes.
[0035] In this way, the ultrasonic vibrator can be driven in a range where the change in the vibration velocity is relatively gentle with respect to the change in the driving frequency. Thus, the ultrasonic motor can be stably controlled.
[0036] According to aspects of the present invention described above, since the ultrasonic vibrator can be driven with the mechanical resonant frequencies in the two different vibration modes substantially matching each other, substantially the maximum vibration amplitudes of the two different vibration modes can be used simultaneously. In this way, a high motor power can be obtained and the driven body can be efficiently driven.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0037] FIG. 1 illustrates the overall structure of an ultrasonic motor according to a first embodiment of the present invention;
[0038] FIG. 2 is a perspective view of an ultrasonic vibrator of the ultrasonic motor illustrated in FIG. 1 ;
[0039] FIG. 3 is a perspective view of a piezoelectric layered member constituting the ultrasonic vibrator illustrated in FIG. 2 ;
[0040] FIG. 4A is a perspective view of a piezoelectric ceramic sheet constituting the piezoelectric layered member illustrated in FIG. 3 ;
[0041] FIG. 4B is a perspective view of another piezoelectric ceramic sheet constituting the piezoelectric layered member illustrated in FIG. 3 ;
[0042] FIG. 5 illustrates the piezoelectric layered member shown in FIG. 2 when vibrating in a first-order longitudinal vibration mode based on a computer analysis;
[0043] FIG. 6 illustrates the piezoelectric layered member shown in FIG. 2 vibrating in a second-order flexural vibration mode based on a computer analysis;
[0044] FIG. 7A is a graph illustrating the change in frequency characteristics of the vibration velocity of the ultrasonic vibrator illustrated in FIG. 2 in response to a predetermined pressing force;
[0045] FIG. 7B is a graph illustrating the change in frequency characteristics of the vibration velocity of the ultrasonic vibrator illustrated in FIG. 2 in response to a predetermined pressing force;
[0046] FIG. 7C is a graph illustrating the change in frequency characteristics of the vibration velocity of the ultrasonic vibrator illustrated in FIG. 2 in response to a predetermined pressing force;
[0047] FIG. 8 is a graph illustrating how the mechanical vibration frequencies in different vibration modes of the ultrasonic vibrator illustrated in FIG. 2 depend on the pressing force;
[0048] FIG. 9 illustrates the overall structure of an ultrasonic motor according to a second embodiment of the present invention;
[0049] FIG. 10 is a perspective view of an ultrasonic vibrator of the ultrasonic motor illustrated in FIG. 9 ; and
[0050] FIG. 11 is a graph illustrating how the mechanical vibration frequencies in different vibration modes of the ultrasonic vibrator illustrated in FIG. 9 depend on the pressing force.
DETAILED DESCRIPTION OF THE INVENTION
First Embodiment
[0051] Now, an ultrasonic motor according to a first embodiment of the present invention will be described below with reference to FIGS. 1 to 8 .
[0052] An ultrasonic motor 1 according to this embodiment, as illustrated in FIG. 1 , includes a driven body 2 , an ultrasonic vibrator 3 disposed in contact with the driven body 2 , and a pressing unit 4 for pressing the ultrasonic vibrator 3 against the driven body 2 . The driven body 2 is fixed to a movable member 7 of a linear bearing 6 , which is fixed to a base 5 . A sliding plate 8 made of, for example, zirconia ceramic is bonded to the driven body 2 on the surface contacting the ultrasonic vibrator 3 . Screws 9 fix a fixed member 10 of the linear bearing 6 to the base 5 .
[0053] The ultrasonic vibrator 3 , as illustrated in FIGS. 2 to 4 B, includes a rectangular piezoelectric layered member 13 , two friction-contact members 14 (output ends) bonded on a side surface of the piezoelectric layered member 13 , and a vibrator holding member 16 having pins 15 protruding from the sides adjacent to the side surface having the friction-contact members 14 . The piezoelectric layered member 13 is made up of a stack of rectangular piezoelectric ceramic sheets 11 . On one side of each of the piezoelectric ceramic sheets 11 , sheets of inner electrodes 12 are provided (refer to FIGS. 4A and 4B ).
[0054] The piezoelectric layered member 13 , as illustrated in FIG. 3 , for example, has a length of 18 mm, a width of 4.4mm, and a thickness of 2 mm.
[0055] The piezoelectric ceramic sheets 11 constituting the piezoelectric layered member 13 , as illustrated in FIGS. 4A and 4B , for example, are lead zirconium titanate (hereinafter referred to as ‘PZT’) based piezoelectric ceramic elements having a thickness of about 80 μm. For the PZT, a hard-type PZT having a large Qm value is selected. The Qm value is about 1,800.
[0056] The inner electrodes 12 , for example, are composed of silver-palladium alloy and have a thickness of about 4 μm. A piezoelectric ceramic sheet 11 a , which is the outermost layer of the stack of the piezoelectric ceramic sheets 11 , is not provided with the inner electrodes 12 . The piezoelectric ceramic sheets 11 , except for the piezoelectric ceramic sheet 11 a , each include a pair of inner electrodes 12 of one of the two different types. The two different types of inner electrodes 12 are illustrated in FIGS. 4A and 4B .
[0057] The type of piezoelectric ceramic sheet 11 illustrated in FIG. 4A has the inner electrodes 12 disposed on most of the surface. Two inner electrodes 12 are disposed adjacent to each other in the longitudinal direction with an insulating distance of about 0.4 mm. The inner electrodes 12 are disposed about 0.4 mm from the edges, while a portion of the piezoelectric ceramic sheet 11 extends to the edge.
[0058] The type of piezoelectric ceramic sheet 11 illustrated in FIG. 4B has the inner electrodes 12 disposed in an area corresponding to substantially half of the width of the piezoelectric ceramic sheet 11 . Two inner electrodes 12 are disposed adjacent to each other in the longitudinal direction with an insulating distance of about 0.4 mm. The inner electrodes 12 are disposed about 0.4 mm from the edge, while a portion of the piezoelectric ceramic sheet 11 extends to the edge.
[0059] The two different types of piezoelectric ceramic sheets 11 provided with the different-shaped inner electrodes 12 (i.e., the piezoelectric ceramic sheet 11 illustrated in FIGS. 4A provided with a large inner electrode 12 and the piezoelectric ceramic sheet 11 illustrated in FIGS. 4B provided with a small inner electrode 12 ) are alternately stacked so as to form the rectangular piezoelectric layered member 13 .
[0060] Four external electrodes 17 are disposed on the piezoelectric layered member 13 , one pair of external electrodes 17 being disposed on each longitudinal end of the piezoelectric layered member 13 . The external electrodes 17 are each connected to a group of inner electrodes 12 provided at the same position on the same type of piezoelectric ceramic sheets 11 . In this way, the inner electrodes 12 provided at the same position on the same type of piezoelectric ceramic sheets 11 have the same electric potential. The external electrodes 17 have electrical connections not shown in the drawings. The electrical connections may be established by any type of flexible wiring material, such as lead wires or flexible substrates.
[0061] The piezoelectric layered member 13 is manufactured, for example, as described below.
[0062] To manufacture the piezoelectric layered member 13 , first, the piezoelectric ceramic sheets 11 are prepared. The piezoelectric ceramic sheets 11 are prepared, for example, by casting a slurry mixture of a calcinated powder of PZT and a predetermined binder onto a film using a doctor blade method, drying the mixture, and removing the dried mixture from the film.
[0063] The material for the inner electrodes 12 is printed on each of the prepared piezoelectric ceramic sheets 11 using a mask having a pattern for the inner electrode 12 . First, the piezoelectric ceramic sheet 11 la with no inner electrode 12 is provided. Then, the two types of piezoelectric ceramic sheets 11 having different-shaped inner electrodes 12 are carefully aligned and alternately stacked on the piezoelectric ceramic sheet 11 a with the inner electrodes 12 facing downward towards the piezoelectric ceramic sheet 11 a . The stacked piezoelectric ceramic sheets 11 are bonded by thermocompression, cut into a predetermined shape, and fired at a temperature of about 1,200° C. In this way, the piezoelectric layered member 13 is manufactured.
[0064] Subsequently, silver is plated onto the inner electrodes 12 exposed at the edge of the piezoelectric ceramic sheets 11 such that the inner electrodes 12 are joined together to form the external electrodes 17 .
[0065] Finally, a high-voltage direct current is applied between the opposing inner electrodes 12 to polarize and piezoelectrically activate the piezoelectric ceramic sheets 11 .
[0066] Now, the operation of the piezoelectric layered member 13 , manufactured by the above-described process, will be described.
[0067] The two external electrodes 17 that are provided on a first longitudinal end of the piezoelectric layered member 13 are defined as A-phase (A+and A−) external electrodes 17 , and the two external electrodes 17 that are provided on a second longitudinal end of the piezoelectric layered member 13 correspond to B-phase (B+and B−) external electrodes 17 . By applying alternating-current voltages corresponding to resonant frequencies and having synchronous phases to the A-phase and B-phase external electrodes 17 , the piezoelectric layered member 13 is excited and a first-order longitudinal vibration is generated, as illustrated in FIG. 5 . By applying alternating-current voltages corresponding to resonant frequencies and having opposite phases to the A-phase and B-phase external electrodes 17 , the piezoelectric layered member 13 is excited and a second-order flexural vibration is generated, as illustrated in FIG. 6 . FIGS. 5 and 6 illustrate the results of a computer analysis based on a finite element method.
[0068] The two friction-contact members 14 are bonded on the piezoelectric layered member 13 at positions corresponding to the loops of the second-order flexural vibration. In this way, the friction-contact members 14 are displaced in the longitudinal direction of the piezoelectric layered member 13 (i.e., X direction in FIG. 2 ) when a first-order longitudinal vibration is generated and are displaced in the width direction of the piezoelectric layered member 13 (i.e., Z direction in FIG. 2 ) when a second-order flexural vibration is generated.
[0069] Consequently, by applying the alternating-current voltages corresponding to the resonant frequencies that have a phase difference of 90° to the A-phase and B-phase external electrodes 17 of the ultrasonic vibrator 3 , the first-order longitudinal vibration and the second-order flexural vibration are generated simultaneously. As a result, a vibration in a substantially elliptic motion in a clockwise or counterclockwise direction is generated at the friction-contact members 14 , as indicated by arrows C in FIG. 2 .
[0070] The vibrator holding member 16 includes a substantially U-shaped holding member 16 a , and the pins 15 , which are integrated with the holding member 16 a and protrude orthogonally from both side surfaces of the holding member 16 a . The holding member 16 a is bonded to the piezoelectric layered member 13 with, for example, silicone resin or epoxy resin, in such a manner that the piezoelectric layered member 13 is clamped in the width direction. With the holding member 16 a bonded to the piezoelectric layered member 13 , the pins 15 are disposed coaxially on both sides of the holding member 16 a at a position on the piezoelectric layered member 13 corresponding to a common node of the longitudinal vibration and the flexural vibration.
[0071] The pressing unit 4 , as illustrated in FIG. 1 , includes a bracket 18 , a pressing member 19 , a coil spring 20 , an adjustment screw 21 , and guiding bushes 22 . The bracket 18 is fixed on the base 5 with screws 23 at a position a predetermined distance away from the ultrasonic vibrator 3 in the width direction (Z direction) on the opposite side of the ultrasonic vibrator 3 from the friction-contact members 14 . The pressing member 19 is supported so that it is movable in the width direction of the ultrasonic vibrator 3 with respect to the bracket 18 . The coil spring 20 applies a pressing force to the pressing member 19 , and the adjustment screw 21 adjusts the pressing force. The guiding bushes 22 guide the movement of the pressing member 19 with respect to the bracket 18 .
[0072] The pressing member 19 includes two support plates 24 sandwiching the ultrasonic vibrator 3 in the thickness direction thereof. The support plates 24 have through-holes 25 for passing through the pins 15 of the vibrator holding member 16 . The pressing force applied to the pressing member 19 is transmitted to the ultrasonic vibrator 3 through the support plates 24 and the pins 15 passed through the through-holes 25 .
[0073] The coil spring 20 is a compression coil spring interposed between the adjustment screw 21 and the pressing member 19 . By changing the fastening position of the adjustment screw 21 with respect to the bracket 18 , the amount of elastic deformation of the coil spring 20 is changed so as to change the pressing force applied to the pressing member 19 in a direction toward the ultrasonic vibrator 3 .
[0074] In the ultrasonic motor 1 according to this embodiment, the adjustment screw 21 is adjusted as described below.
[0075] FIGS. 7A to 7 C illustrate the measurement results of the vibration velocity in the vicinity of the ultrasonic vibrator 3 measured by a three-dimensional Doppler vibration meter when the phase difference of the voltages applied to the A-phase and B-phase external electrodes 17 of the ultrasonic vibrator 3 is 90° or −90°. FIG. 7A illustrates the resonance characteristics when the adjustment screw 21 is completely loosened and a pressing force is not applied to the pressing member 19 . FIGS. 7B and 7C illustrate the resonance characteristics when the adjustment screw 21 is at different fastening positions. The pressing force applied by the adjustment screw 21 is greater in FIG. 7C than in FIG. 7B .
[0076] As illustrated in FIG. 7A , when a pressing force is not applied, the maximum mechanical vibration frequency fl in the longitudinal vibration mode is greater than the maximum mechanical vibration frequency ff in the flexural vibration mode. As illustrated in FIG. 7B , as the pressing force is gradually increased, the maximum mechanical vibration frequencies fl and ff gradually become closer and eventually match each other. As illustrated in FIG. 7C , by continuing to increase the pressing force, the magnitudes of the maximum mechanical vibration frequencies will be reversed so that the maximum mechanical vibration frequency fl becomes smaller than the maximum mechanical vibration frequency ff.
[0077] In the ultrasonic motor 1 according to this embodiment, the adjustment screw 21 is adjusted so that the maximum mechanical vibration frequency fl and the maximum mechanical vibration frequency ff match each other, as illustrated in FIG. 7B .
[0078] FIG. 8 is a graph illustrating how the mechanical vibration frequencies fl and ff in the different vibration modes depend on the pressing force.
[0079] As illustrated in FIG. 8 , in the ultrasonic motor 1 according to this embodiment, when a pressing force is not applied to the pressing unit 4 , the mechanical resonant frequency fl 0 in the longitudinal vibration mode is higher than the mechanical resonant frequency ff 0 in the flexural vibration mode. As a concrete example, the mechanical resonant frequency fl 0 of the longitudinal vibration mode may be 89.0 khz and the mechanical resonant frequency ff 0 of the flexural vibration mode may be 86.2 khz. By gradually increasing the pressing force, the maximum mechanical vibration frequencies fl and ff gradually become closer and eventually match each other at a pressing force F 1 . Here, for example, the pressing force F 1 is 800 gf (7.85 N) and the mechanical resonant frequency f 1 corresponding to the pressing force F 1 , as illustrated in FIG. 8 , is 89.6 khz.
[0080] By continuing to increase the pressing force, the maximum mechanical vibration frequencies fl and ff continue to match each other until a pressing force F 2 . When the pressing force is greater than the pressing force F 2 , the mechanical resonant frequency of the flexural vibration mode ff becomes higher than the mechanical resonant frequency of the longitudinal vibration mode fl. Here, for example, the pressure F 2 is 1.4 kgf (13.7 N) and the mechanical resonant frequency f 2 corresponding to the pressing force, F 2 as illustrated in FIG. 8 , is 90.8 khz.
[0081] In the ultrasonic motor 1 according to this embodiment, the adjustment screw 21 is adjusted so that the pressing force falls between the pressing forces F 1 and F 2 at which the mechanical resonant frequency fl in the longitudinal vibration mode and the mechanical resonant frequency ff in the flexural vibration mode match each other. It is more desirable to adjust the adjustment screw 21 so that the pressing force is half of the sum of the pressing forces F 1 and F 2 (F=(F1+F2)/2).
[0082] Now, the operation of the ultrasonic motor 1 according to this embodiment, having the above-described structure, will be described below.
[0083] To operate the ultrasonic motor 1 according to this embodiment, high-frequency voltages (A-phase and B-phase) having a phase difference of 90° are supplied to the A-phase and B-phase external electrodes 17 via the wires connected to the external electrodes 17 .
[0084] In this way, a substantially elliptic vibration, which is the outcome of combining the longitudinal vibration mode and the flexural vibration mode, is generated at the friction-contact members 14 bonded to the ultrasonic vibrator 3 . The driven body 2 is driven by the frictional force generated between the driven body 2 and the sliding plate 8 in the tangential direction of the elliptic motion.
[0085] In the ultrasonic motor 1 according to this embodiment, having the above-described structure, the pressing force is set between the pressing forces F 1 and F 2 so that the mechanical resonant frequency fl in the longitudinal vibration mode and the mechanical resonant frequency ff in the flexural vibration mode, which are simultaneously generated in the ultrasonic vibrator 3 , match each other. In this way, the maximum vibration amplitude in each vibration mode can be used to drive the driven body 2 and obtain large output force.
[0086] By adjusting the adjustment screw 21 so that pressing force is F=(F1+F2)/2, where the mechanical vibration frequencies fl and ff match each other, the pressing force F can be maintained so that the mechanical vibration frequencies fl and ff match each other even when the actual value of the pressure F changes for some reason. Consequently, a stable large output force can be obtained.
[0087] When the ultrasonic motor 1 is driven with the mechanical vibration frequencies fl and ff matching each other in such a manner as described above, it is desirable that the frequencies of the high-frequency voltages applied to the A-phase and B-phase external electrodes 17 be in the high-frequency range (region D in FIG. 8 ) where frequencies are higher than the mechanical resonant frequencies. More specifically, as illustrated in FIGS. 7A to 7 C, the vibration characteristics of the ultrasonic motor 1 differ in the low-frequency region and the high-frequency region, separated by the mechanical resonant frequencies fl and ff. In the low-frequency region, where the frequency is lower than the mechanical resonant frequencies fl and ff, the vibration velocity changes rapidly in response to a change in frequency, whereas, in the high-frequency region, where the frequency is higher than the mechanical resonant frequencies fl and ff, the vibration velocity changes slowly in response to a change in frequency. For this reason, by driving the ultrasonic motor 1 at a frequency in the high-frequency region, where the frequency is higher than the mechanical resonant frequencies fl and ff, stable vibration velocity is maintained even when the frequency changes.
Second Embodiment
[0088] Now, an ultrasonic motor 30 according to a second embodiment of the present invention will be described with reference to FIGS. 9 to 11 .
[0089] In the description below, components that are the same as those in the ultrasonic motor 1 according to the first embodiment are represented by the same reference numerals and their descriptions are omitted.
[0090] The ultrasonic motor 30 according to this embodiment differs from the ultrasonic motor 1 according to the first embodiment in that an ultrasonic vibrator 31 facing a different direction compared to the ultrasonic vibrator 3 according to the first embodiment is disposed in contact with a driven body 2 , as illustrated in FIG. 9 .
[0091] The ultrasonic vibrator 31 according to this embodiment, as illustrated in FIG. 10 , includes a piezoelectric layered member 13 similar to that according to the first embodiment. However, the ultrasonic vibrator 31 differs from the ultrasonic vibrator 3 according to the first embodiment in that a friction-contact member 14 is provided only on one of the longitudinal ends of the piezoelectric layered member 13 . External electrodes 17 connected to inner electrodes 12 of the piezoelectric layered member 13 extend to the side surfaces (i.e., outermost surfaces in the thickness direction) of the piezoelectric layered member 13 so that there is enough wiring space for the external electrodes 17 even when the longitudinal end surface of the piezoelectric layered member 13 is disposed close to the driven body 2 .
[0092] In the ultrasonic vibrators 31 having the above-described structure, two external electrodes 17 extending from a first end of the piezoelectric layered member 13 in the longitudinal direction are defined as the A-phase (A+ and A−) external electrodes 17 , and two external electrodes 17 extending from a second end of the piezoelectric layered member 13 in the longitudinal direction are defined as the B-phase (B+ and B−) external electrodes 17 . Similar to the first embodiment, by applying alternating-current voltages corresponding to resonant frequencies and having synchronous phases to the A-phase and B-phase external electrodes 17 , the piezoelectric layered member 13 is excited and a first-order longitudinal vibration is generated, as illustrated in FIG. 5 . By applying alternating-current voltages corresponding to resonant frequencies and having opposite phases to the A-phase and B-phase external electrodes 17 , the piezoelectric layered member 13 is excited and a second-order flexural vibration is generated, as illustrated in FIG. 6 .
[0093] The friction-contact member 14 provided on one of the longitudinal ends of the piezoelectric layered member 13 is displaced in the longitudinal direction of the piezoelectric layered member 13 (i.e., Z direction in FIG. 9 ) when a first-order longitudinal vibration is generated in the piezoelectric layered member 13 and is displaced in the width direction of the piezoelectric layered member 13 (i.e., X direction in FIG. 9 ) when a second-order flexural vibration is generated.
[0094] Consequently, by applying the alternating-current voltages corresponding to the resonant frequencies that have a phase difference of 90° to the A-phase and B-phases external electrodes 17 of the ultrasonic vibrator 31 , the first-order longitudinal vibration and the second-order flexural vibration are generated simultaneously. As a result, a vibration in a substantially elliptic motion in a clockwise or counterclockwise direction is generated at the friction-contact member 14 .
[0095] FIG. 11 is a graph illustrating how the mechanical vibration frequencies fl and ff in the different vibration modes depend on the pressing force.
[0096] As illustrated in FIG. 11 , in the ultrasonic motor 30 according to this embodiment, in contrast to the ultrasonic motor 1 according to the first embodiment, when a pressing force is not applied to the pressing unit 4 , the mechanical resonant frequency ff 0 in the flexural vibration mode is higher than the mechanical resonant frequency fl 0 in the longitudinal vibration mode. As a concrete example, the mechanical resonant frequency ff 0 of the flexural vibration mode may be 92.0 khz and the mechanical resonant frequency fl 0 of the longitudinal vibration mode may be 89.0 khz.
[0097] By gradually increasing the pressing force, the maximum mechanical vibration frequencies fl and ff gradually become closer and eventually match each other at a pressing force F 1 . Here, for example, the pressing force F 1 is 800 gf (7.85 N) and the mechanical resonant frequency fl corresponding to the pressing force F 1 , as illustrated in FIG. 11 , is 92.6 khz.
[0098] By continuously increasing the pressing force, the maximum mechanical vibration frequencies fl and ff continue to match each other until a pressing force F 2 . When the pressing force is greater than the pressing force F 2 , the mechanical resonant frequency of the longitudinal vibration mode f 1 becomes higher than the mechanical resonant frequency of the flexural vibration mode ff. Here, for example, the pressing force F 2 is 1.4 kgf (13.7 N) and the mechanical resonant frequency f 2 corresponding to the pressing force F 2 , as illustrated in FIG. 11 , is 93.8 khz.
[0099] In the ultrasonic motor 30 according to this embodiment, the adjustment screw 21 is adjusted so that the pressing force falls between the pressing forces F 1 and F 2 at which the mechanical resonant frequency fl in the longitudinal vibration mode and the mechanical resonant frequency ff in the flexural vibration mode match each other. It is more desirable to adjust the adjustment screw 21 so that the pressing force is half of the sum of the pressing forces Fl and F 2 (F=(F1+F2)/2).
[0100] In the ultrasonic motor 30 according to this embodiment, having the above-described structure, the pressing force is set between the pressing forces F 1 and F 2 so that the mechanical resonant frequency fl in the longitudinal vibration mode and the mechanical resonant frequency ff in the flexural vibration mode, which are simultaneously generated in the ultrasonic vibrator 3 , match each other. In this way, the maximum vibration amplitude in each vibration mode can be used to drive the driven body 2 and to obtain a large output force.
[0101] By adjusting the adjustment screw 21 so that the pressing force is F=(F1+F2)/2, where the mechanical vibration frequencies fl and ff match each other, the pressing force F can be maintained so that the mechanical vibration frequencies fl and ff match each other even when the actual value of the pressure F changes for some reason. Consequently, a stable large output force can be obtained.
[0102] When the ultrasonic motor 30 is driven with the mechanical vibration frequencies fl and ff matching each other in such a manner as described above, it is desirable that the frequencies of the high-frequency voltages applied to the A-phase and B-phase external electrodes 17 be in the high-frequency range (region D in FIG. 11 ) where frequencies are higher than the mechanical resonant frequencies. In this way, stable vibration velocity is maintained even when the frequencies changes.
[0103] In the above-described embodiments, PZT was used for the piezoelectric ceramic sheets. However, the piezoelectric ceramic sheets are not limited to PZT, and any other material may be used so long as the element has piezoelectricity.
[0104] In the above-described embodiments, silver-palladium alloy was used as the material constituting the inner electrodes. Instead, silver, nickel, platinum, or gold may be used.
[0105] Moreover, instead of bonding a sliding plate composed of zirconia ceramic on the surface of the driven body 2 , -zirconia ceramic may be applied to the surface of the driven body 2 by sputtering.
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An ultrasonic motor capable of simultaneously generating a plurality of vibration modes efficiently generates each vibration mode so as to stably obtain high motor power. The ultrasonic motor an ultrasonic vibrator and a pressing unit. The ultrasonic vibrator includes an electromechanical converting element that generates a substantially elliptic vibration at an output end of the ultrasonic vibrator by simultaneously generating two different vibration modes by applying a first alternating-current voltage of a first phase and a second alternating-current voltage of a second phase to the electromechanical converting elements, wherein the first and second alternating-current voltages have a predetermined phase difference and predetermined driving frequencies. The pressing unit is configured to press the output end of the ultrasonic vibrator against a driven body. The output end of the ultrasonic vibrator is pressed against the driven body by a pressing force that causes mechanical resonant frequencies in the two different vibration modes to substantially match each other.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to cam mechanisms used for forming the shed in weaving machines.
2. History of the Related Art
The term "cam mechanism" is known generally to designate an assembly comprising a series of rocking levers, in a number equal to that of the heddle frames mounted on the weaving machine. Each rocking lever, coupled to one of the frames, is provided with two rollers which cooperate with the two sectioned tracks of a complementary cam driven in rotation by a common shaft connected to that of the corresponding weaving machine. It will be understood that the drive of these cams, which are suitably offset angularly with respect to one another, on the common shaft, ensures control of the levers and the reciprocating vertical displacement of the heddle frames.
Experience has shown that, whenever the weaving machine stopped, either at the end of work or for the purpose of a momentary intervention on the machine or the cam mechanism, all the heddle frames had to be brought to the same height. To that end, the mechanisms are generally provided with a so-called "levelling" device which may take different forms, but of which the most current structure is that schematically shown in FIG. 1 of the drawings accompanying the present specification.
In this FIG. 1, reference 1 designates one of the rocking levers coupled to one of the heddle frames CL of the weaving machine, while reference 2 corresponds to the two rollers which are offset laterally with respect to each other to cooperate with the two tracks of a complementary cam 3, fitted on a drive shaft 4. The different rocking levers 1 of the mechanism are mounted idly on a common pin 5 oriented parallel to the shaft and it will be observed that each of the small-diameter ends 5a of this pin 5 is supported by an eccentric 6 of circular profile, housed in a cylindrical bore of a bearing 7 secured to the frame of the mechanism.
It will be readily appreciated that if, after the drive shaft 4 has stopped, the two eccentrics 6 are rotated in their bearings 7, the common pin 5 on which all the levers 1 pivot moves in the direction of the arrow appearing in FIG. 1. This recoil movement of the pin brings all the levers 1 in abutment against a fixed stop 8 of the frame 9 of the mechanism.
Consequently, all the rocking levers 1 are brought to the same angular orientation, whatever, at the moment of stop, the orientation of their complementary cam 3.
The present invention is based on the observation that the assembly of the ends 5a of the pin 5 inside the eccentrics 6 and the maintenance of the latter in the bearings 7 were detrimental to the rigidity of the point of fixation of the pin. During normal operation (weaving) of the mechanism, this pin is subjected to very high forces and to considerable vibratory effects. These forces and vibrations rapidly wear the pieces which support the pivot pin, generating the formation of rust in the bearings 7, as well as the appearance of a residual clearance detrimental to correct functioning of the mechanism assembly.
It is a principal object of the present invention to overcome this drawback.
SUMMARY OF THE INVENTION
To that end, the present invention relates to a cam mechanism for forming the shed in weaving machines, of the type in which the ends of the pivot pin which supports the rocking levers coupled to the heddle frames are carried by two eccentrics which cooperate with the frame of the mechanism so that the rotation of the eccentrics under the effect of maneuvering means provokes, by transverse displacement of the pin and rocking of the levers which abut against a stop, the levelling of the assembly of the heddle frames. The comprises means adapted to exert on the ends of the pivot pin a force which tends to apply the latter elastically against fixed bearing surfaces in the frame of the mechanism during normal operation thereof.
In fact, the invention essentially consists in causing elastic means to act on the ends of the pivot axis, which elastic means are adapted to maintain the ends very firmly pressed against fixed bearing surfaces secured to the frame of the mechanism.
Tests have shown that the forces of contact thus obtained between the pin and its bearing surfaces, coupled with the forces of adherence following therefrom, radically opposed all the micro-displacements observed in the conventional constructions.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be more readily understood on reading the following description with reference to the accompanying drawings, in which:
As indicated hereinbefore, FIG. 1 schematically shows the structure of the conventional levelling devices.
FIG. 2 illustrates in the same manner the arrangement of a mechanism equipped with a levelling device according to the invention.
FIG. 3 reproduces FIG. 2 in position of levelling.
FIG. 4 is a view in perspective clearly showing the assembly of the pivot pin.
FIGS. 5 and 6 are schematic vertical sections similar to those of FIGS. 2 and 3, but illustrating another embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring again to the drawings, FIG. 2 shows the rocking lever 1 provided with its two rollers 2 cooperating with the tracks of a complementary cam 3 fitted on a drive shaft 4. All the levers 1 of the mechanism pivot about a common pin 5 adjacent which is arranged the levelling device which includes a system of eccentrics adapted to bring said pin to a position for which the rollers 2 are no longer in contact with the cams 3.
In the embodiment shown, these eccentric assemblies are in the form of two lateral arms 10 of which the upper end supports, for example by screws 11, the corresponding end 5a of the pin 5, while the lower end is mounted on a pivot 12 secured to the frame 9 of the mechanism. Adjacent its upper end, each arm 10 is coupled by a connecting rod 13 to a cylindrical eccentric 14 engaged in a bore of the frame 9 and provided with a means for rotating, shown schematically in the form of a handle 15, adapted to move between two fixed angular end-of-stroke stops indicated at 15'.
In the position of weaving illustrated in FIG. 2, the eccentrics 14 are oriented so that, in their bearing, the connecting rods 13, which are an arcuate profile so as to be capable of a slight elastic deformability along their axis, tend to push arms 10 elastically in the direction of the shaft 4. Under these conditions, the system applies to the pivot pin 5 an elastic pre-load which tends to maintain its ends applied against two bearing surfaces 9a provided in the frame 9. The pin 5 is thus perfectly immobilized and the wear generated by the vibrations imparted to this pin 5 during weaving is consequently avoided.
The elastic pre-stress thus created extends its beneficial effects to the whole control system, avoiding any appearance of rust in the area of the articulations. Furthermore, it will be observed that the two positions according to FIGS. 2 and 3 are perfectly stable, the two lateral assemblies 13-14 being comparable to knuckle joint systems exceeding dead center are limited in angular displacement by the two stops 15'.
Of course, it suffices to move the handle 15 to effect levelling of all the levers 1 of the mechanism. As illustrated in FIGS. 3 and 4, the angular displacement of the two eccentrics 14 initially stops the buttressing exerted on the pin 5, then causes the latter to recoil with respect to the shaft 4 until the levers 1 abut against the fixed stop 8, the rollers 2 in that case no longer being in contact with the cams 3.
It goes without saying that other forms of embodiment may be imagined for the means which act elastically on the pivot pin 5 during the weaving operations.
In the embodiment illustrated in FIGS. 5 and 6, the ends 5a of the pin 5 are carried by eccentrics or arms 10 of short length, in the manner of crank pins oriented radially with respect to the pin. The free end of each arm 10 is coupled to an arcuate connecting rod 13 which is articulated on the frame 9 via a lateral pivot pin 16, located between pin 5 and shaft 4. The ends 5a of pin 5 are engaged in slots 9b made in the frame 9, the axis of each slot 9b being oriented substantially at right angles to the direction of guiding that the connecting rods 13 exert on the arms 10 when the latter pivot to pass from the position of weaving according to FIG. 5 to the position of levelling according to FIG. 6.
For actuating the levelling device at least one lateral jack is provided, whose cylinder 17 is articulated at 9c on frame 9, while the piston rod 18 is coupled to a lug 10a on arm 10. The mean position of this lug 10a is perpendicular to the axis of jack 17-18, so that actuation of the latter is translated by a rotation of the arms 10 and of the shaft 5 causing the passage from one to the other of the arrangements shown in FIGS. 5 and 6. Here, too, a stop 13' is provided to limit the amplitude of the angular displacement of the connecting rods 13.
Operation of the device is similar to that set forth with reference to FIGS. 2 to 4. Effectively, the end, referenced 9a, of the slots 9b which faces shaft 4 replaces the bearing surfaces 9a of FIGS. 2 to 4. Under these conditions, in the position according to FIG. 5, the connecting rods 13 apply to the pivot pin 5 an elastic pre-load which opposes any untimely displacement of the pin, while, in the levelled position of FIG. 6, the actuation effected by the jack or jacks 17-18 has brought the assembly of the levers 1 in abutment against the fixed stop 8 by transverse sliding of the ends 5a of this pin 5 in the slots 9b.
In this case too, the locked position of equilibrium according to FIG. 5, i.e. after the point of maximum extension of the connecting rods 13 has been exceeded, is rendered stable by the presence of the fixed stops 13'.
It should be observed that the slide of the ends 5a in the slots 9a is effected in a virtually rectilinear path, avoiding any displacement of the heddle frames CL in the direction of opening of the shed.
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In a weaving machine with a cam mechanism for forming the shed a heddle frame levelling apparatus includes rocking levers which are pivoted about a pin which is urged against a fixed bearing surface on the frame of the machine during weaving by elastically deformable elements. In a first embodiment the movement of the pivot pin is effected by the rotation of an eccentric bearing whereas in a second embodiment this movement is caused by a jack.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 10/026,844. filed Dec. 21, 2001, which was allowed on Nov. 25, 2003.
TECHNICAL FIELD
[0002] The present invention relates to gas turbine engine design, and in particular, to a gas turbine engine haying an offset driven output shaft.
BACKGROUND OF THE INVENTION
[0003] Light general aviation aircraft typically employ engine driven propellers to provide forward thrust. Many of these aircraft have been designed to employ internal combustion piston engines, but there is a relatively recent trend toward retrofitting such aircraft with gas turbine engines. However, a seemingly simple obstacle has so far stifled a more universal replacement of piston engines with gas turbines, and the difficulty is purely a matter of space. Piston engines are typically “short and fat”, whereas gas turbine engines tend to be relatively “long and thin”. Accordingly, most light aircraft designed to employ a piston engine simply do riot have the space to readily accommodate a retrofitted gas turbine engine.
[0004] A somewhat unrelated matter which occupies turboprop designers is keeping the installation inlet and exhaust losses to a minimum. The rather large gearbox required to reduce the rotational output speed to drive the propeller poses an obstacle which must be negotiated by designers in getting inlet air to the engine and extracting exhaust gas therefrom. A gas path which is long and is not straight suffers significant pressure losses. Long air inlet paths also typically require increased anti-icing protection.
[0005] Accordingly, there is a general need for improvements in the design of gas turbine engines, and in particular, to an engine better adapted for retrofitting a piston-powered aircraft.
SUMMARY OF THE INVENTION
[0006] It is an object of the present invention to provide an improved gas turbine engine.
[0007] It is another object of the present invention to provide a gas turbine engine which is better adapted to retrofitting a piston-powered aircraft.
[0008] It is another object of the present invention to shorten and straighten the gas path of a turboprop or turboshaft engine.
[0009] Therefore, in accordance with the present invention, there is provided a gas turbine engine comprising a gas turbine engine, comprising a gas generator module having an turbine shaft for providing rotating output power, and a reduction gearbox module having a gearbox input shaft and a main output power shaft, wherein the gearbox input shaft is drivingly connected to an intermediate drive shaft, the intermediate drive shaft being drivingly connected to the turbine shaft, and wherein the intermediate drive shaft is disposed at an angle to the turbine shaft.
[0010] There is also provided in accordance with the present invention, a gas turbine engine comprising a gas turbine engine, comprising a gas generator module, the gas generator module including a compressor portion, a combustor portion, and a turbine portion, and having an turbine shaft for providing rotating output power, and a reduction gearbox module adapted to drivingly connect the gas generator module to an output power shaft, the reduction gearbox module being disposed substantially laterally beside the gas generator module.
[0011] There is also provided, in accordance with the present invention, a gas turbine engine comprising a gas generator module having an turbine shaft for providing rotating output power, and a reduction gearbox module adapted to drivingly connect the gas generator module to an output shaft, wherein the reduction gearbox module is drivingly connected to the turbine shaft through a bevel gear on the turbine shaft.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] Further features and advantages of the present invention will become apparent from the following detailed description, in combination with the appended drawings in which:
[0013] FIG. 1 is an isometric view of a gas turbine engine in accordance with the present invention.
[0014] FIG. 2 is a front view of the gas turbine engine of FIG. 1 .
[0015] FIG. 3 is a partial cross-sectional view of the gas turbine engine of FIG. 1 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0016] Referring to FIGS. 1 and 2 , a turboprop gas turbine engines according to the present invention is shown generally at 10 . Engine 10 includes a gas generator module 12 , a reduction gearbox module 14 and an accessory gearbox module 16 . The gas generator module 12 generally has a compressor portion 18 , a turbine portion 20 , and a combustor portion 22 . These components are all generally symmetrically placed about the centreline CL of gas generator module 12 . Referring to FIG. 3 , both the reduction gearbox module 14 and the accessory gearbox module 16 are offset from the main engine centreline CL. The offset centreline of the reduction gearbox module 14 is denoted by OCL.
[0017] In this embodiment, the compressor portion 18 includes an air inlet 24 , a booster stage or boosted rotor type low pressure (LP) compressor 26 (which may be of the type described in co-pending application Ser. No. 09/680,281, incorporated herein by reference), and a centrifugal impeller 28 type high pressure (HP) compressor at the outlet end of a compressor air flow duct 30 . The air inlet configuration is relatively straight and generally parallel and concentric to each of the centreline axis CL, the compressor portion 18 and the turbine portion 20 , as will be discussed further below.
[0018] The turbine portion 20 of the gas generator module 12 is typical and generally includes turbine discs (not shown) connected to a set of drive shafts, in this case an inner LP turbine shaft 36 and an outer HP turbine shaft 38 . The HP shaft 38 drives the impeller 28 , while the LP shaft 36 drives the rotor 26 , the reduction gearbox module 14 and the accessory gearbox module 16 . One will appreciate, however, that these components may be driven by different shafts.
[0019] The reduction gearbox module 14 receives input power from an RGB tower shaft 40 drivingly connected, via bevel gear 42 and bevel gear 44 , to the LP shaft 36 . The tower shaft 40 extends at an angle to the main centreline CL and LP turbine shaft 36 , and in this case is roughly perpendicular thereto. The tower shaft extends through the inlet gas path 30 through a fairing 46 . A bevel gear set 48 transfers rotational power to an RGB input shaft 50 which, in turn, drives an RGB output shaft 52 through an epicyclic reduction gear train 54 . The output shaft 52 terminates (in this example) in a propeller flange 56 for connection of a suitable propeller (not shown).
[0020] The epicyclic reduction gear train 54 is typical and generally includes a central sun gear 60 , a plurality of planet gears 62 on a carrier 64 , mounted for rotation within a fixed outer ring gear 66 . The sun gear 60 is driven by the input shaft 50 and the planet gear carrier 64 drives the output shaft 52 .
[0021] The accessory gearbox module 16 is driven from the LP shaft 36 via an AGB tower shaft 70 . The AGB output shaft 72 is used to drive accessory devices, such as fuel pumps, starter generators, mechanical fuel controls, air/oil separators, and oil pumps, etc.
[0022] All rotating shafts are journalled by suitable bearings. Generally, the bearings of this embodiment include LP turbine shaft bearings 80 , HP turbine shaft bearings 82 , an roller bearing 84 and an ball and roller bearing combination 86 supporting the RGB tower shaft 40 , a ball bearing 88 and a roller bearing 90 journalling shaft 50 , and a ball bearing 92 and a roller bearing 94 journalling shaft 52 . A ball bearing 96 and roller bearing 98 support the AGB tower shaft 70 .
[0023] In use, the operation of the gas generator 12 causes output rotational power to be delivered by the LP turbine shaft 36 . As the LP shaft rotates, Which can be at speeds upward of 25,000 to 30,000 RPM, torque is transferred via bevel gear 42 and bevel gear 44 , to RGB tower shaft 40 , then through bevel gear set 48 to RGB input shaft 50 , and through reduction gear train 54 to the RGB output shaft 52 . The reduced speed of the output shaft 52 is typically around 2000 RPM, but depends on the application.
[0024] While it is known to have turbine engines with reduction gearboxes and output drive shafts which are offset from the main turbine shaft, such devices typically utilize spur gear trains to drive the output shaft. An example of such a configuration is shown in U.S. Pat. No. 4,825,645. The spur gear drive train, however, poses a large obstacle which must be negotiated by the gas path. In contrast, the shaft 40 of the present invention crosses the gas path relatively unobtrusively, housed in a fairing or other housing. Thus, a relatively simple means of locating the main or reduction gear box laterally beside the gas generator is provided. Also novel in the present invention is the use of a bevel gear set (i.e. gear 42 and 44 ) to take power directly from the LP shaft to drive the reduction gear box.
[0025] Many gas turbine engines have accessory gearboxes which are offset from the engine centreline. However, the present invention has a reduction gearbox module which is offset from the main centreline, driven by a drive shaft which is angled relative to the main turbine output shaft. This offset permits a substantially more compact design to be achieved, with the overall shape approximating the “short and fat” engine envelopes in aircraft designed to be powered by piston engines. It allows the reduction gearbox to be placed more or less laterally beside the gas generator module, significantly shortening the length of the overall unit.
[0026] When the offset centreline OCL of the reduction gearbox is sufficiently offset from the main centreline CL, the gas path is relatively unobstructed by the main gearbox and thus a straighter, “line-of-sight” inlet air flow is possible. Similarly, the present invention permits a parallel (rather than serial) arrangement of main gearbox and gas generator, which permits the overall length of the gas path to be substantially shortened. The benefits of a shorter, straighter gas path are well known. The straight inlet also allows “ram” air pressure effect increase the inlet air pressure in the turboprop when in flight, which improves engine output power and performance.
[0027] Also, the shorter inlet duct length reduces the area where de-icing is required, and the use of the boosted rotor multiplies the benefit in this respect.
[0028] The shaft 40 of the present invent ion extends at an angle to the main centreline CL (i.e. is not parallel to it), and in this case is almost perpendicular thereto. In fact, in this case, the shaft 40 is canted slightly aft to permit a placement for propeller flange 40 which is as close as possible to inlet duct 24 . The relative positioning of the gas generator module 12 and the reduction gearbox module 14 is a matter of design choice, and the amount of offset and the relative angles between the modules may vary, depending on the parameters of the intended application.
[0029] Advantageously, the present invention also permits the placement of the engine on the wing to be optimized. Typically, it is desirable to keep the engine relatively low on the wing to reduce losses, however the propeller of course cannot be permitted to touch the ground. The present invention can permit the prop to be positioned higher, relative to the wing, while the engine is kept lower, which is particularly advantageous in low-wing applications.
[0030] The offset output drive also permits the propeller in a turboprop application to include a double acting propeller pitch control, which offers an additional weight savings.
[0031] The placement of the reduction gearbox module 14 also permits the boosted rotor and high turbine rotor to be removed without disturbing the oil system, which reduces the potential for oil contamination.
[0032] The embodiment of the invention described above is intended to be exemplary only. Modifications may be made which do not depart from the spirit and intent of the invention disclosed herein. While a turboprop configuration is described, the design has application to other gas turbine configurations such as turboshafts, for example. The scope of the invention is, therefore, intended to be limited solely by the scope of the appended claims.
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A gas turbine engine including a gas generator module and a reduction gearbox module. The gas generator module has an axis which extends longitudinally along a centreline of the gas generator module, and the reduction gearbox module has an axis which extending longitudinally along the centreline of the reduction gearbox and is offset from said generator axis. The reduction gearbox is driven by an intermediate shaft angled relative to the turbine output shaft.
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RELATED APPLICATIONS
This application is a continuation of application Ser. No. 047,180 filed June 8, 1979, abandoned, which is a continuation of application Ser. No. 853,342 filed Nov. 21, 1977, U.S. Pat. No. 4,164,729.
BACKGROUND OF THE INVENTION
This invention relates to synchro to digital tracking converters in general and more particularly to an improved synchro to digital tracking converter which contains fewer components than those of the prior art and yet has a higher intrinsic accuracy.
Synchro to digital tracking converters are used most commonly to accept analog synchro information and translate that information into a digital format which can be understood by a digital computer. The net result of this translation is the ability of a computer to, for example, interrogate a synchro to determine the angular position of its shaft. A tracking converter differs from the other types of converters, i.e., successive approximation and sampling, in that there is no minimum conversion time required to generate the angular information. Furthermore, tracking converters most commonly have a feedback loop which simulates a Type II servo loop, which allows it to track a constantly changing input with no lag errors. (The velocity constant approaches infinity until the maximum tracking speed is reached.)
Basic to all tracking converters is the ability to accurately generate a steering voltage whose magnitude and phase contains information which causes the Type II control loop to null itself when the digital output angle β is representative of the analog input information θ. Most commonly, the steering voltage is proportional to sin (θ-β) because this expression does null itself as θ approaches β.
Most commonly, the function which is actually implemented is the trigonometric expression:
sin (θ-β)≠ sin θ cos β- cos θ sin β.
Sin θ and cos θ are given analog inputs to the converter. They are either provided directly, when the inputs are four wire resolver signals, or are generated by standard Scott "T" transformers from three wire synchro inputs. In order to implement the expression, it is necessary to generate information representing sin β and cos β.
The non-linear functions sin β and cos β are generated from the linear digital output angle β by means of an approximation which forms the "heart" of the converter.
Prior state of the art converters most typically generated the sin β, cos β approximation by use of two sets of precision ladder networks and two sets of switches.
Information was generated over a full quadrant )0°to 90°) and quadrant switching was required to artificially maintain the information in the first quadrant. Furthermore, a commonly used approximation was that: ##EQU1## where K 1 is the best fit constant from 0° to 90°, and is equal to 0.555R.
N is a running variable from 0 to 1 as the output angle β varies from 0° to 90°. This approximation is accurate to within ±1.8 arc minutes over the quadrant, when evaluated as a tangent function, i.e., when tan θ=(sin θ/cos θ)≠(sin β/cos β)= tan β. Since the end item accuracy is most typically four arc minutes, this inherent error is a significant portion of the total error budget.
The use of two ladder networks and two sets of switches represent duplication of the most costly and critical components in the converter. Furthermore, the impedance of the switch in the most significant bit of the ladder network, with a weight of 45°, represented a significant error source, since a 20 ohm error in series with a nominal resistance of 20,000 ohms (i.e., a 0.1% error) would be an error source of 1.35 arc minutes.
Thus, it can be seen that there is a need for a simpler, more accurate synchro to digital tracking converter.
SUMMARY OF THE INVENTION
The present invention provides such through the use of a new approximation which requires fewer components and yet has a higher intrinsic accuracy.
The new approximation generates information octally and uses digital complementing to generate the information over the balance of the quadrant. Octant selection is used to artificially maintain the information in the first octant. The approximation developed is that: ##EQU2##
Where K 1 is the best fit constant for a sine function from 0° to 45° and is equal to 0.316R.
K 2 is the best fit constant for a cosine function from 0° to 45° and is equal to 0.195755R.
K 3 is the constant at the end point and is equal to
K.sub.1 /(1+K.sub.1)=0.240122R
N is a running variable from 0 to 1 as β varies from 0° to 45°.
This approximation, when evaluated as a tangent function, is accurate to within ±0.5 arc minutes, significantly, better than the ±1.8 arc minutes attained by the conventional approximation.
Since sin (θ-β)=sin θ cos β- cos θ sin β ##EQU3## This equation is implemented using one precision ladder network and one set of single pole, double throw switches. Since the sin θ term has a scaling of K 2 /K 1 =0.61948 and since opposite polarities of sin θ and cos θ must be maintained so that the expression always sums toward zero, the proper scaling and phasing is maintained by the octant select circuitry which is required in order to artificially maintain the sin θ, cos θ information in the first octant.
Although the octal embodiment is shown, the single ladder concept is also usable over a quadrant with the well known constant 0.555R used.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a logic diagram of a sine-cosine generator according to the present invention.
FIG. 2 is a similar diagram of an embodiment for octant selection.
FIG. 3 is a block diagram of an overall conversion system utilizing the circuits of FIGS. 1 and 2.
FIG. 3A is a Table helpful in understanding the operation of FIG. 3.
FIGS. 4A-D combined are a logic circuit diagram of the stem of FIG. 4.
FIG. 5 is a logic diagram of the reference phasing block of FIG. 3.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 is a circuit-logic diagram illustrating the manner in which the approximation of the present invention is implemented. Synchro input voltages K 2 /K 1 sin θ and cos θ, developed in a manner to be described below, are provided respectively on lines 11 and 13. The sin voltage on line 11 coupled through a resistor 15 having a relative value K 2 and the cosine value on line 13 through a resistor 17 having a relative value K 1 . The sine voltage on line 11 is also provided to a resistor 18 having a relative value K 2 /K 3 . The line coming from the resistor K 2 is designated 21 and that from resistor 17 as 23. Both lines are coupled through a resistor ladder network by means of a plurality of single pole double throw switches. Thus, there are shown switches 25, 27, 29, 31, and 33. The switches will be implemented preferably using semi-conductor analog switching devices such as CD 4053 BF manufactured by R.C.A. Each switch has a control input. The control inputs for the respective switches being designated 25a, 27a, 29a, 31a and 33a. Each switch is shown as having two halves, i.e., two poles, one designated "1" and the other designated "0". This indicates that if, for example, a 1 input is present on a control input 25a, the 1 section of switch 25 will be closed. Similarly, if the input is a 0, and 0 side of the switch will be closed. The "1" sides of all of the switches 25,27,29, 31 and 33 have as their input the cosine signal on line 23. Similarly, all the "0" sides of the switches have as their input the sine signal on line 21. The outputs of both sides of each switch are tied together into a resistor, the resistors forming the ladder network. Thus, the output of the switch 25 is tied to a resistor 37 having a relative value 2R. The switch 27 is tied to a resistor 39 having a relative value 4R. The output of switch 29 is tied to resistor 41 having a relative value 8R. Between the switch 29 and the switch 31, there are a plurality of additional switches, not shown, the exact number depending on the resolution of the converter. The switch 31, has its output tied to a resistor 43 having a relative value 2.sup.(M-3) R where M is the resolution of the converter. The output of switch 33 is tied to a resistor 45 having the same value. The other sides of all the resistors 37, 39, 41, 43 and 45, along with resistor 19, are tied to a line 47 which is coupled to the inverting input of an amplifier 49 having a feedback resistor 51 of a value which will give a convenient scale factor in its feedback path. The respective switches 25, 27,29,31, and 33, are controlled by exclusive OR gates 53, 55, 57, 59 and 61. Each of the gates have as one input the 2 3 bit. The gate 53 has as a second input the 2 4 bit, the gate 55 the 2 5 bit, the gate 57 the 2 6 bit and the gate 61 the 2 n bit. The angle β is represented by the digital inputs to the exclusive OR gates 53, 55, 57 and 59. Gate 59 has its second input grounded. With the circuit of FIG. 1 the expression ##EQU4## is implemented as a voltage, where the K terms and the N terms are resistances and admittances. More precisely, ##EQU5## and similarly, the ##EQU6## is implemented as ##EQU7## a voltage propositional to cos θ sin β, and the voltage sum at the output of the operational amplifier 49 is the steering voltage proportional to sin θ cos β- cos θ sin β. The R/N term perhaps needs further explanation. The impedance in series with resistor 17 can be expressed as the parallel impedances ##EQU8## where each A 0 , A 1 etc. has a value of 0, if the switch is open, or 1 is the switch is closed. ##EQU9## ∴R N1 =R/N where N varies from 0 to 1 as the switches open and close, i.e., as β varies from 0° to 45°.
Similarly, the impedance in series with resistor 16 can be shown to be R N2 =R/1-N). (The second resistor 43 labeled 2.sup.(M-3) R which is controlled by the 2 3 bit is the roundoff resistor required to make the series of parallel resistors, with all switches closed, exactly equal to R. i.e., an infinitely long network M→∞.
It can be seen that each resistor of the ladder network is always coupled to either resistor 15 or resistor 17, but is never required to be switched to both, nor neither, resistor at the same time. Therefore, the one resistor network can be shared between implementation of the sin β function and implementation of the cos β function. This is a significant reduction in component cost, complexity and error sensitivity (there is no mistracking between networks as in the conventional implementation). No switches are required in series with resistors 15, 17 or 19, removing another significant error source. As noted above, such sharing is also possible when implementing the more conventional conversion using the constant 0.555R.
The new approximation demonstrates less sensitivity to switch impedance in the ladder network. An error of 0.1% caused by switch impedance in series with the most significant bit of the network causes an error of only 0.65 arc minutes, which is half the sensitivity displayed by the conventional approximation.
Conventional digital complementing is used to allow the octant information to be valid for the entire first quadrant. This is accomplished by taking advantage of the inherent symmetry of the sine and cosine functions about 45°. The exclusive OR logic which provides the complement capability also serves to isolate the digital output β from the actual switch control lines. Since these control lines are often sensitive to static electricity, when CMOS switches are used, the exclusive OR logic can be used to prevent the outputs from being damaged by static electricity, minimizing handling precautions required of the end item user. The octant select circuit is capable of inverting or non-inverting the cos θ term so that, regardless of the actual quadrant, the appropriate phase relationship is maintained. It also channels the larger of the sin θ, cos θ signals into the |cos θ| input on line 13, and similarly places the smaller signal into |sin θ| input on line 11 as a function of octant.
FIG. 2 illustrates the octant selection circuit and scaling. This circuit includes two operational amplifiers 71 and 73. The operational amplifier 71 is the one which provides the K 2 /K 1 sin θ signal on line 11. It has a feedback resistor 75 and an input resistor 77. The relative ratio of feedback to input is 0.618921. The amplifier 73 has a feedback resistor 79 and an input resistor 81 of equal value so as to result in a gain of 1. It provides -cos θ on line 13. The circuit also includes three switches 83,85 and 87, of the same type described above, in connection with FIG. 1. The sin θ signal from the resolver is the input to the "0" half of switch 83 and the "1" half of switch 85. The cos θ signal from the resolver is the input to the "1" half of switch 83 and the "0" half of switch 85. The outputs of switch 83 are tied together and coupled to the input resistor 77 of amplifier 71. Similarly, the outputs of switch 85 are tied together and coupled to the input resistor 81 of amplifier 73. Amplifier 71 has its non-inverting input grounded through a resistor 89. The non-inverting input to the amplifier 73 is controlled by the switch 87. The output of the switch 85 also forms an input to the "I" half of the switch 87. The output of this part of the switch is coupled through a resistor 91 to the non-inverting input. The output of this switch also couples to a resistor 93 having its other side connected to ground. The input to the "0" half of the switch 87 is also connected to ground. The switches 83 and 85 are controlled by an exclusive OR gate 95 having as inputs the second and third most significant bits. If only one of these is present, the exclusive OR gate will have a "1" output. This will couple the sine signal to the amplifier 73 and the cosine signal to the amplifier 71. If neither bit is present or if both bits are present, the cosine signal will be coupled to the amplifier 73 and the sine signal to amplifier 71. The switch 87 is controlled by an exclusive OR gate 97 having as its one input to +5 volts DC and as its second input the second most significant bit input. If the output of the gate 97 is a 1, the output of switch 85 is coupled into the input resistor 91. If it is a 0, the "0" half of the switch closes and the non-inverting input is essentially grounded. In a converter of this nature, as is well known, the most significant bit represents 180°, and the second most significant bit 90° and the third most significant bit 45°. Thus, the second most significant bit determines which quadrant the angle is in. Thus, this circuit acts to invert the cosine signal in the first and third quadrants and to not invert it in the second and fourth quadrants.
FIG. 3 illustrates an overall block diagram of the system. Assuming, that the input is from a synchro rather than a resolver, the synchro inputs S 1 , S 2 and S 3 are provided to Scott "T" transformer 101, the output of which will be cosine θ and sin θ on lines 103 and 104, respectively. These outputs are coupled into an octant selection module 103 providing as outputs a =cos θ signal on line 13 and a sin θ signal on line 11. These form inputs to the sine/cosine generator 109, described above in connection with FIG. 1. The octant select module 103 is controlled from three bits of the digital signal in a manner described more fully above in connection with FIG. 2. The output of the sine/cosine generator 109 is coupled into a summer 111 which takes the difference of θand β, θ being the analog angle from the synchro and β being the digital angle. This is implemented as amplifier 49 of FIG. 1. This output is coupled into a demodulator 113 having a reference input on line 115 obtained from a reference isolation transformer 117, through a comparator 120 which converts it to a square wave. In the demodulator, the sin (θ-β) signal is demodulated and forms an input to an integrator and voltage controlled oscillator unit 119. This module provides two outputs, a clock signal and a directional signal, respectively, on lines 121 and 123. These are inputs to an up-down counter 125, the clock being coupled into the count input thereof, and the direction signal on line 123 into the up/down input thereof. The output of the up-down counter 125 is the digital angle β. The third through nth bits thereof are coupled into a digital complement module 127, the output of which is the input angle β to the sine-cosine generator 109. The complement module is implemented with the exclusive OR gates of FIG. 1. The third bit is the complement bit. In other words, when that bit is absent, the digital angle is coupled through directly and when that bit is present, the complement of the angle is coupled through. The third bit is the 45° bit and thus, complementation takes place in every other octant. In general terms, in operation the sine-cosine generator 109 and the summing means 111 generate an error signal representative of the error between the actual angle θ and the digital output and β. This error is demodulated in the demodulator 113 and provided to the integrator in the module 119. The integrator adjusts itself in accordance with the error, the output of the integrator driving the voltage controlled oscillator. The output of the voltage controlled oscillator in turn increments the counter up and down to being the angle β into agreement with the angle θ.
Because the only constraint on the octant select circuit is to maintain opposite polarities between sin θ and cos θ in the same octants, a positive error or steering voltage would indicate a "positive" angular error, in other octants the same voltage would indicate a "negative" error. This would seemingly indicate that the phasing of the steering voltage was not containing the correct information. This phase information is interpreted by the phase sensitive demodulator 113 of FIG. 3, which is referenced by the phase of the reference voltage. The phasing of the reference voltage is changed versus the octant so that the phasing information of the steering voltage is always correctly interpreted by the phase sensitive demodulator by a reference phase module 118. The required logic for the octant select circuit 103, including which inputs the sin θ and cos θ information should be channeled to, which polarity (invert or non-invert) the cos θ channel should have and whether the reference voltage phasing should be inverted or non-inverted in order to correctly interpret the steering voltage, can be determined from the chart of FIG. 3A.
Implementation of the logic for the octant select circuit consists simply of the exclusive OR gate 95 decoding the second and third most significant bits of β as follows:
______________________________________1st 2nd 3rd Output______________________________________0 0 0 00 0 1 10 1 0 10 1 1 01 0 0 01 0 1 11 1 0 11 1 1 0______________________________________
When the output is a 0, the sin θ input is channeled to the "sine" output, and the cos θ input is channeled to the "cosine" output. When the output is a 1, the sin θ input is channeled to the "cosine" output, and the cos θ input is channeled to the "sine" output.
Implementation of the logic for the cosine invert/non-invert function is simply the 2nd M.S.B. through gate 97. For the 2nd M.S.B.=0, the cosine channel shall be non-inverted, for 2nd M.S.B.=1, the cosine channel shall be inverted. The switching controlled by this logic is standard in that the operational amplifier 73 is connected as a voltage follower for a non-inverting function and as a unity gain inverting amplifier for the inverting function.
FIG. 5 illustrates the implementation of the reference phasing inversion/non-inversion of block 118 of FIG. 3. As indicated, the reference voltage from the transformer 117 is coupled through a comparator 120 to generate a square wave. As shown by FIG. 5, the reference square wave is an input to an exclusive OR gate 201. The second input to gate 201 is from another exclusive OR gate 203 having as one input the first most significant bit. The second input to gate 203 is the output of an AND gate 205 having as inputs the second most significant bit and third most significant bit. This circuit has the following truth table:
______________________________________2.sup.1 2.sup.2 2.sup.3 V.sup.1 REFERENCE OUTPUT______________________________________0 0 0 0 non-inverted reference0 0 1 1 inverted reference0 1 0 1 inverted reference0 1 1 1 Inverted reference1 0 0 1 Inverted reference1 0 1 0 non-inverted reference1 1 0 0 non-inverted reference1 1 1 0 non-inverted reference______________________________________
The steering voltage thus generated is used to provide the required magnitude and phasing information to the feedback loop of FIG. 3 which typically simulates a Type II servo loop.
Thus the phase sensitive demodulator 113 generates a polarity sensitive d-c voltage from the 400 Hz steering voltage on line 112. This d-c voltage is integrated by a conventional operational amplifier integrator in block 119. The appropriate loop frequency stabilization can be incorporated into the same operational amplifier. The output is fed into a voltage controlled oscillator, also in block 119, which generates pulses at the appropriate frequency and which is used to increment up/down counts in the appropriate direction. The output of the counter 125 contains the output angle β directly, which is used to control the ladder network in generator 109 generating the steering voltage. This circuitry displays the capability to maintain a null at the steering voltage even when the counter is being rapidly changed i.e., when the converter is tracking a constantly changing input.
The feedback loop characteristic equation is typically ##EQU10##
It has an acceleration constant K a =40,000. The voltage controlled oscillator typically can generate a maximum frequency, before saturation, which allows a 14 bit resolution converter to track a constantly changing input at speeds up to 3600°/sec.
FIGS. 4A-D are a detailed diagram of the converter of the present invention. Parts which are identical to those previously described, will be given the same reference numerals. As previously described, the input signal is coupled through Scott "T" transformer 101. Isolation amplifiers 301 and 303 connected as voltage followers are provided. Each has a resistor 305 coupling the sine or cosine signal into its non-inverting input and an output resistor 307 from which negative feedback is coupled back to the inverting input. The outputs of these amplifiers are the inputs to the switches 83 and 85 described in connection with FIG. 2. The switches along with switch 87 are contained within a module designate U 11 . The outputs of the amplifier 71 and 73 on lines 11 and 13 are as described above. In the embodiment shown on FIG. 4A-D, in the sine-cosine generator 109, three switches, 251, 252 and 253, in parallel, all have their outputs coupled to the resistor 37 and are functionally equivalent to the switch 25. This is done to compensate for variations in switch resistance. Similarly, two switches in parallel, 271 and 272, feed the resistor 39. The additional switches not shown on FIG. 1 for the remaining bits are shown. Thus, there are switches 281, 282,283,284,285,286, and 287, in addition to the switches 25, 27, 29, 31 and 33 of FIG. 1. Associated with the respective switches 281-287 are resistors 291-297. The resistors 294 and 295 are made up of two resistors in parallel designated as 294a and b and 295 a and b. The relative resistance ratios remain as shown on FIG. 2, as will be described in more detail below. Naturally, with these additional switches, additional exclusive OR gates are required. Thus, in addition to the exclusive OR gates 53, 55, 57, 59 and 61, there are shown exclusive OR gates 261-267 associated respectively with the switches 281-287. Because the 2 3 bit must be coupled into each of these exclusive OR gates, drivers 309 having their inputs coupled to the 2 3 bit and their outputs coupled across a resistor network comprising two resistors 311 of equal value are provided. These outputs are then coupled to groups of the exclusive OR gates to provide the one input thereto. Because the drivers 309 invert the positions of the "0" and "1", inputs to the switches of FIGS. 4A-D are the inverse of those of FIG. 1.
The up/down counter 125 is made up of four counter stages 125a, 125b, 125c and 125d. The output of the ladder network, as described above, is the input to amplifier 49 with the feedback resistor 51 in its feedback path. The output thereof is the error or steering voltage. It is coupled through a capacitor 313 to a switch 315. Before explaining further the input at this switch, the generation of the reference phasing will be described.
Shown is the reference isolation transformer 117 and the comparator 120. As illustrated, the comparator 120 has a pull up resistor 319 coupling its output to +5 v. The reference voltage output of the transformer 117 is coupled across a voltage divider made up of two equal resistors 321 with the center tap thereof coupled to the non-inverting input of the comparator 120. The transformer is referenced to +5 volts in order to avoid voltages below ground potential. The comparator 120 provides a square wave voltage input to the exclusive OR gate 201 described above in connection with FIG. 5. That gate, along with gates 203 and 205 carry out the phase reversal as described above. The only difference with respect to FIG. 5 is that the one input to gate 205 is taken from the driver 309 and the second input from the output of gate 97 of FIG. 2 associated with the octant select circuit. This input is also coupled to 5 volts d-c through a pull-up resistor 323. The output signal of gate 201 on a line 325, is coupled through an inverter 327 to a switch 335. A voltage divider network including a resistor 331 and a Zener diode 333 between 15 v and ground is provided to supply a reference level for this part of the circuit on line 346. Switch 335 has as its input the output of the switch 315 described above. These two switches along with an amplifier 337, having a feedback resistor 339 and an input resistor coupled to its inverting input 341, form the phase sensitive demodulator. Construction here is essentially the same as that associated with amplifier 73 of FIG. 2. The output of the switch 335 is coupled to the non-inverting input of the amplifier 337 and to a resistor 343 which is coupled to the reference level on line 346. The second input of switch 315 is also coupled to the reference level on line 346. This level shifting permits operating between 0 and 15 volts rather than having positive and negative swings. Inverter 327 has its output coupled to +15 through pull-up resistor 329.
The output of the amplifier 337 is coupled through a resistor 345 to the inverting input of an amplifier 347 having in its feedback path two capacitors 399 and 351 in series with a resistor 353 in parallel across the capacitor 351. The reference line 346 is also coupled to the non-inverting input of amplifier 347 through a resistor 355 and capacitor 357 in parallel. This input of the amplifier 347 is also coupled through a resistor 359, to the output of an amplifier 361. Amplifier 347 and its associated components is the integrator of block 119 of FIG. 3.
Amplifier 361, which with its associated components forms the voltage controlled oscillator, has its inverting input coupled through resistor 363 and 365 to the output of amplifier 347. Its non-inverting input is tied to line 346. Capacitive feedback is provided from the output of amplifier 361 to its non-inverting input through a capacitor 367. An additional feedback capacitor 369 is inserted between the output and junction of resistor 363 and 365. A resistor 371 is also tied to this point and provides the 0 input to a switch 373 which has its one input coupled back from its output. The output of this switch is also tied to the output of the amplifier 361. The control line for this switch is 375 and is fed by an inverter 377, is self driven by a NAND gate 379. The NAND gate 379 has as an inhibit input an external signal on line 381. This inhibit input is also coupled to an inverter 383 with the output of which forms the control input for the switch 315. A pull-up resistor 316 is provided for inverter 383. The output of amplifier 361 is coupled through a resistor 385 to an amplifier 387. It is also coupled through a resistor 389 to the inverting input of an amplifier 391. These amplifiers are comparators for generating up and down counts for counter 125. The inverting inputs of amplifier 391 is also tied through a resistor 393 to ground. The non-inverting input of amplifier 391 is coupled through a resistor 395 to +5 v. Positive feedback from the output of amplifier 391 is accomplished through a resistor 397.
The inverting input of amplifier 387 is tied to +5 v through a resistor 399. It has a positive feedback through resistor 400. The outputs of amplifiers 391 and 387 are inputs to a NAND gate 401 which also has its two inputs tied to +5 v through pull-up resistors 403 and 405. The output gate 401 is coupled to inverter 407 which provides the second input to NAND gate 379. It is also coupled through a resistor 409 to the inverting input of an amplifier 411. The non-inverting input of amplifier 411 is coupled to ground through a resistor 413. A capacitor 415 is provided between ground and the non-inverting input. Feedback in the amplifier 411 is through a resistor 417 and a resistor 419. The junction of these two resistors is tied to the +5 volts lines which is also one side of the secondary of the reference transformer and to one input of a NAND gate 421. The second input of the NAND gate 421 is the output of the amplifier 411. This gate generates a busy signal indicating that conversion is taking place.
The outputs of the amplifiers 387 and 391, respectively, suppy the signals into the counter 125. A positive steering voltage, with respect to line 346, after demodulation will result in integrator 347 generating a negative output. This in turn will result in a positive output from VCO amplifier 361. When the VCO voltage goes negative by approximately 2.5 v with respect to line 346, the output of comparator 387 will go to zero. This output over line 501 provides an up count to counter 125. It also through gate 401, inverter 407, gate 379 and inverter 377 is coupled as the control input of switch 373 to reset the VCO amplifier 361 to start another cycle. Similarly, the comparator 391 responds to a positive going output of VCO amplifier 361, with respect to line 361, to provide a down count on line 503 and also to reset the VCO through the same path. Typical values for these various resistors are as follows:
______________________________________RESISTORS VALUES______________________________________305,409,94,365,316,329 10K307,311 5.1K77,81,79,339,353,385,395,419 100K91 57K93,51,343 240K75 61.948K17 1.9576K15 3.160K19 8.1523K37 19.9K39 39.92K41 79.88K291,341 160K292 320K293 640K294a 470K294b 820K295a 560K295b 2.0M296 5.1M297 10M45,43 20M399,405,403,414,413,417,323 20K319,321 30K389,393 200K397 910K400 710K331 6.3M371 1K345 300K355,363 51K344 62K359 6.8MCAPACITORS369 .001UF357 10PF399 .1UF351 .01UF313 .33UF415 33PF362 150PF______________________________________ZENER DIODES VALUES______________________________________314 IN751A333 IN755A______________________________________EXCLUSIVE OR GATES DM5486NAND GATES DM5400INVERTERS DM5406DRIVERS DM5400AMPLIFIERS LM747,LM101ASWITCHES CD4053BFCOUNTER DM54193COMPARATOR 120 LM139D______________________________________
As described previously, the new approximation generates more accurate information using less components and at less cost. The intrinsic error is ±0.5 arc minutes as compared to ±1.8. One ladder network is used as compared to two. One set of switches is used as compared to two. A 0.1% error in the M.S.B. results in an error of 0.65 arc minutes as compared to 1.3. There are no differential tracking errors due to mismatch of two networks over temperature.
Conventional and inexpensive CMOS switches can be used to drive the ladder network because:
(a) it is less sensitive to switch impedance
(b) the static electricity sensitive control logic is not exposed to the end item user.
The octant select and scaling circuit combine to provide not only the requisite functions but also:
(a) isolate the input Scott "T" transformer from mismatched loading-reducing errors
(b) eliminate switch resistance of quadrant select from being a direct error source in the approximation resistors.
Various modifications of the embodiment disclosed are possible, such as the following:
A. Invert/non-invert circuitry could be used for both the sin θ and the cos θ channels, thus maintaining the appropriate phasing of the steering voltage without requiring the need for invert/non-invert logic to change the phasing of the reference drive of the phase sensitive demodulator. Alternatively, inversion of the sine with appropriate selection logic is also possible.
B. The resistor 19 of FIG. 1 with the weight K 2 /K 3 could be connected to the sin θ function before it was scaled down by the ratio of K 2 /K 1 . This would change the value of the resistor to K 1 /K 3 .
C. The scaling of the cos θ function could be made K 1 /K 2 and the sin θ function kept at a unity gain with appropriate changes in value to the balance of the resistors.
D. The analog input could be a 4 wire 400 Hz resolver information, isolated by 1:1 transformers.
E. The analog input could be as shown on FIG. 3, but with an electronic Scott "T" used to generate sin θ, cos θ information.
F. The analog input could be a 4 wire resolver input with conventional operational amplifiers acting as isolation and voltage translators.
G. The analog inputs could be 60 Hz or any other appropriate frequency rather than 400 Hz or could even be d-c voltages.
H. The steering voltage could be used to control other, conventional types of feedback loops simulating Type 1 and/or Type 2 loops with various characteristics.
I. The steering voltage could be used to be interpreted by a comparator or similarly for use in a conventional successive approximation converter.
J. Digital complementing can be eliminated and/or quadrant selection used instead of octant selection by switching the "K 2 /K 3 " resistor 19 to the appropriate sin θ, cos θ output. This would require either pre-scaling of the sin θ, cos θ inputs so that the same value resistor could be used to either side, or two "K 2 /K 3 " resistors, used with single poles single throw switches, could be used if the appropriate difference in value is maintained in order to eliminate the extra pre-scaling.
K. The basic converter can be used in other standard alternative configurations, such as in two-speed devices, digital C.T.'s (where the output is the analog voltage proportional to the steering voltage sin (θ-β)) and similar devices.
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An improved ladder network for use in a converter utilizing a single ladder network with single pole double throw switches to simultaneously implement nonlinear sine and cosine functions.
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FIELD OF THE INVENTION
[0001] The invention concerns a nanowire structural element, a process for production of said and a micro-reactor system, specifically a microcatalyzer system.
BACKGROUND OF THE INVENTION
[0002] In “Chemistry in Microstructured Reactors,” Ang. Chem. Int. Ed. 2004, 43, 406-466 [: Applied Chemistry, International Edition], K. Jähnisch et al. have demonstrated the advantages that microstructured components have in chemical reactions and for analytical purposes. This has led to an increase in the importance that such systems have for chemical synthesis and analysis. In comparison to conventional reactors, these microstructures have a large surface area/volume ratio, which has a positive influence on the transference of heat as well as the process of the transportation of matter (see also: O. Wörz et al. “Micro-reactors—A New Efficient Tool for Reactor Development,” Chem. Eng. Technol. 2001, 24, 138-142).
[0003] Many known reactions have been carried out in microstructure reactors, including many catalytic reactions. For these, it is unimportant whether the reactions are liquid phase, gas phase or gas-liquid phase reactions. In order to take advantage of the potential activity of the catalyzer, the catalytic material is integrated in microstructured systems with various geometric forms. In the simplest case, the reaction material used for the construction of the micro-reactor consists in itself of the catalytically active substance (see also: M. Ficthner, “Microstructured Rhodium Catalysts for the Partial Oxidation of Methane to Syngas under Pressure,” Ind. Eng. Chem. Res. 2001, 40, 3475-3483). This means however that the catalytic surface is limited to the walls of the reactor. This disadvantage is partially resolved by means of optimized catalyzer/carrier systems. For the most part, current micro-structure reactors contain small particles or powder, which are incorporated in a channel.
[0004] Catalyzer filaments, wires and membranes are also used however (see also: G. Veser, “Experimental and Theoretical Investigation of H 2 Oxidation in a High-Temperature Catalytic Microreactor,” Chem. Eng. Sci. 2001, 56, 1265-1273). Metallic nanostructures, particularly those from transition metals, are known in heterogenic catalysis due to their high ratio of surface area/mass, resulting in lower production costs (see also: R. Narayanan et al. “Catalysis with Transition Metal Nanoparticles in Colloidal Solution: Nanoparticle Shape Dependence and Stability,” J. Chem. Phys. B, 2005, 109, 12633-12676).
[0005] Originally, research was concentrated on the examination of isotropic metal particles, and as a result, their catalytic characteristics have been studied at length. At present, however, many one-dimensional nanostructures have been analyzed regarding their use in heterogenic catalysis. The stabilization of these is a major problem. The incorporation of nanostructures on a carrier or storage of them in porous matter such as, e.g. Nafion is known from Z. Chen et al. “Supportless Pt and PtPd Nanotubes as Electrocatalysts for Oxygen-Reduction Reactions,” Ang. Chem. 2007, 119, p. 4138-4141, which leads however directly to a decrease in the utilizable catalyzer surface area. Furthermore, it must be noted that the catalytic activity is dependent on the distribution of the catalyzer material due to the diffusion processes. Accordingly, the nanoparticles significantly increase the surface area/volume ratio, but long-term stability of such reactors is relatively limited due to the following:
[0000] 1. Loss of contact between nanoparticles due to corrosion of the carrier.
2. Dissolving and renewed deposition or Ostwald ripening.
3. Aggregation of the nanoparticles in order to minimize the surface energy.
4. Dissolving of the nanoparticles and migration of the dissolvable ions.
[0006] Parallel wire and tube structures have already been used as glucose sensors (J. H. Yuan et al., “Highly Ordered Platinum-Nanotubule Arrays for Amperometric Glucose Sensing,” Adv. Funct. Mater. 2005, 15, 803), as electrocatalysts, for example, in alcohol oxidation (H. Wang et al., “Pd Nanowire Arrays as Electrocatalysts for Ethanol Electrooxidation,” Electrochem. Commun. 2007, 9, 1212-1216) and for hydrogen peroxide reduction (H. M. Zhang et al., “Novel Electrocatalytic Activity in Layered Ni—Cu Nanowire Arrays,” Chem. Commun. 2003, 3022). In these cases however, the nanostructures are freestanding, such that the arrangement is open and instable. Nielsch et al. have reported in “Uniform Nickel Deposition into Ordered Alumina Pores by Pulsed Electrodeposition,” Adv. Mater. 2000, 12, 582-586, that pulsed deposition is used for deposition of thin metallic foils.
[0007] All in all, there is still a great deal of potential for innovation in the field of nanotechnology.
GENERAL DESCRIPTION OF THE INVENTION
[0008] The invention has the object of providing a novel nanowire structural element which may be used in a variety of manners.
[0009] A further object of the invention is to provide a process wherein the production of a nanowire structural element having a hollow chamber-like structure is possible.
[0010] A further object of the invention is to provide a nanowire structural element having a hollow chamber-like structure with a large specific surface area and which is suited for use as a catalytic element.
[0011] The object of the invention is achieved by means of the object of the independent claims. Advantageous embodiments of the invention are defined in the dependent claims.
[0012] A process is provided for the production of a nanowire structural element which contains a nanowire array located between two cover layers such that a hollow chamber-like structure is created containing nanowires in a column-like formation. A so-called template based process is used as follows. The hollow chamber-like structure may also be envisioned as a chamber that may be open at one or more edges.
[0013] In a first process step (a), first, a dielectric template foil is created. Depending on which process is used for creating the nano-pores, the template foil is, for example, conventional synthetic foil, particularly a polymer foil, but said may also be a glass or mica foil, or an aluminum foil.
[0014] In a process step (b) a first electroconductive cover layer encompassing the surface is applied to a first side of the template foil, ideally a metal layer. Ideally, a thing metal layer, e.g. gold is sputtered onto said and subsequently said gold layer is reinforced electrochemically, with copper, for example. This has the advantage that, firstly, a relatively thin layer can be sputtered on. The first electroconductive cover layer has a double function: on one hand, it serves as a cathode for the subsequent electrochemical deposition procedure and on the other hand, later functions as a stable sealed cover layer for the nanowire structural element to be created, i.e. it remains as an integral component of the nanowire structural element to be created, and is not subsequently removed from said.
[0015] In a process step (c) numerous nanopores are created in the template foil, which fully penetrate the template foil at a right angle. Regarding the steps (b) and (c), there is no specific order implied by the letters. In regard to this, various alternatives to the order of the processes are possible, which can be derived from the following description.
[0016] In a subsequent partial step (d 1 ), starting at the inner side of the first cover layer, nanowires are grown within the template foil by means of electrochemical deposition, i.e. the nanopores are filled from the first cover layer by means of electrochemical deposition, wherein the nanowires develop in the nanopores. For this, the coated dielectric foil penetrated with pores and which has an electroconductive coating on one side, is placed in an electrochemical deposition device, wherein the first cover layer serves as a cathode for the electrochemical deposition procedure of the nanowires. By means of electrochemical deposition of metallic ions, the nanowires are then grown in the nanopores, wherein the nanowires grow from metal within the nanopores, in particular, developing directly on the first cover layer, and are thereby firmly joined to the first cover layer by reason of being grow together as integrally formed elements.
[0017] A process of this sort for the creation of nanowires is basically known, and has been demonstrated, for example, in the “Controlled Fabrication of Poly- and Single-Crystalline Bismuth Nanowires” by T. W. Cornelius et al., Nanotechnology 2005, 16, p. 246-249; and in the dissertation by Thomas Walter Cornelius, GSI, 2006; Florian Maurer, GSI, 2007, as well as by Shafqat Karim, GSI, 2007, which is hereby incorporated as a reference.
[0018] In these processes, however, only single nanowires are created. In contrast to this, in the present invention a freestanding structural element is produced, wherein the first cover layer is obtained and remains connected to the nanowires, and additionally, in a partial step (d 2 ) a second electroconductive cover layer coating the entire surface is applied to the opposite side of the template foil, which is also an integral component of the nanowire structural element to be created.
[0019] The first and second cover layers are integrally joined to the nanowires and cannot be removed later.
[0020] Accordingly, the nanowires, in the form of a column array, connect the two cover layers to each other. At this point in the process, directly after the creation of the second cover layer the template foil is still present sandwiched between the two cover layers, as both cover layers are applied directly to the template foil. At this point in the process, the template foil is penetrated by the nanowires, in the same manner as with concrete reinforcement.
[0021] When the sandwich-like arrangement consisting of the two cover layers and the template foil penetrated by a large quantity of nanowires has been established to the degree that both cover layers are of sufficient thickness and are thereby stable, the template foil, in a step (e), between the two cover layers, is dissolved, specifically by a chemical process, thereby forming a hollow chamber between the two cover layers, while the nanowires remain intact. If the template foil is a synthetic foil, said can, for example, be removed using a solvent. Other foils, such as glass and mica, are dissolved, for example, using hydrofluoric acid (HF). To dissolve aluminum oxide, diluted bases such as NaOH are sufficient. The template foil is reduced to such small components in the dissolving process that said components can be removed from the hollow chamber permeated with nanowires between the two cover layers without damaging the cover layers or the nanowires.
[0022] After the template foil has been fully removed, a structurally stable, hollow component remains, in which the two cover layers are connected by numerous nanowires, and are separated from and parallel to each other. Thereby, the first end of each respective nanowire is integrally connected to the first cover layer, and the respective second end is integrally connected to the second cover layer. Accordingly, as a result of the removal of the template foil, a structured hollow chamber is formed between the two cover layers, wherein the hollow chamber is contained on each side by the cover layers, and penetrated at a right angle to the two cover layers by parallel nanowires. The spaces between the nanowires and between the two cover layers are interconnected in the plane of the two cover layers in such a manner that in the plane of the cover layers, a two dimensional open celled hollow chamber-like structure is defined. In other words, a stable, freestanding nanowire structural element is constructed, which consists of the two closed cover layers and the column-like nanowire array contained in a sandwich-like manner between the cover layers and connected to said cover layers.
[0023] This nanowire structural element having a nanowire array enclosed at both surfaces, or respectively, a layered hollow chamber-like structure permeated with a nanowire array, is suited in an ideal manner for use as, for example, a microreactor component for heterogenic catalysis. Furthermore, the nanowire structural element remains stable over a long period of time, as the nanowires are firmly anchored, and do not lie, for example, loosely in microchannels.
[0024] In order to obtain a stable connection between the nanowire array and the second cover layer, the electrochemical deposition procedure is carried out at least until caps have been developed on the nanowires at the second side of the template foil. In order to create the second cover layer, furthermore, two particular possibilities are suggested in the following: The electrochemical deposition procedure is continued after the complete filling of the nanopores, wherein caps are generated on the nanowires on the second side of the template foil. In the course of continuation of the electrochemical deposition procedure, the caps grow together to form a coating covering the surface, and this surface covering layer increases in thickness when the deposition period is increased. Accordingly, one can continue the electrochemical deposition wherein the nanowires are generated for as long as necessary until the second cover layer has developed to the point where it forms a sufficiently thick, stable, surface covering layer. In this manner, the nanowires and the entire second cover layer form a unitary integrally formed complete structure consisting of electrochemically depositioned matter. For this, the partial steps (d 1 ) and (d 2 ) are carried out using the same electrochemical deposition procedure with the same electroconductive material.
[0025] Alternatively, the electrochemical deposition procedure according to partial step (d 1 ) for the generation of the nanowires is carried out until caps form on the nanowires of the second side of the template foil, and said caps grow together at least in part, but a second stable cover layer is not yet generated, and then arrested. The completion of the second cover layer is obtained thereby in a separate second deposition procedure, wherein a surface covering additional layer is depositioned on the partially merged caps, such that the stable second cover layer is created from the second layer by the partially merged caps and the surface covering additional layer. The, at least partially, merged caps form thereby a first partial layer of the second cover layer, and the additional layer forms a second partial layer of the second cover layer. The separate deposition can also be an electrochemical deposition, but can also be a PVD process, such as, for example, an evaporation process or a sputtering process. Even when the separate deposition procedure is an electrochemical deposition, a different material may be used for the second partial layer than that used for the nanowires and the caps. It has been shown to be particularly beneficial when the nanowires and the caps are generated using a pulsed electrochemical deposition procedure, and the second partial cover is created using a direct current process for the electrochemical deposition. As an example, the nanowires and the caps are created from platinum using a reversed pulse deposition and the second partial layer is created from copper using direct current deposition. By this means, the deposition period and the material costs can be reduced.
[0026] Accordingly, the second cover layer is either partially or fully formed of an electroconductive material by means of electrochemical deposition according to partial step (d 2 ), ideally of metal, on the second side of the template foil, such that the second cover layer is integrally joined to the nanowires.
[0027] At least the nanowires and the, at least partially, merged caps are accordingly depositioned preferably through pulsation. The pulsed deposition has at least the following alternatives:
[0000] 1) The deposition is carried out using pulsed deposition, i.e. deposition pulses alternating with deposition free diffusion periods.
2) The deposition is carried out by means of reversed pulse deposition, i.e. deposition pulses alternating with anodic counter pulses.
[0028] Both alternatives have the advantage that in the breaks between the deposition pulses, ions in the electrolyte solution can re-diffuse in the nanopores, which leads to a uniform development of the nanowires and the layer of caps which develops therefrom.
[0029] The first cover layer can be applied as an integral unit by means of a coating process such as, for example PVD, vaporization or sputtering. Ideally, the first cover layer is however generated at least in two layers, wherein the first partial layer is depositioned by means of PVD, e.g. sputtering or vaporization and said first partial layer is then reinforced, as the case may be, by means of electrochemical deposition, with a second partial layer of another material such as copper on gold.
[0030] Currently, two basic known processes for creating nanopores in the template foil are under consideration: firstly, ion radiation induced etching and secondly, anodizing of aluminum foil.
[0031] Reference is made regarding the production of nanopore arrays in anodic aluminum oxide to A. P. Li et al., “Hexagonal Pore Arrays with a 50-420 nm Interpore Distance Formed by Self-Organization in Anodic Alumina,” Journal of Applied Physics, 84-11, 1998, p. 6023-6026, and a review article by J. W. Diggle, Thomas C. Downie, And C. W. Goulding; p. 365-405 DOI: 10.1021/cr60259a005, which are hereby incorporated as references. Anodic aluminum oxide templates have the characteristic, in particular, that the nanopores are arranged in a regular hexagonal pattern.
[0032] With modification of etching properties, induced by ion radiation, a stochastic distribution of the nanopores is obtained. The production of ion track etched templates consists of the generation of nanopores in the following partial steps:
[0033] First, a commercially available synthetic foil, e.g. a polymer foil, is irradiated (c 1 ) with high-energy radiation, in particular with a highly energetic ion radiation, such as is available, for example, in the accelerator facility of the Gesellschaft für Schwerionenforschung mbH [: Center for Heavy Ion Research] in Darmstadt. As a result of the irradiation a large number of latent tracks cover the template foil. The tracks thereby indicate that the polymer structure of the foil is corrupted along the trajectory of each irradiation ion. In the un-etched state, these tracks are referred to as “latent.” They are then later enlarged to visible tracks by means of an etching process, creating the nanopores (c 2 ).
[0034] Ideally, the ion irradiation is first carried out and then, before etching, the first cover layer is applied. Once the first cover layer is applied to the template foil, the nanopores are etched from the latent ion-induced tracks. In particular thereby, the electroconductive metallic layer is applied to the template foil, and said is electrochemically reinforced, before the latent ion tracks are subjected to the chemical etching process. In this manner, the possibility of deposition of material from the first cover layer in the pores is avoided. By this means, it is possible to obtain an improved mechanical stability of the generated nanowire structural element. Furthermore, the pores are strictly cylindrical and do not taper at either end.
[0035] The result of the production process described above is accordingly a nanowire structural element with a hollow chamber-like structure which consists of an array of numerous nanowires arranged next to each other and two parallel, separated, closed surface cover layers, from which the template foil is removed. The two cover layers are integral components of the nanowire structural element and are not separated from the nanowires, but rather remain firmly integrally joined to the nanowires, and more precisely are integrally joined to each other by means of the electrochemical deposition procedure at the atomic/molecular level.
[0036] Accordingly, the nanowires extend perpendicularly between the two cover layers and the nanowires are integrally joined with their first ends to the first cover layer and with their second ends to the second cover layer such that the nanowires firmly connect the two cover layers to each other, and define a spacing between the two cover layers like an array of columns. In this manner, a stable sandwich-like nanostructure is formed with a two sided hollow chamber-like structure contained by the cover layers and permeated with the numerous columns of nanowires running through said.
[0037] Furthermore, the nanowires themselves are separated such that there are interconnected open spaces between the nanowires. The hollow chamber-like structure is open celled on the two-dimensional plane parallel to the tow cover layers, such that between the two cover layers a fluid can be introduced in the two-dimensional open cell hollow chamber-like structure in order to interact with the cylindrical surfaces of the nanowires forming a large surface area.
[0038] By means of the production process, there are however further certain structural properties of the constructed nanowire structural element. Because the nanowires are generated from electrochemical deposition materials, they can have a specific crystal structure which, for example, can be examined by means of X-ray diffraction.
[0039] Furthermore, the nanowires are directly, integrally joined at both ends to the respective cover layers due to the electrochemical deposition. As a result of the electrochemical deposition of the nanowires being carried out at least until the caps are formed and where applicable, until they have merged, the nanowires, and at least a part of the second cover layer form an integral unit. This too can be structurally proven, particularly if the nano wires form an integrally formed unit with the caps, and said are at least partially merged together. If the deposition procedure wherein the nanowires are created, after the merging of the caps has been completed and thereby the first partial layer of the second cover layer is formed and a deposition is made of a second partial layer in which the caps have merged in a separate step with modified process parameters, then this can also be structurally provable. This does not only apply to when the cover layer consists of two partial layers of different material.
[0040] The diameter of the nanowires is ideally less than or equal to 2000 nm, and particularly preferable is less than or equal to 500 nm, or respectively less than or equal to 100 nm. Currently, diameters of as little as 10 nm or even less appear to be possible to produce.
[0041] A larger aspect ratio allows for the production of a larger active surface area of the nanowire structural element. The aspect ratio of the nanowires is therefore ideally greater than or equal to 1:50, particularly preferred is greater than or equal to 1:100.
[0042] The distance between the two cover layers, or respectively, the length of the nanowires is determined by the thickness of the template foil, and is ideally less than or equal to 200 μm, particularly preferred is less than or equal to 50 μm.
[0043] The surface density of the number of nanowires is equally a measure for the active surface area and is ideally greater than or equal to n/F=10 7 cm −2 , particularly preferred is greater than or equal to n/F=10 8 cm −2 .
[0044] As a specific size for the active surface area of the nanowire structural element, the geometric specific surface of the nanowires per area of the nanostructure structure element and per length of the nanowires may be used. Accordingly, this geometrically specific surface area A v is:
[0000]
A
v
=
π
D
·
n
F
,
[0045] Wherein D is the average diameter of the nanowire and n/F is the surface density of the nanowires.
[0046] The geometrically specific surface area A v should be at least 1 mm 2 /(cm 2 μm); larger values however are preferred, specifically where A v is greater than or equal to 5 mm 2 /(cm 2 μm), greater than or equal to 20 mm 2 /(cm 2 μm) or even greater than or equal to 100 mm 2 /(cm 2 μm). Where applicable, values of up to 1000 mm 2 /(cm 2 μm) may even be obtained.
[0047] In the production of the nanowires with the reversed pulse process, the nanowires have a distinct <100> texture, or respectively, a crystalline structure. With certain metals such as, for example, gold, it may be advantageous to create the smallest crystallite possible. For this a crystallite size of less than or equal 4 nm is preferred, wherein in general an average crystallite size of less than or equal to 10 nm may be advantageous.
[0048] Due to the crystalline texture, the actual size of the surface area is larger than the geometrically specific surface area A v , which is based on the smooth cylindrical surface area, ideally by a factor of around 4-5.
[0049] According to a special embodiment of the invention, very small nanowire structural elements can be produced as well. For this, the template foil is irradiated through a mask with one or more openings such that the latent tracks are only generated in the region of the openings in the mask. In this manner, islands of latent tracks are created. After the etching and application of a first cathode layer on the first side of the template foil, a deposition of the nanowires to the nanopores and the caps to the second side of the template foil is carried out until caps on the second side of the template foil merge together to form islands. Subsequently, an electroconductive cap bridging layer is depositioned to the islands of merged caps thus connecting the islands with each other. This layer serves later as a second cathode layer. After this second cathode layer has been created, the first cathode layer is removed and the electrochemical deposition is continued in the opposite direction, wherein caps are now formed on the nanowires on the first side of the template foil. This deposition procedure is also carried out until the caps merge together in islands. Subsequently, the second cathode layer is removed and the template foil is dissolved. In this manner, numerous island-like nanowire structural elements are created with cover layers on both sides made of merged caps. These island-like nanowire structural elements are very small, e.g. having a diameter of a few micrometers to a few tens of micrometers, and if applicable a few hundred micrometers and are therefore denoted here as microelements.
[0050] It is even possible to design components with numerous island-like microelements. For this the second cathode layer is not removed, or one or more cover layers are applied before the template foil is dissolved. The newly applied cover layer(s) may be electroconductive or even electrically insulating. The size and distribution of the islands is predetermined by the openings in the irradiation mask. Accordingly, it is possible to produce a component consisting of numerous predetermined microelements distributed in an island-like manner on a substrate layer, wherein the island-like microelements are distributed on the substrate layer in a pattern predetermined by the radiation mask and which are integrally joined to the substrate layer. The substrate layer specifically, can be either electroconductive or electrically isolating, such that the microelements are either connected with each other electrically or insulated from each other.
[0051] A particularly preferred field of application for the nanowire structural elements produced according to the invention is heterogenic catalysis. This means one or more components serve as catalytic components, particularly for microcatalyzers. For this, it is advantageous to extend a cover layer on one or more of the faces over the edge and allow it to merge with the other cover layer, i.e. the respective edge is integrally connected to the nanowire structural element. It is particularly simple to first close all of the edges and then slice off, for example, two opposite edges of the nanowire structural element at right angles to the cover layers.
[0052] A microcatalyzer ideally contains a microstructured channel system with a fluid intake and a fluid discharge and at least one nanowire structural element as a catalyzer element between the fluid intake and the fluid discharge, in order that fluid may be introduced by means of the fluid intake to the hollow chamber-like structure between the two cover layers, fed through the spaces between the nanowires and then removed by means of the discharge from the hollow chamber-like structure. In this manner, the two-dimensional open cell hollow chamber-like structure of the nanowire structural element is formed between the two cover layers of the catalytic reaction volumes and the cylindrical surfaces of the nanowire form the catalytically active surface area which interacts with the fluid within the hollow chamber-like structure. Ideally, due to deposition, the nanowires are formed significantly of for example, platinum, in order that the catalytic element is a fully catalytic element.
[0053] In the following, the invention will be explained in detail using the embodiment examples and in reference to the illustrations, wherein identical and similar elements have the same reference symbols in part and the characteristics of different embodiments, particularly the procedures with and without radiation masks, can be combined with each other.
SHORT DESCRIPTION OF THE ILLUSTRATIONS
[0054] They show:
[0055] FIG. 1 An overview of the production of a nanowire structural element; (c 1 ) bombardment with ions, (b) application of an electroconductive layer, (c 2 ) etching of the ion tracks, (d 1 ) deposition of the nanowires and cap development, (d 2 ) deposition of a second metallic layer, (e) dissolving of the template.
[0056] FIG. 2 A three-dimensional schematic presentation of the nanowire structural element according to the invention.
[0057] FIG. 3 A three-dimensional presentation of the deposition device used for electrochemical deposition.
[0058] FIG. 4 A three-dimensional transparent exploded view of the deposition device for the deposition of the first cover layer.
[0059] FIG. 5 A three-dimensional transparent exploded view of the deposition device for the deposition of the nanowires and the second cover layer.
[0060] FIG. 6 A scanning electron microscope (SEM) image of a nanowire structural element according to the invention.
[0061] FIG. 7 An enlarged side view of the nanowire structural element from FIG. 6 .
[0062] FIG. 8 An SEM image of a nanowire structural element open at two sides and closed at two sides with a nanowire array of platinum nanowires.
[0063] FIG. 9 An enlarged SEM image of the nanowire array from FIG. 8 .
[0064] FIG. 10 An SEM image (edge length approx. 350 μm) of a platinum nanowire array subjected to direct current deposition with caps of different sizes.
[0065] FIG. 11 An enlarged detail from FIG. 10 (edge length approx. 100 μm).
[0066] FIG. 12 An SEM image of a Pt nanowire array subjected to direct current deposition, wherein the spatial distribution of the caps is shown and showing the locally contained development of caps.
[0067] FIG. 13 A cut-away enlargement of the image from FIG. 12 .
[0068] FIG. 14 An SEM image of a Pt nanowire array subjected to reversed pulse deposition with caps merged together to form a closed layer.
[0069] FIG. 15 An enlarged detail from FIG. 14 .
[0070] FIG. 16 An SEM image of a Pt nanowire array exposed to a mechanical load.
[0071] FIG. 17 An enlargement of a detail from FIG. 16 .
[0072] FIG. 18 A schematic exploded view of a microreactor with the nanowire structural element for flow-through operation.
[0073] FIG. 19 An enlargement of a detail of a perforated mask.
[0074] FIG. 20 An enlargement of a detail of an opening in the perforated mask from FIG. 19
[0075] FIG. 21 An overview of the production of numerous island-like microelement nanowire structural elements using a perforated mask.
[0076] FIG. 22 An SEM image of a microelement nanowire structural element with a view of one of the two cover layers.
[0077] FIG. 23 Another SEM image of the microelement nanowire structural element from FIG. 22 with a diagonal view of the extent of the microelement nanowire structural element.
[0078] FIG. 24 A schematic presentation of a sensor element with two microelement nanowire structural elements.
DETAILED DESCRIPTION OF THE INVENTION
Overview of the Production Process
[0079] The production of nanowire structural elements is based on a template based process. The partial steps of the process are schematically presented in FIG. 1 . For purposes of clarity, the letters correspond to the above mentioned process steps, which ideally are carried out in the order shown in FIG. 1 , i.e. (c 1 ), (b), (c 2 ), (d 1 ), (d 2 ), (e). It is, however, basically possible to use a different sequence, such as, to etch from two sides and subsequently to then first to apply the cathode layer partial step ((c 2 ) before (b)).
[0080] In accordance with FIG. 1 , first a template foil 12 is bombarded with ions 14 , wherein latent ion tracks 16 are generated in the substance of the template foil 12 along the trajectory (c 1 ). The template foil 12 is a polymer foil in this example, specifically, a polycarbonate foil.
[0081] Subsequently, on the first side 12 a of the template foil 12 , a thin, conductive metallic layer 22 a , e.g. gold, is sputtered onto said, forming a first partial layer.
[0082] Subsequently, the first partial layer 22 a is reinforced electrochemically with a second partial layer 24 a thus forming the first cover layer 26 a , which later serves as a cathode for nanowire deposition (b). For the electrochemical deposition of the second partial layer 24 a , the template foil 12 is mounted in the deposition device 82 shown in FIGS. 3-5 .
[0083] Subsequently, the template foil 12 coated on one side is then removed from the deposition device 82 , and the latent ion tracks 16 are chemically etched, wherein uniform nanopores 32 are created. Alternatively, the etching process may also be carried out in the deposition device 82 , in that the etching solution is placed in the appropriate cell 88 , and after completion of the etching, removed from said. A removal of the template foil and the replacement of said are not necessary. The diameter of the nanopores 32 can be controlled by controlling the etching time period (c 2 ).
[0084] Following this, the template foil 12 prepared in this manner is placed again in the deposition device 82 , and using the appropriate electrochemical process, the desired metal is depositioned in the nanopores 32 (d 1 ). When the nanowires 34 reach the ends of the pores 32 b at the second side 12 b of the template foil 12 , caps 36 begin to form. Under suitable conditions, the caps 36 merge together in a layer, forming a second, closed, but not yet sufficiently stable, metallic layer 22 b parallel to the first cover layer or cathode layer (d 2 ). This metallic layer, in this example, is a first partial layer 22 b , on which a second metallic layer is depositioned, forming a second partial layer 24 b (d 2 ). By means of the second partial layer 24 b , the caps which have merged together are embedded in a mechanically stable manner. In this way, the first and second partial layers 22 b , 24 b together form the second cover layer 26 b.
[0085] Finally, the polymer foil 12 is dissolved in an organic solvent suited to this purpose (e). The nanowire structural element 1 produced hereby in accordance with the invention is shown in FIG. 2 . At least the inner side facing the hollow chamber-like structure 42 of the second cover layer 26 b is at least partially formed hereby by means of an electrochemically depositioned layer 22 b.
[0086] The template based method has the advantage that many of the parameters can be specifically manipulated. The length of the nanowires 34 is determined by the thickness of the template 12 used and ideally is 10-100 μm, particularly preferred is circa 30 μm±50%. The surface density of the nanowires 34 is determined by the irradiation and for production of the array is ideally between 1×10 7 and 1×10 9 cm −2 . The diameter D of the nanowires 34 is determined by the time period of the etching and may be from ca. 20 nm to 2000 nm. The aspect ratio may have values of up to 1000.
[0087] The thickness of the two cover layers 26 a , 26 b is controlled through the time period of the respective electrochemical deposition, and should be thick enough that sufficient stability is obtained. Ideally, it is from ca. 5 μm to 10 μm.
[0088] Possible materials for the nanowires are metals which are suited to electrochemical deposition. Experience has been made with the following metals: Cu, Au, Bi, Pt, Ag, Cu, Cu/Co multilayer, Bi 2 Te 3 .
[0089] On the one hand a large number of nanowires 34 with small diameters D is desired, in order to obtain a large active surface area, and on the other hand a good mechanical stability should be obtained. The optimization of this depends on the material used and is adjusted to the needs accordingly.
[0090] For nanowire structural elements 1 with platinum nanowires 34 between copper partial layers 24 a , 24 b , a stable construction is produced with 10 8 wires per cm 2 having a diameter of 250 nm and a length of 30 μm. The aspect ratio here is 120. Such elements are suited, for example, for use as catalytic elements.
[0091] To produce the nanowire structural elements 1 , as an alternative to polymer foils 12 , other template foils such as hard template foils of aluminum oxide may also be implemented. The pore diameters which can be achieved here are between 10 and 200 nm. The density hereby is sufficient at ca. 6.5×10 8 -1.3×10 11 cm −2 . Porous aluminum oxide templates allow for the generation of uniformly arranged structures. It is also conceivable to use templates of ion track etched glasses and mica-films. With these templates, the removal of the template is achieved with hydrofluoric acid (HF), wherein the selection of the metal for the wire deposition and the metallic layers is somewhat limited.
Example 1
[0092] For the production of a nanowire structural element 1 , a circular shaped (r=1.5 cm) polycarbonate foil 12 (Macrofol®) irradiated with heavy ions 14 having an energy of 11.1 MeV/u and a fluence of 3×10 7 ions/cm 2 is used. Prior to the application of the conductive metallic layer 22 a , each side of the polymer foil 12 is irradiated for one hour with UV light, in order to increase the selectivity of the etching along the tracks 16 .
[0093] A gold layer 22 a is sputtered onto the first side 12 a of the polymer foil 12 , having a thickness of ca. 30 nm. This is reinforced by a potentiostatic deposition of copper from a CuSO 4 based electrolyte solution (Cupatierbad, Riedel) with a voltage of U=−500 mV, wherein a copper rod electrode serves as the anode (partial step 24 a ). The deposition is stopped after 30 minutes, at which point the copper layer 24 a is approx. 10 μm thick. Subsequently, etching is carried out from the untreated side 12 b of the template foil 12 at 60° C. with an NaOH solution (6 M) for 25 minutes and thoroughly rinsed with deionized water, to remove residual etching solution. At this point, the nanoporous template foil 12 is mounted in the deposition device 82 .
[0094] The deposition of nanowires 34 is carried out at 65° C. with alkaline Pt electrolytes (Pt-OH bath, Metakem). To generate the nanowires 34 and the caps 36 , the process of the reversed pulse deposition is used in order to compensate for the slow diffusion driven transportation in the nanopores 32 , and to obtain uniform development of nanowires 34 and caps 36 . Following a deposition pulse of U=−1.3 V for 4 seconds, there is an anodic pulse for 1 second at U=+0.4 V. After ca. 80 minutes, the deposition is stopped, and the development is checked. The caps 36 at this point are sufficiently merged for a partial cover 22 b , such that subsequently the potentiostatic deposition of a copper partial cover 24 b at U=−500 V for ca. 30 minutes can be carried out.
[0095] Finally, the template foil is removed, wherein the entire nanowire structural element with the template foil 12 is placed in a container with 10 ml dichloromethane for several hours. The solvent is replaced three times in order to fully remove residual polymers from the interior 38 of the structure which is enclosed on both sides by the cover layers. The hollow chamber-like structure 42 between the cover layers 26 a , 26 b with the nanowire array 35 can be seen in a scanning electron microscope (SEM) image in FIGS. 6 and 7 . The nanowires 34 here have a diameter of approx. 650 nm.
Example 2
[0096] In reference to FIGS. 8 and 9 , a further embodiment is presented, to show, among other points, that the parameter diameter and number of nanowires 31 can be varied. The etching period of 18 minutes results in nanowires 34 having a diameter of ca. 250 nm. The surface density (number per unit of surface area) is 10 8 cm −2 . For electrochemical deposition of the wires, the reversed pulse method is again used. A deposition pulse of U 1 =−1.4 V for 40 ms is followed by a shorter counter pulse of U 2 =−0.1 V for 2 ms and a pulse interval of 100 ms with a voltage of U=−0.4 V, which corresponds to an excess voltage of ca. 0 V. I.e., during the counter pulse, the system is in a state of equilibrium.
[0097] The nanowire array 35 is cut to a rectangular nanowire structural element 1 . Subsequently, a copper layer is potentiostatically depositioned onto the entire nanowire structural element again with a template foil 12 , in order that it is also closed on all sides. Following this, the two short ends are cut and the template 12 is then removed in order to obtain a nanowire structural element 1 which is open on two opposing ends and sealed on the other two opposing edges. It is important to realize that the edge 28 shown at the right in FIGS. 8 and 9 is sealed in a water tight manner, in that the upper cover layer 26 b is extended over the edge 28 . This nanowire structural element 1 is suited ideally for use as a catalytic element for conducting a fluid which is to be catalyzed, which can be introduced at one of the open ends and expelled at the opposite open end.
Construction for the Electrochemical Deposition
[0098] With reference again to the FIGS. 3-5 the electrochemical deposition of the nanowire array 35 consisting of numerous nanowires 34 is carried out using the deposition device 82 which shown in FIG. 3 in its entirety. It consists of a metal housing 84 , in which the metal sled containing one of the two electrolysis cells 86 , 88 can be inserted. Due to the good heat transfer properties of metal, it is possible to temper the deposition device by controlled external heating.
[0099] The electrolysis cells 86 , 88 made of PCTFE have on their two facing sides, in each case, circular openings 87 , 89 of the same size and can be pressed together firmly with a hand turned screw. A copper ring 92 between the two electrolysis cells 86 , 88 serves as a cathode, or respectively, to establish contact with the first cover layer for the electrochemical deposition.
[0100] With reference to FIG. 4 , for electrochemical reinforcement of the partial layer 22 a , the ion track etched template foil 12 is mounted between the two electrolysis cells 86 , 88 such that the partial layer 22 a , in this case, the sputtered gold layer 22 a , makes good contact with the ring shaped copper electrode 92 . On both sides of the copper ring being used as a cathode, electrolytes are injected into the electrolysis cells. The electrochemical reinforcement of the gold layer 22 a on the first cover layer 26 a is carried out with a first anode 94 , which is placed in the electrolysis cell 86 facing the partial layer 22 a , and an external power source with a control device.
[0101] After removing the template foil 12 and etching the nanopores 32 outside of the deposition device 82 , the template foil 12 is placed again in the deposition device 82 .
[0102] With reference to FIG. 5 , the template foil 12 which has been coated on one side and made porous is again placed in the deposition device 82 as in FIG. 4 for electrochemical deposition of the nanowires 34 , the caps 36 and, where applicable, the completion of the second cover layer 26 b , such that the first cover layer 26 a makes contact with the ring electrode 92 . At this point, deposition is carried out on the second side 12 b of the template foil 12 with a second anode 96 located in the electrolysis cell 88 on the side away from the first cover layer 26 a.
Examination of the Influence of the Electrochemical Deposition Conditions to the Development of the Nanowires and Caps
[0103] With the pulsed deposition procedure for generating nanowires 34 , a uniform length of the nanowires can be advantageously obtained at any point in time of the deposition. This can be explained, without claim to completeness and accuracy, in that the diffusion layers are kept relatively short in comparison to direct current deposition. In the intervals (equilibrium or counter pulse) between the deposition pulses, metal ions can re-diffuse such that on the entire electrode surface a nearly uniform concentration is obtained at the beginning of each deposition pulse, which results in a homogenous development. The diffusion layers barely overlap each other and irregularities in the surface are not enhanced.
[0104] It has been determined that the pulsed deposition procedure ensures a size distribution of the caps 36 and it is therefore advantageous to implement the pulsed deposition procedure at least for the production of the caps.
[0105] In order to examine the development of the caps, experiments using direct current deposition and reversed pulse deposition were carried out and compared.
[0000] Deposition with Direct Current
[0106] FIGS. 10 and 11 show a nanowire array formed using direct current after the formation of the caps 36 . This means that the production process is interrupted after the formation of the caps 36 and the template foil 12 is removed before formation of the complete second cover layer 26 b in order to more exactly study development of the caps. If the enlargement is not to large, the caps 36 seem to be more or less homogenous in their size distribution ( FIG. 10 ). It may be clearly seen however that the caps 36 are partially merged but there are a few larger gaps 37 between them. Furthermore, a few isolated caps 36 can be distinguished.
[0107] This becomes clearer in the enlargement in FIG. 11 , which furthermore gives an impression of the size distribution. The caps demonstrate both a strong fluctuation in their spatial distribution as well as in their connectivity to other caps 36 .
[0108] FIG. 12 shows a large surface of a nanowire array which was produced using direct current for the purpose of studying said, after removal of the template foil 12 before generating the complete second cover layer 26 b . It is possible to see that the development of the caps 36 is dependent on their position in the array.
[0109] With reference to the enlarged presentation in FIG. 13 , the spatial distribution of the caps is not homogenous. In particular, single isolated caps 36 , surrounded by numerous wires which do not show even the beginnings of caps, can be observed.
[0110] Without claim to completeness and accuracy, the main cause for the unevenness of the size distribution is seen to be the overlapping of the diffusion layers of individual nanoelectrodes which may be treated as nanowires. If the nanowires 34 are still deep in the nanopores 32 , the metal ions must travel a long distance through the planar diffusion. The longer the nanowires 34 grow, the higher they climb into the pores 32 and come closer to the end of the pore 32 b , where the development of the caps 36 begins. In connection with this, the diffusion layer extends further into the solution and the probability of overlapping other layers increases. In addition, it must be taken into consideration that the diffusion deviates from planar behavior as the development progresses, and in the end can be seen as completely hemispherical, as soon as the length of the nanowires 34 corresponds to the thickness of the polymer foil 12 .
[0111] Nanoelectrodes which are fairly close to others compete for metal ions in the solution and as a result develop more slowly than electrodes which are relatively isolated. The unevenness of the size distribution, accordingly, is a direct result of the randomness wherein the pores 32 are arranged.
[0112] Presumably the differences in the development rates assume greater importance as soon as planar and hemispherical diffusion occur in the same area. This is the case when a nanowire 34 has achieved the end of the pore 32 b and begins to form a cap 36 , while the wires 34 in the direct surroundings are still in the pores 32 where they are subjected to planar diffusion. Due to the naturally uneven surface of the polymer foil 12 , the pores 32 have different sizes from the beginning, wherein the nanowires 34 , when growing at the same rate will reach the ends of said pores at different times.
[0113] The possibility that nanowire arrays with caps generated using direct current for the production of a stable nanowire structural element 1 may be used has not been eliminated. Accordingly, further tests using pulsed deposition have been carried out in order to study the development of caps using this process.
Reversed Pulse Deposition
[0114] In the FIGS. 14 and 15 a platinum nanowire array 35 produced with reversed pulse deposition is shown. The caps 36 have merged to form a dense, closed layer 22 b made possible due to a better size distribution, which is the aim of the reversed pulse deposition. The layer 22 b is homogenous throughout the entire electrode surface and has no gaps. It should be noted that with this test as well, after the formation of the metal layer 22 b consisting of the fully merged caps 36 , the deposition procedure of the second cover layer 26 b is not yet fully carried out, and thus the second cover layer 26 b is not yet completely formed, but rather the metal layer 22 b consisting of the merged caps 36 represents only a partial layer 22 b of the second cover layer 26 b.
[0115] Should this incomplete array be exposed to a mechanical load in that, for example, it were to be squeezed with a forceps, the layer 22 b formed by the merged caps 36 would tear, as is shown in FIG. 16 , allowing for a view between the metal cover layers into the interior of the array. FIG. 17 shows a cut-away enlargement of a tear. It can be clearly seen that the parallel nanowires 34 hold the metal layers, with which they are integrally joined, at a uniform distance from each other.
[0116] The advantageously narrower size distribution of the caps 36 in comparison to those produced with direct current deposition can be explained, without claim to completeness and accuracy, by the shorter diffusion layer. In the intervals between pulses, metal ions can re-diffuse, and as a result, on the entire surface of the electrode a nearly uniform level of concentration at the beginning of each deposition pulse is obtained, which results in a homogenous development. The diffusion layers hardly overlap each other and irregularities in the surface are not enhanced.
[0117] In summary, it may be determined that the pulsed deposition of the nanowires 34 and the caps 36 , particularly when using reversed pulse deposition, allows for an excellent uniformity in development of the caps. In this case, the electrochemical deposition for the generation of the nanowires 34 is carried out at least until the caps 36 have formed on the nanowires, and said have merged to form a surface covering layer 22 b . Subsequently, either an additional deposition of electrochemical material is carried out in order to reinforce the layer 22 b comprised of merged caps 36 to the point where the stable second cover layer 26 b is generated, or, in a separate deposition procedure a second partial layer 24 b is created in which the merged caps 36 are embedded. For the production of the stable nanowire structural element 1 according to the invention, the template foil 12 is removed specifically after this step has first been completed. The thickness of the second cover layer 26 b should be at least 1 um. However, the thickness is preferably greater than 5 μm, e.g. between 5 μm and 10 um. The same applies to the first cover layer 26 a.
Structural Characteristics of the Nanowires
[0118] In the framework of the invention the structural characteristics of the nanowires 34 made of different materials is also studied. With electrochemically depositioned material it is possible, for example, to control the size of the crystallite. This affects the mechanical stability, the thermal and electrical transference characteristics as well as the surface area and thereby also the catalytic activity. Many characteristics can thereby be strategically influenced.
[0119] In particular, the structure of the nanowires 34 is studied using X-ray diffraction. For this, the texture as a function of the electrochemical deposition is analyzed.
[0120] Pt nanowires 34 produced using direct current show a clear <100> texture. The texture coefficient TC 100 is 2.32, wherein the maximum value is 3. The size of the crystallite is determined by the half-width of the platinum signal by means of the Scherrer equation, and is 8 nm. For catalytic application, the smallest possible crystallite is desired. The value given here lies in the range of the nanoparticles otherwise used for catalysis. Based on this it may be assumed that the crystallite size can be reduced even more through modification of the electrochemical deposition conditions.
[0121] When studying nanowires 34 which are produced using pulsed deposition, one finds no specific texture. The intensity of the signals corresponds to those of polycrystalline platinum.
[0122] Finally, a sample produced using reversed pulse deposition, is studied. This also shows a clear <100> texture, wherein the texture coefficient TC 100 is 4.6. The crystallites display accordingly a preferred orientation, wherein the degree of the alignment is 83%. An alignment of at least 50% in this case is advantageous.
[0123] The characterization by means of X-ray diffraction of nanowires 34 produced using different means has shown that the deposition conditions have an effect on the texture. Therefore, the structure of the nanowire can be strategically influenced. It is expected that even single crystalline nanowires can be produced when the surplus voltage is selected at a correspondingly low level.
[0124] The surface of a nanowire 34 does not correspond to smooth surface of a cylinder, which is the basis for the calculation of the geometrical surface, but rather, it displays numerous recesses and swellings in its contour which significantly increases the surface area. The actual size of the surface area is therefore typically larger than the geometrical surface area, because, among other reasons, the crystallites from which the nanowires 34 are constructed are very small. In order to obtain a more precise idea of the surface area of the nanowire arrays 35 , cyclovoltammetric measurements at 60° C. in 0.5 M H 2 SO 4 are carried out for a potential range of 0-1,300 mV with a standard hydrogen electrode. From the load in which the adsorption of hydrogen is transmitted, it is possible, taking into account the capacitive currents, to calculate the surface area of the electrodes. The cyclovoltammetric examination of nanowire arrays shows that the actual surface area is greater than the geometrical surface area by a factor ranging from 4-5.
Applications
[0125] As a catalyzes it is possible to connect a series of numerous nanowire structural elements 1 according to the invention. Based on measurements, the nanowire structural element 1 is suited individually for application in microstructured systems having three-dimensional structures wherein the internal measurement is less than 1 mm and for the most part lies between ten and a few hundred micrometers.
[0126] FIG. 18 is a schematic illustration of a microcatalyzer 100 , in which a nanowire structural element 1 according to the invention is placed between a fluid intake 102 and a fluid discharge 104 . It is conceivable that in a microcatalyzer 100 of this sort gas or fluid phase reactions can be carried out. For this purpose, a gas or fluid flow is directed under pressure through the microcatalyzer 100 .
[0127] The nanowire structural element 1 produced according to the invention furthermore inherently contains an electric contact to all of the nanowires located between the two metal layers. As a result, a controlled voltage may be applied to the nanowires 34 thereby enabling Electrocatalytic processes. Furthermore, the component may be used as an amperometric sensor.
Production of Microelements Using a Radiation Mask
[0128] In accordance with the invention, it is possible to create nanowire structural elements or nanowire arrays of very small sizes enclosed at both sides by the two cover layers 26 a , 26 b , in that the template foil 12 , a polymer foil in this example, is irradiated with heavy ions through a corresponding mask 110 (step (c 1 ) in FIG. 21 ). The mask 110 , e.g. a perforated mask, which is already applied in step (c 0 ) contains numerous openings 112 or perforations, wherein each opening 112 defines a future microelement 1 a . The mask 110 covers the template foil 12 during the irradiation, and latent ion tracks 16 are formed thereby, which are subsequently etched to form nanopores 32 in the areas which are not covered by the mask, i.e. at the openings 112 of the mask 110 . The layout and the shape of the microelement 1 a are determined therefore by the mask 110 .
[0129] This process is specifically for the production of many very small nanowire structural elements, as stated, in the form of microelements 1 a . The microelements 1 a which may be produced in this manner consist of two cover layers, integrally joined to the nanowires, which may have a diameter of less than 500 μm, and particularly less than 100 μm, and where applicable, even less, to a size of only a few micrometers. The diameter refers to the size measured on a plane parallel to the cover layers 26 a , 26 b or perpendicular to the nanowires 34 . For this, for example, the aspect ratio of the diameter of the microelement to the thickness of the microelement may be less than 20:1 or 5:1. The thickness of the microelement refers to the measurement perpendicular to the plane of the cover layers 26 a , 26 b (approximately the distance separating the two cover layers).
[0130] FIG. 19 shows a detail of an exemplary perforated mask 110 and FIG. 20 shows an enlargement of a perforation 112 . The perforations 112 of the perforated mask 110 in this example have a diameter of 50 μm, such that only nanowires 34 having a diameter of around 50 μm can be electrochemically depositioned, thereby allowing for the production of microelements 1 a having a diameter of approximately 50 μm.
[0131] The FIGS. 22 and 23 show one of the many microelements 1 a produced using the perforated mask 110 having a diameter of approximately 50 μm and a thickness of approximately 30 μm. The microelement 1 a has cover layers 26 a , 26 b sealed on both sides, which are integrally joined to nanowires 34 . The sealed metal layers 26 a , 26 b , comprised of merged caps 36 , 126 which have formed on both sides 12 a , 12 b of the template foil 12 , display a minimally larger fluctuation than the nanowire array 35 a in the interior. The irradiation is carried out with 10 8 ions per cm 2 . Accordingly, there are approximately 2,000 nanowires located between the metal layers 26 a , 26 b of the 50 μm microelement 1 a.
[0132] In this example, the perforated mask 110 for the ion irradiation has approximately 2,000 perforations 112 on the entire deposition surface of approximately 0.5 cm 2 , such that approximately 2,000 microelements 1 a with nanowire arrays 35 a in islands 116 in the template foil 12 can be created at once.
[0133] This production of many microelements 1 a with nanowire arrays 35 a in a template foil 12 is more labor intensive than the production of a nanowire array 35 over an entire deposition surface because additional steps must be carried out.
[0134] Prior to the etching of the latent ion tracks 16 into nanopores 32 , a metallic initial layer 25 is applied to the first side 12 a of the template foil 12 . The initial layer 25 serves in turn as a temporary cathode layer for the deposition of the nanowires 34 . This initial layer 25 is removed after the caps 36 have formed on the second side 12 b of the template foil 12 opposite the initial layer 25 , in order that the microelements 1 a can later be separated. A selective removal is possible, in particular, when the initial layer 25 is comprised of a different electroconductive material, in particular, a metal other than that from which the nanowires 34 are made.
[0135] Furthermore, the caps 36 which are formed first, those on the second side 12 b of the template foil 12 , using a selectively removable conductive layer, also preferably a metallic layer, are extended, forming a second temporary cathode layer 118 for further deposition. By means of the second cathode layer 118 , the nanowires 34 of the numerous island-like distributed microelements 1 a are in contact electrically with the caps 36 on the second side 12 b , and it is now possible to form second caps 126 on the nanowires 34 on the first side 12 a of the template foil 12 , on which the initial layer 25 is located. When a—sufficiently stable—metal layer of merged second caps 126 has formed over the nanowires 34 , the second temporary cathode layer 118 on the second side 12 b can be removed. Subsequently, the template foil 12 , a polymer matrix in this example, is dissolved and individual microelement nanowire structural elements 1 a are left having the size of the perforated mask 112 with cover layers 26 a , 26 b on each side, consisting of merged caps in each case. An example of a microelement nanowire structural element 1 a produced in this manner is shown in FIGS. 22 and 23 , wherein in a single processing, as described above, numerous microelement nanowire structural elements 1 a are produced.
[0136] Through the use of masks 110 for irradiation there is the advantage that the microelements 1 a with nanowire arrays 35 a produced can be used directly for integration, without further processing. The nanowire arrays 35 a of the microelements 1 a are open celled along the perimeter 132 in the plane parallel to the cover layers 26 a , 26 b , wherein the open cell characteristic is already generated in the deposition, such that an uncut microelement 1 a with a nanowire array 35 a is generated on all sides along the perimeter 132 . Mechanical loads, such as resulting from cutting the sides or edges 134 can in this manner be avoided. In FIGS. 22 and 23 it may be seen that the cover layers 26 a , 26 b are formed of merged caps 126 or 36 , and that these protrude somewhat at the edges. The edge is therefore formed by the naturally developed and merged caps. Here it is readily seen that the microelement nanowire structural element 1 a is produced using this special process and in particular, that it is uncut at the edges.
[0137] Because all nanowires 34 have electrical contact at both ends, the microelement 1 a with nanowire arrays 35 a is suited for production of miniaturized sensors. Due to the large number of wires, not only a high sensitivity but also a defect tolerance should result.
[0138] FIG. 24 shows an example of a sensor 150 , for measuring gas flow, temperature and use as a motion sensor, for example. The sensor 150 has at least one measuring device with a first and second microelement nanowire structural element 1 a , wherein the microelement nanowire structural elements 1 a in each case have cover layers 26 a , 26 b , wherein each of the two nanowire structural elements 1 a have electrical contact through one or both of the two cover layers 26 a , 26 b , wherein the two nanowire structural elements 1 a are contacted separately. A heating element is located between the two microelement nanowire structural elements, such as a microwire 152 which may be heated by means of applying voltage. The adjustment of the resistance of the sensor element 150 is used as a measure for the gas flow rate or the change in temperature, or change in position.
[0139] It is clear to the person skilled in the art that the preceding descriptions of embodiments are to be understood as exemplary, and that the invention is not limited to said, but rather, can be varied in numerous ways, without abandoning the scope of the invention. In particular, the production of a microcatalyzer is only one of many uses for the nanowire structural element of the invention. Furthermore, it is clear that the characteristics are, regardless of whether they are presented in the description, the claims, the illustrations or otherwise, also define significant components of the invention, even if they are described in conjunction with other characteristics.
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The invention concerns a nanowire structural element which is suited for implementation in, for example, a microreactor system or microcatalyzer system.
For the production of the nanowire structural element, a template based process is used wherein the electrochemical deposition of the nanowires in nanopores is ideally carried out at least until caps are formed and said caps ideally are at least partially merged together. After reinforcing the two cover layers the structured hollow chamber between the two cover layers is cleared by dissolving the template foil and removing the dissolved template material, wherein the two cover layers remain intact. In this manner, a stable sandwich-like nanostructure is constructed with a two-dimensional hollow chamber-like structure in the plane parallel to the cover layers contained on both sides by the cover layers and permeated in a column-like manner with nanowires.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is based on and hereby claims priority to Japanese Application No. 2000-69606 filed on Mar. 14, 2000 in Japan, the contents of which are hereby incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to equipment used for exchanging sensible heat, latent heat, or total heat energy between plural fluid streams.
[0004] 2. Description of the Related Art
[0005] Heat exchangers are classified into roughly two categories; those in which the heat exchange medium does not move and those in which the heat exchange medium moves.
[0006] Heat exchangers that move the heat exchange medium generally exchange heat efficiently. However, they also have a complicated structure.
[0007] One example of a movable heat exchange medium is a honeycomb rotor, in which the rotor has small passages that resemble the nest of a bee. The honeycomb rotor is cylinder shaped. For this device, gas is passed through the honeycomb rotor as it rotates.
[0008] A heat exchanger using a honeycomb rotor will exchange sensible heat if the sheet material forming the honeycomb rotor does not have water adsorption properties. The same heat exchanger will serve as a latent heat or total heat exchanger, if the sheet material carries a moisture adsorbing agent thereon.
[0009] Heat exchangers that use a honeycomb rotor have the problem that gas remains in the small channels of the honeycomb rotor as it rotates between the hot and cold fluids. Some of the retained gas from one zone is the released in the other zone. Therefore, when performing heat exchange between different kinds of gases, there may be some mixing of the different kinds of gases.
[0010] When this problem is serious, a purge zone may be provided to drive out gas remaining in the small channels of the honeycomb rotor. Within the purge zone a fluid is passed through the honeycomb rotor to expel gas retained within the rotor.
[0011] However, there is a problem associated with processing the gas which comes out of the purge zone. The gas which comes out of the purge zone is a mixture of gases. Previously, there were two ways of treating the purged and mixed gas: by discharging it into the atmosphere or by returning the gas mixture to one of the gas streams, which gas stream can tolerate having another gas mixed therein.
[0012] Both solutions have problems. In the former, the method of treatment is often not available because the purged and mixed gas may not be acceptable for discharge into the atmosphere for health or environmental reasons. Furthermore, even if discharge is acceptable, it detracts from heat exchange efficiency. The latter method of treatment is often not ideal because often neither of the gas streams can tolerate having another gas mixed therein.
SUMMARY OF THE INVENTION
[0013] In response to the difficulties discussed above and problems encountered in the prior art, a new heat exchanger, method of heat exchange and vehicle drive device having heat exchanger have been invented. The heat exchanger includes a honeycomb rotor, a drive unit and a gas movement device. The honeycomb rotor has at least two heat exchange passages and at least two purge zones provided respectively between the at least two heat exchange passages. The drive unit rotates the honeycomb rotor. The gas movement device circulates a gas through the at least two purge zones.
[0014] The gas movement device may include a blower, and the drive unit may include a motor. In this case rotation of the blower can be synchronized with rotation of the motor. Specifically, rotation of the blower can be synchronized with rotation of the motor by supplying the blower and the motor with power from a common inverter.
[0015] An adsorbent, such as a zeolite or a silica gel may be carried on the honeycomb rotor. The honeycomb rotor may be formed of alternately laminated flat and corrugated sheets.
[0016] The vehicle drive device having a heat exchanger includes a power source, a honeycomb rotor, a drive unit and a gas movement device. The power source emits exhaust gas and employs a fuel battery having an air intake. The honeycomb rotor has at least two heat exchange passages, with the exhaust gas being directed through a first of the heat exchange passages and inlet air being directed though a second of the heat exchange passages prior to being sent to the air intake of the fuel battery. The honeycomb rotor also has at least two purge zones provided respectively between the at least two heat exchange passages. The drive unit rotates the honeycomb rotor. The gas movement device circulates a gas through the at least two purge zones.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] These and other objects and advantages of the present invention will become more apparent and more readily appreciated from the following description of the preferred embodiments, taken in conjunction with the accompanying drawings of which:
[0018] [0018]FIG. 1 is the perspective diagram showing a first embodiment of heat exchange equipment of the present invention;
[0019] [0019]FIG. 2 is the perspective diagram showing a second embodiment of heat exchange equipment of the present invention; and
[0020] [0020]FIG. 3 is a perspective schematic view of an exemplary application for the heat exchange equipment shown in FIGS. 1 and 2.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0021] Reference will now be made in detail to the preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings, wherein like reference numerals refer to like elements throughout.
[0022] [0022]FIG. 1 is the perspective diagram showing a first embodiment of heat exchange equipment of the present invention. A honeycomb rotor 1 including honeycomb shaped chambers, is made of laminated aluminum sheets, for example. Corrugated sheets may be alternately laminated with flat sheets to form small channels. A moisture adsorbing agent, such as silica gel particles or zeolite, may be formed on the surfaces of the sheets.
[0023] Four seals 2 , 3 , 4 and 5 divide the honeycomb rotor 1 into a first passage 6 , a second passage 7 , a first purge zone 8 , and a second purge zone 9 . According to one embodiment, the central angle of the first passage 6 is the same as that of the second passage 7 , and the central angle of the first purge zone 8 is the same as that of the second purge zone 9 . Seals with the same shapes and analogous positions as seals 2 , 3 , 4 , and 5 are arranged on the opposite side of the honeycomb rotor 1 . The seals corresponding to seals 2 and 3 are partially visible in FIG. 1.
[0024] As the honeycomb rotor 1 turns, it rotates through the passages and zones formed by the seals 2 , 3 , 4 and 5 on the front side and the seals on the back side. That is, the rotor 1 rotates with respect to the seals.
[0025] Also shown in FIG. 1 are paths 11 , 12 representing conduits. The outlet of the first purge zone 8 and the inlet of the second purge zone 9 are connected by path/conduit 11 . The outlet of the second purge zone 9 and the inlet of the first purge zone 8 are connected by path/conduit 12 . Together, paths/conduits 11 and 12 , the second purge zone 9 , and the first purge zone 8 constitute an annular structure through which fluid is circulated. A blower 13 , which is perhaps arranged in the middle of path/conduit 11 circulates air through the annular structure and the zones 8 , 9 . The blower 13 , together with the paths/conduits 11 and 12 , serves as a gas movement device.
[0026] A geared motor 14 rotates the honeycomb rotor 1 through a belt 15 . The geared motor 14 rotates the honeycomb rotor 1 in the direction of arrow 16 . The geared motor 14 and the belt 15 together serve as a drive unit.
[0027] The action of the heat exchanger in the case where a cold and dry gas A passes through the first passage 6 and a hot and highly humid gas B passes through the second passage 7 will now be explained. The moisture contained in the hot and highly humid gas B is adsorbed on the honeycomb rotor 1 , within the second passage 7 . Simultaneously, the honeycomb rotor 1 is warmed. Conversely, gas B loses humidity and is cooled within the second passage 7 of the honeycomb rotor 1 .
[0028] Humidity adsorbed on the honeycomb rotor 1 is desorbed by cool and dry gas A in the first passage 6 and the honeycomb rotor 1 is cooled. Conversely, gas A is humidified and warmed by the honeycomb rotor 1 . In this way sensible heat and latent heat are exchanged between gas B and gas A.
[0029] The operation of the first and second purge zones 8 , 9 will now be explained. First, immediately after small channels of the honeycomb rotor 1 pass seal 7 on the front side and the corresponding seal on the back side (passes the second passage 7 ), gas B remains in the small channels of the honeycomb rotor 1 . Blower 13 then sucks gas B out of the first purge zone 8 and sends gas B through path/conduit 11 and into the second purge zone 9 . With further rotation of the honeycomb rotor 1 , gas B in the second purge zone 9 moves to the second passage 7 where it is mixed into the flow of gas B.
[0030] Immediately after small channels of the honeycomb rotor 1 rotate past seal 5 on the front side and the corresponding seal on the back side (passes the first passage 6 ), gas A remains in the small channels of the honeycomb rotor 1 . Blower 13 then drives gas A out of the second purge zone 9 and sends gas A through path/conduit 12 and into the first purge zone 8 . With further rotation of the honeycomb rotor 1 , gas A in the first purge zone 8 moves to the first passage 6 where it is mixed into the flow of gas A.
[0031] As described above, it may be desirable for gas A flowing in the first passage 6 and gas B flowing in the second passage 7 to not be mixed. In order to prevent the mixing of the gas A flowing in the first passage 6 with the gas B flowing in the second passage 7 , it may be preferable to set the flow velocity of the blower 13 so that it is sufficient for gas to emerge from the first purge zone 8 and from the second purge zone 9 during the time that it takes the honeycomb rotor 1 to rotate one half of a rotation. That is, gas should be able to move from the inlet of one of the purge zones 8 , 9 , to move through one of the paths/conduits 11 , 12 and to arrive at the inlet of the other purge zone 9 , 8 in the time it takes an incremental part of the honeycomb rotor 1 , which is located between one set of seals 2 , 3 or 4 , 5 , to rotate and become located between the other set of seals 4 , 5 or 2 , 3 . If the rotor rotates at a rate of n rpm, it takes t 1 seconds for the rotor to rotate one half a turn, where
t 1 = 1 n · 1 2 · 60 seconds
[0032] On the other hand, if blower 30 moves gas at a velocity v, and the length of one of the paths/conduits 11 , 12 is L, then it takes a time t 2 for gas to travel from one of the purge zones 8 , 9 to the other of the purge zones 9 , 8 , where
t
2
=L/v
[0033] Although in the above embodiment the central angle of the first purge zone 8 equals the central angle of the second purge zone 9 , it is not necessary to make the central angles equal.
[0034] In order to change the flow rate or the heat exchange efficiency between gases, the rotational frequency of the honeycomb rotor 1 may be varied. In order to maintain the speed of the blower 13 relative to the speed of the honeycomb rotor 1 , it is preferable to synchronize the blower 13 with the geared motor 14 by using a common inverter as a power source. Using a common inverter is ideal because when the rotational frequency of the honeycomb rotor 1 increases, the volume of gas discharged from the blower 13 increases at a proportional rate. When the rotational frequency of the honeycomb rotor 1 decreases, the volume of air discharged from the blower 13 decreases at a proportional rate.
[0035] As mentioned above, a geared motor may be used to rotate the honeycomb rotor 1 . The geared motor 14 may be a synchronous motor 14 having a stator and a rotor, with rotation of the rotor being synchronized with an AC frequency. When both the geared motor 14 and the blower 13 are supplied with power from a common inverter, the rotation of the geared motor 14 will be synchronized with that of the blower 13 . Generally, the blower 13 is powered with three phase electric current, and the geared motor 14 is powered with single phase electric current. In this case, to allow use of a single inverter, the geared motor 14 can be powered by one of the three phases supplied to the blower 13 .
[0036] [0036]FIG. 2 is the perspective diagram showing a second embodiment of the heat exchange equipment of the present invention. The difference of this second embodiment from the first embodiment is that the direction of the blower 13 is reversed. That is, in the second embodiment, the flow of the purge gas in the paths/conduits 11 and 12 is in the opposite direction to that of the first embodiment.
[0037] [0037]FIG. 3 is a perspective schematic view of an exemplary application for the heat exchange equipment shown in FIGS. 1 and 2. In FIG. 3, heat is exchanged between inlet air 17 supplied to a fuel battery 18 and exhaust gas 19 . For example, the fuel battery 18 may be an automobile fuel battery. Such fuel batteries 18 use hydrogen 20 as a fuel, which is oxidized with oxygen contained in the inlet air 17 . The oxidation generates electricity and produces water vapor as the exhaust 19 . To improve efficiency, the air fed to the fuel battery 18 should be warm and rich in both oxygen and moisture. The exhaust gas 19 discharged by the fuel battery 18 is hot and rich in moisture, but oxygen deficient. With the configuration shown in FIG. 3, the honeycomb rotor 1 can exchange heat between the hot exhaust gas 19 and the cool inlet air 17 . Also, moisture from the exhaust gas 19 can be adsorbed on the honeycomb rotor 1 and desorbed by the inlet air 17 . The additional moisture may increase the efficiency of the fuel battery 18 .
[0038] Because of the different oxygen concentrations, it is important that mixing between the exhaust gas 19 and the inlet air 17 be minimized. The present invention enables this to occur.
[0039] Although the above embodiments describe the honeycomb rotor 1 as containing a moisture adsorbing agent, it is possible to perform sensible-heat exchange between gas A and gas B using a honeycomb rotor that contains no moisture adsorbing agent.
[0040] Furthermore, heat exchanger examples were given for exchanging heat between gases such as gas A and gas B. However, the invention can be used to exchange heat between any gases, such as between nitrogen or hydrogen.
[0041] Even if heat exchange is performed between different kinds of gases, the amount of gas mixing is very small. That is, because the heat exchange equipment of the present invention is constructed as described above, when the heat exchange equipment performs heat exchange between the gases flowing in plural passages, the mutual mixing of the gases flowing in each passage can be made extremely small. Furthermore, the heat exchange equipment of the present invention minimizes mixing of the gases while maintaining a high heat exchange efficiency.
[0042] Moreover, the passages and the charge zones of the heat exchanger of the present invention may be completely sealed so that gases are not emitted. With sealing, the gases flowing through the passages are not discharged to the atmosphere. Therefore, the heat exchanger can exchange heat between gases for which discharge to the atmosphere is undesirable.
[0043] Although preferred embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that changes may be made in these embodiments without departing from the principle and spirit of the invention, the scope of which is defined in the appended claims and their equivalents.
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A heat exchanger includes a honeycomb rotor, a drive unit and a gas movement device. The honeycomb rotor has at least two heat exchange passages and at least two purge zones provided respectively between the at least two heat exchange passages. The drive unit rotates the honeycomb rotor. The gas movement device circulates a gas through the at least two purge zones. The gas movement device may include a blower, and the drive unit may include a motor. In this case rotation of the blower can be synchronized with rotation of the motor. A vehicle drive device includes a power source that emits exhaust gas. The power source has a fuel battery having an air intake. Heat may be exchanged between the exhaust gas and air supplied to the air intake.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to acoustic ground vibration detectors which are used to detect vibrations in the ground and render them audible. Such ground vibration detectors are used inter alia in disaster control and rescue work, especially for detecting knocking sounds from persons buried under the surface and locating the trapped persons.
2. Description of the Prior Art
Known ground vibration detectors operate with one or more three-component geophone probes. These three-component geophone probes contain three individual geophones operating on electrodynamic principles to detect vibrations in the ground. The effective axes of vibration of the individual geophones are positioned like the three axes x, y, z of a three-dimensional, rectangular system of coordinates;see e.g. the leatlet "3D unit", July 1984 of the Dutch company Sensor Nederland bv, 2251 AP Voorschoten. This arrangement enables the three-component geophone probe to detect P-waves (primary waves or longitudinal waves), S-waves (shear waves or transverse waves) and O-waves (surface waves). These different types of waves are propagated at different velocities; the high frequency primary wave has the highest propagation velocity, the low frequency shear wave a medium velocity and the surface wave is propagated at the lowest velocity.
The geophone probes of the known ground vibration detectors are connected by a cable to an amplifier arrangement by which the signals corresponding to the ground vibrations received by the individual geophones are rendered audible, e.g. in hoadphones, and processed to locate the source of the ground vibration.
The known ground vibration detectors are, however, not entirely satisfactory as they are only able to process frequencies within the audible range, i.e. above 30 Hz or thereabouts. In some cases, it is necessary to detect ground waves at very low frequencies far below the range to which the human ear is receptive. Thus it has been found, for example, that in areas of soft ground or compacted sand or areas covered with grass or rubble or loose stone, ground vibrations at audible frequencies, say above 30 Hz, may be entirely absent, at least if these areas are at some distance from the source of the ground vibration, e.g. from a person trapped underground, but in such cases these areas still carry ground vibrations at a very low frequency which could be described as "ground infrasound".
SUMMARY OF THE INVENTION
It is an object of the present invention to provide an acoustic ground vibration detector having at least one three-component geophone probe which is capable of detecting ground vibrations and rendering them audible for location even if their frequency is below the human audibility limit.
It is a further object of this invention to provide a particularly sturdy acoustic ground vibration detector in which each three-component geophone probe is connected by a simple two-cord cable to an amplifier arrangement to render the detected ground vibrations audible.
Lastly, it is an object of the invention to provide a ground vibration detector in which the detected ground vibrations are rendered audible by simple and reliable means in that the signals corresponding to the ground vibrations actuate a sound frequency generator to produce an audible signal.
In the acoustic ground vibration detector according to the invention, the three individual geophones of each three-component geophone probe arranged along the three axes of a three-dimensional, rectangular coordinate system are electrically connected in series. This arrangement deliberately foregoes the differential reception of separate signals for each of the three axes and instead produces a mixed signal which is common to the three axes because it has been found that infrasound ground vibrations which are at a frequency below the range of the human ear can thereby be detected much more clearly than by means of individual signals.
There is also the important constructional advantage that a simple two-core cable can be used to connect the three-component geophone probe to the amplifier arrangement. This is particularly important when the geophone probes are to be laid out in chains or carpets for exact location. The signals corresponding to the infrasound ground vibrations, which are not directly audible, e.g. with a frequency of 5Hz, are readily and reliably made audible by the ground vibration detector according to the invention by means of the fact that throughout their duration these frequencies activate a sound-frequency generator by way of a high speed relay, e.g. a Reed relay, so that the sound frequency generator emits an audio signal at a fixed frequency within the hearing range of the human ear, e.g. at 2.5 KHz, which is rendered audible. The ground vibration detector according to the invention is particularly suitable for locating buried persons in difficult terrain in which relatively high frequency vibrations are only propagated over short distances, if at all. Moreover, it serves to protect important objects by registering infrasound ground vibrations produced by footfall sound; but the detector is, of course, not limited to such applications since it can also be used to detect ground vibrations of a higher frequency and render them audible.
The high-speed electronic relays used may be, for example, field effect transistor circuits, but in the embodiment of the ground vibration detector which is preferred at the present time the preferred high-speed relay used is a Reed relay because it is very simple to set up, in contrast to transistor circuits, and responds to very brief impulses, in the millisecond range.
Moreover, due to its construction, the apparatus has an accurately defined threshold voltage such that the output signal of the operation amplifier must lie above or, respectively, below this threshold so that the Reed relay will switch on or off. This operation with a threshold voltage prevents creeping or wobbling contact and eliminates any interferences in the output signal of the operation amplifier which lie below the threshold voltage. Since the individual geophones have a natural frequency below 10 Hz and preferably below 4.5 Hz, they are particularly sensitive in the required frequency range of infrasound ground vibrations, which extends right down to below 2 Hz. To suppress unwanted resonance vibrations at the natural frequency, the individual geophones may be damped by an ohmic damping resistor connected in parallel. The resistance of this resistor is calculated to make the sensitivity of the geophone as frequency-independent as possible, also in the region of its natural frequency that is, to keep the sensitivity/frequency curve as flat as possible. A filter capacitor connected in parallel with the series circuit of the three individual geophones eliminates interference signals of a higher frequency, e.g. stray radio frequencies.
If the sound frequency generator is supplied from a source of direct voltage, i.e. is connected to a direct voltage source through the Reed relay, a storage capacitor connected in parallel with the sound frequency generator may enable the sound frequency generator to continue in operation for some time after decay of the Reed relay, i.e. for longer than the duration of the particular ground vibration signal. The audibility of very brief ground vibration signals is thereby improved.
In the preferred exemplary embodiment, the sound frequency generator is a piezoelectric signal transmitter which converts a direct voltage directly into an audible signal and thus constitutes a second frequency generator and sound transmitter combined in a single unit.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention together with further advantageous details thereof will now be described with reference to an exemplary embodiment schematically illustrated in the drawings, in which
FIG. 1 is a block circuit diagram of an acoustic ground vibration detector having two different three-component geophone probes,
FIG. 2 shows schematically the three-dimensional arrangement of a three-component geophone probe for the ground vibration detector of FIG. 1,
FIG. 3 is the electric circuit diagram of a three-component geophone probe for the ground vibration detector of FIG. 1,
FIG. 4 is the electric circuit diagram of the amplifier arrangement of the ground vibration detector of FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
As shown in FIG. 1, an acoustic ground vibration detector 10 for detecting infrasound ground vibrations of a frequency down to below 2 Hz and rendering them audible comprises two vibration receivers in the form of three-component geophone probes 11 and 11a and an amplifier arrangement 19,20. The two three-component geophone probes 11 and 11a differ only in the form of their housing.
The housing of the geophone probe 11 comprises an elongated, circular cylindrical casing 12 extending into a truncated cone-shaped section 13 at the free end of the probe. By virtue of its external form, the geophone probe 11 is particularly suitable for use in boreholes into which it can be introduced with the truncated cone section 13 forwards. The housing 12, 13 contains three individual geophones G x , G y and G z (not shown in FIG. 1) extending along the three axes x, y and z of a three-component dimensional rectangular coordinate system.
The three-component geophone probe 11a has a parallelipiped or rectangular housing 14 which also contains three individual geophones G x , G y and G z . As shown in FIG. 2, these individual geophones are orientated along the three axes x, y and z of a three-dimensional, rectangular coordinate system so as to be placed at rightangles to the walls of the housing 14.
FIG. 3 is the electronic circuit diagram of the three-component geophone probe 11a and is identical to the electric circuit diagram of the geophone probe 11. Each individual geophone G x , G y and G z has two output terminals 15 and 16. The three individual geophones are electrically connected in series so that their terminals are all arranged in the same direction. Each individual geophone has a damping resistor R D connected in parallel therewith. Each individual geophone has a natural frequency of about 4.5 Hz so that the geophones are very sensitive also at the low frequency range of infrasound ground vibrations. The magnitude of resistance of the damping resistors R D is calculated on the one hand to suppress unwanted resonance vibrations and, on the other hand, to keep the sensitivity/frequency curve as flat as possible right into the region of the natural frequency. A filter capacitor 26 is connected in parallel with the whole series circuit of the three individual geophones. This filter capacitor 26 short-circuits interference signals at a higher frequency, in particular stray radio frequency signals. The two output terminals A and B of the series circuit are connected to the amplifier arrangement 19,20 by a simple, two-cord cable 17 as shown in FIG. 1. A communicator 18 connected into the cable 17 can be used to switch selectively to the cylindrical three-component geophone probe 11 or the rectangular (parallelipiped) three-component geophone probe 11a. The switch is only functionally represented in FIG. 1. Constructionally, it is best positioned at the amplifier arrangement. It can also be replaced by plugs, across which the geophone probe can alternatively be connected.
Details of the amplier arrangement 19,20 are shown in FIG. 4. The two output terminals A and B of the series circuit of the individual geophones are connected to two input terminals 21 and 22 by the two-cord cable 17. The input terminal 22 is earthed at M 1 and connected to the negative input terminal of an operation amplifier 19 by a series resistor R V . The input terminal 21 is directly connected to the positive input terminal of the operation amplifier 19. The output terminal 23 of the operation amplifier 19 is connected back to the negative input terminal of the operation amplifier 19 through the series circuit composed of a fixed resister R 1 and an adjustable resistor R p . The required degree of amplification can be adjusted by means of the adjustable resistor R p . The excitation coil of a Reed relay 24 is connected between the output terminal 23 and the earth point M 2 and is therefore actuated by the output signal of the operation amplifier 19. The Reed relay has a threshold voltage determined by its construction and amounting to about 2 V so that the relay is switched on and off, respectively, when the output voltage of the operation amplifier 19 exceeds or falls below this threshold. The output terminal 23 is in addition connected to a capacitor 25 to suppress natural high frequency vibrations of the operation amplifier 19.
The operation amplifier 19 is supplied symmetrically with current from two batteries 30 which are connected on one side to earth M 3 and on the other side to the operation amplifier 19 by a terminal of an On/Off switch 29. A trimming resistor R e serves to adjust the offset voltage at the output terminal 23 to zero.
The circuit arrangement f 1 described so far (see also FIG. 1) comprising the operation amplifier 19 which functions as direct voltage amplifier amplifies the extremely low frequency signals which are transmitted from the three-component geophone probe 11 or 11a by way of the two-cord cable 17 and correspond to the detected infrasound ground vibrations. The corresponding output signal at the output terminal 23 of the operation amplifier 19 activates the Reed relay 24 so that a normally open contact of the Reed relay 24 remains closed whenever and so long as the output signal exceeds the threshold voltage of 2 V of the Reed relay.
The normally open contact of the Reed relay 24 forms part of a circuit arrangement f 2 which produces an audible signal of about 2.5 KHz when the normally open contact is closed and thus indicates by its audible sound at 2.5 KHz the presence of a low frequency ground vibration signal which in itself is not audible. For this operation, the circuit arrangement f 2 comprises a sound frequency generator in the form of a piezoelectric signal transmitter 20 which is connected to a battery 27 by its two current supply terminals 31 and 32 by way of the normally open contact of the Reed relay 24. When the signal transmitter 20 is supplied with direct voltage from the battery 27, i.e. when the normally open contact is closed, the signal transmitter 20 directly produces an audible sound of about 2.5 KHz. A storage capacitor 28 is connected in parallel with the current supply terminals 31 and 32. This capacitor 28 charges up when the normally open contact is closed and discharges through the signal transmitter 20 when the normally open contact has opened again so that the signal transmitter 20 can continue to operate for a short time after the normally open contact of the Reed relay 24 has opened. The audibility of very brief ground vibration signals is thereby improved.
When the ground vibration detector is to be put into use, it is switched on by means of the switch 29 and one of the two three-component geophone probes 11 or 11a is selected by means of the commutator 18. The selected three-component geophone probe is introduced into a borehole or placed on the ground. Any infrasound ground vibrations, for example with a frequency in the region of 2 to 8 Hz, detected by at least one of the three individual geophones of the three-component geophone probe give rise to a signal at the input terminals 21, 22, and this signal is amplified by the operation amplifier 19. The amplified signal at the output terminal 23 of the operation amplifier 19 causes the normally open contact of the Reed relay 24 to be closed for the duration of the ground vibration signal so that a 2.5 KHz sound is produced by the signal transmitter 20, thereby rendering the ground vibration audible. The degree of amplification produced by the operation amplifier 19 is adjusted by means of the adjustable resistor R p so that in the event of any undesirable interferences, the voltage of the output signal of the amplifier 19 will remain below the threshold voltage of the Reed relay 24 and the interferences will therefore not give rise to an audible signal. In addition, several geophone probes laid out in chains or carpets may be used for improved location.
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In an acoustic ground vibration detector for the detection of infrasound ground vibrations, comprising at least one three-component geophone probe, the three individual geophones of said geophone probe are electrically connected in series and act upon an operation amplifier whose output signal activates a Reed relay. The activated Reed relay switches on a sound signal transmitter which produces an audible acoustic signal for the duration of the ground vibration signal. The acoustic ground vibration detector is intended in particular for locating buried persons. Moreover, it serves to protect important objects by registering infrasound ground vibrations produced by footfall sound.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates generally to tinted or colored glass and, in one particular embodiment, to a method of making colored glass in a float glass process.
[0003] 2. Technical Considerations
[0004] In a typical float glass process, glass batch materials are melted in a glass furnace to produce a glass melt. The glass melt is poured onto a bath of molten metal, typically tin, in a float bath. The glass melt is drawn across the top of the molten tin to form a dimensionally stable float glass ribbon.
[0005] To form a colored glass sheet, one or more colorant materials are added to the glass batch materials. For example, the primary colorant in green colored glass compositions is iron, which can be present in ferric (Fe 2 O 3 ) and ferrous (FeO) forms. Other common colorants include transition or rare earth metal oxides such as cobalt, nickel, chromium, manganese, and titanium, erbium, neodymium, and selenium in its elemental or ionized states, depending on the desired color of the glass sheet. These colorants are added to the glass batch material and become homogeneously dissolved throughout the resultant piece of glass.
[0006] In producing conventional colored glass, the relative amounts of these colorants is closely monitored and controlled within an operating range to provide the glass with the desired color and spectral properties for a particular use. Varying the colorants outside of this operating range or inadequately melting these colorants in the glass melt can detrimentally effect the final color and light transmittance characteristics of the glass as well as the melting qualities of the glass composition. Additionally, some blue or green colored glass compositions contain selenium as one of the major colorants. However, a problem with selenium is that it is highly volatile at the temperature is used for conventional glass manufacture. The selenium can rapidly volatilize before it can be incorporated into the glass and can thus affect the final glass color. Selenium volatilization can also lead to other production problems, such as, unacceptable furnace emissions, color streaks, and poor color control.
[0007] If more than one color of glass is in production, a separate furnace is required for each glass melt composition. This increases the capital investment required and makes color changes difficult. Alternatively, in the same furnace, it takes days or more than a week to change glass color from one to another, during which process hundreds of tons of out-of-color specification glass might be discarded or recycled. This glass color change process can be particularly long if it involves changing from an intensely colored product to a lightly colored product.
[0008] Therefore, it would be advantageous to provide a method of making colored float glass that eliminates or reduces at least some of the problems described above.
SUMMARY OF THE INVENTION
[0009] A method of making colored glass in a float glass process comprises melting glass batch materials in a furnace to form a glass melt and transporting the glass melt into a float glass chamber having a flame spray device. The glass melt forms a float glass ribbon in the float chamber. At least one coloring material is supplied to the flame spray device to form a spray having coloring particles. The spray is directed onto the float glass ribbon to diffuse the coating particles into the surface of the float glass ribbon to form a glass sheet of a desired color.
[0010] A particular method of making colored glass in a float glass process comprises melting glass batch materials in a furnace to form a glass melt and transporting the glass melt into a float glass chamber having a flame spray device. The glass melt forms a float glass ribbon in the float chamber. Two or more coloring materials are supplied to the flame spray device to form a spray having coloring particles. The spray is directed onto the float glass ribbon to diffuse the coating particles into the surface of the float glass ribbon to form a glass sheet of a desired color.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a graph of transmittance (%) versus wavelength (nanometers) for Example 1;
[0012] FIG. 2 shows XRF amount of oxides of cobalt [Co] and iron [Fe] incorporated inside the glass surface for case one samples of Example 2 described below (with [Fe] from the base glass excluded);
[0013] FIG. 3 shows XRF amount of [Co] and [Fe] incorporated inside the glass surface for case two samples of Example 2 described below (with [Fe] from the base glass excluded);
[0014] FIG. 4 shows haze from case one samples of Example 2 described below;
[0015] FIG. 5 shows haze from case two samples of Example 2 described below;
[0016] FIG. 6 shows color change of case one and case two samples for Example 2 described below; and
[0017] FIG. 7 shows the optical transmittance of case one and case two samples of Example 2 described below.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0018] As used herein, spatial or directional terms, such as “left”, “right”, “inner”, “outer”, “above”, “below”, and the like, relate to the invention as it is shown in the drawing figures. However, it is to be understood that the invention can assume various alternative orientations and, accordingly, such terms are not to be considered as limiting. Further, as used herein, all numbers expressing dimensions, physical characteristics, processing parameters, quantities of ingredients, reaction conditions, and the like, used in the specification and claims are to be understood as being modified in all instances by the term “about”. Accordingly, unless indicated to the contrary, the numerical values set forth in the following specification and claims may vary depending upon the desired properties sought to be obtained by the present invention. At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claims, each numerical value should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques. Moreover, all ranges disclosed herein are to be understood to encompass the beginning and ending range values and any and all subranges subsumed therein. For example, a stated range of “1 to 10” should be considered to include any and all subranges between (and inclusive of) the minimum value of 1 and the maximum value of 10; that is, all subranges beginning with a minimum value of 1 or more and ending with a maximum value of 10 or less, e.g., 1 to 3.3, 4.7 to 7.5, 5.5 to 10, and the like. Additionally, all documents, such as, but not limited to, issued patents and patent applications, referred to herein are to be considered to be “incorporated by reference” in their entirety. In the following discussion, the refractive index values are those for a reference wavelength of 550 nanometers (nm). Any reference to amounts, unless otherwise specified, is “by weight percent”. The total iron content of the glass compositions disclosed herein is expressed in terms of Fe 2 O 3 in accordance with standard analytical practice, regardless of the form actually present. Likewise, the amount of iron in the ferrous state is reported as FeO, even though it may not actually be present in the glass as FeO. The term “total iron” means total iron expressed in terms of Fe 2 O 3 and the term “FeO” means iron in the ferrous state expressed in terms of FeO. The term “redox ratio” means the amount of iron in the ferrous state (expressed as FeO) divided by the amount of total iron (expressed as Fe 2 O 3 ). Selenium is expressed in terms of elemental Se and cobalt is expressed in terms of CoO. Chromium and titanium are expressed as Cr 2 O 3 and TiO 2 , respectively. As used herein, the terms “solar control” and “solar control properties” mean characteristics or properties which affect the solar properties of the glass, such as visible, infrared (IR) and/or ultraviolet (UV) transmittance and/or reflectance of the glass. As used herein, the term “essentially free of Se” means less than or equal to 3 ppm, such as less than or equal to 2 ppm, such as less than or equal to 1 ppm, such as less than or equal to 0.5 ppm, such as less than or equal to 0.1 ppm, such as no intentional addition of Se to the glass composition.
[0019] Float glass compositions typically have a base portion and major colorants. By “base portion” is meant the major constituents of the glass without the major colorants. By “major colorants” is meant materials intentionally added to provide the glass with a color in a desired dominant wavelength range. Although the invention can be practiced with any type of conventional glass, the general principles of the invention will be described with respect to a conventional soda-lime-silica glass composition. An exemplary soda-lime-silica type glass has a base portion characterized as follows (all values are in weight percent):
[0000]
SiO 2
65 to 75
B 2 O 3
0 to 5
Na 2 O
10 to 20
CaO
5 to 15
MgO
0 to 5
Al 2 O 3
0 to 5
K 2 O
0 to 5
[0020] SiO 2 is the principle component for the glass. Na 2 O and K 2 O impact the melting characteristics of the glass. MgO and CaO impact glass durability and affect the divitrification temperature and viscosity of the glass during molding. Al 2 O 3 also influences glass durability.
[0021] It is also known to add iron to the glass batch materials. For example, in one non-limiting embodiment, the total iron (Fe 2 O 3 ) is present in an amount of 0.7 wt. % to 0.9 wt. %, such as 0.7 wt. % to 0.85 wt. %, such as 0.73 wt. % to 0.81 wt. %. The iron, typically in the form of iron oxides, provides the glass with one or more functions. For example, ferric oxide is a strong ultraviolet radiation absorber and operates as a yellow colorant in the glass. Ferrous oxide is a strong infrared radiation absorber and operates as a blue colorant. The amount of ferrous oxide and ferric oxide (with or without the presence of other major colorants) can be adjusted to provide the glass with a desired color. The redox ratio of the glass can be, for example, in the range of 0.2 to 0.4, such as 0.25 to 0.35.
[0022] In a typical float glass process, selected colorants would be added to this basic composition to become mixed in with the other components and affect the final color of the glass. However, in the practice of the invention, rather than adding major colorants to the glass batch materials, the glass is provided with a desired color while the float ribbon is in the float chamber, as described below.
[0023] In the practice of the invention, the glass batch materials are melted in the furnace to form a glass melt. The glass melt can be clear glass or can have a first color. For example, for iron containing glass, the glass may have a slight greenish tint. The glass melt is poured into the float chamber and onto the molten metal. However, once in the float chamber, the glass is imparted with a different color than that of the glass melt. This is accomplished by providing a flame spray device in the float chamber above the glass ribbon. A suitable flame spray device is commercially available from Beneq Oy of Vantaa, Finland. A flame spray device is also described in WO 01/28941. In a flame spray device, coating materials are atomized to form a spray having coloring agents, such as coating particles. In the practice of the invention, this spray is then directed on to the hot float glass ribbon and the particles become defused into the surface or the upper portion of the float glass ribbon to impart the glass sheet with a desired color. The coating particles can be metal oxide nanoparticles. The coloring agents defuse into the glass and react with the glass matrix producing a characteristic color. This color can be changed simply by changing the coloring agents supplied to the flame spray device. Thus, no separate color glass furnaces or lengthy color change period are required and material consumption is therefore optimized. Also, rather than being homogeneously mixed throughout the glass, the coloring agents in the invention are only present at or near the top surface of the glass sheet. This reduces the overall amount of coloring agent required to make glass sheets of a desired color.
[0024] This process can be practiced anywhere in the float chamber but it is believed to be more practical at locations where the temperature of the float glass ribbon is in the range of 400° C. to 1,000° C., such as 500° C. to 900° C., such as 500° C. to 800° C., such as 600° C. to 800° C., such as 700° C. to 800° C.
[0025] It has been found that using a conventional flame spray device in a float chamber can provide resultant glass sheets of varying color dependent upon the coating material supplied to the flame spray device. For example, iron (e.g., iron oxides) provides a red or pink color to the glass sheet. Cobalt (e.g., in the form of CoO) provides a blue color. Silver provides a yellow color. A mixture of iron (e.g., iron oxides) and manganese (e.g., MnO) provides a gray color. The perceived color and/or the darkness of the glass will increase by increasing the density of the nanoparticles into the glass surface. As an additional benefit of the invention, since iron oxide nanoparticles incorporated into the glass surface produce a red or purple-pink color, this colorant (alone or in combination with other colorants) can be used as a replacement for selenium in the glass melt to alleviate the problems with using selenium described above.
[0026] Exemplary aspects of the invention will now be described. However, it is to be understood that the invention is not limited to these specific examples.
Example 1
[0027] In this example, a 0.2364 inch thick piece of Solex® Glass (standard) was compared to the same type of glass but having its surface modified by cobalt oxide and iron oxide nanoparticles to change the glass color from green to gray or blue.
[0028] Samples of Solex® glass were coated according to the following process. The glass pieces were placed in a pre-heated coating chamber. When the glass temperature reached the desired temperature, the coloring metal oxides were deposited by a flame spray device (Beneq nHALO device) onto and into the surface of the glass. Nanosized metal oxide or elemental particles entered the glass matrix via diffusional flow or ionic exchange. The glass was placed in an annealing furnace (500° C.). The glass was cooled down to room temperature under controlled cooling conditions. Table 1 shows the optical properties modeled for this example.
[0000]
TABLE 1
Total Iron
in glass
Co 2 O 3
Fe x O y
Ltc(Y)
Glass
(%)
Redox
(PPM)
(PPM)
%
TSET
a*
b*
L*
color
Standard
0.507
0.270
0
0
76.67
47.81
−7.51
0.65
90.29
Green
Sample 1
0.507
0.270
50
8
46.16
35.55
−0.51
−0.62
73.54
Neutral
gray
Sample 2
0.507
0.270
110
9
33.38
30.79
−0.41
−10.55
64.65
Blue
[0029] The modeled percent transmittance versus wavelength (nm) for the samples is shown in FIG. 1 .
[0030] Thus, it can be seen that using the same basic glass composition (for example, Solex Glass), the color of the resultant glass sheet can be effectively changed using surface modification by a flame spray apparatus in the float bath.
Example 2
[0031] Samples of Solex® glass were coated as described above in Example 1. This Example included two cases:
[0032] Case 1: deposited material with Co/Fe precursor ratio 12.2:1. In this case, the mixture was diluted by 1:20 and 1:5. The glass was treated at various temperatures.
[0033] Case 2: deposited material with Co/Fe precursor ratio 6.25:1. In this case, the mixture was diluted by 1:20, 1:5, and 1:2.5. The glass was treated at various temperatures.
[0034] Results:
[0035] X-Ray Diffraction (XRD)
[0036] XRD results show that with low concentration (dilution ratio of 1:20), samples prepared at low temperature (550° C.) are amorphous. Crystalline CO 3 O 4 or CoO appear when increasing deposition temperature. The crystalline peak nearly disappears when temperature reached 750° C.
[0037] For high concentration (dilution ratio of 1:5), samples had crystalline CO 3 O 4 or CoO at a temperature around 600° C. The XRD peaks became sharp and their intensity increased significantly when increasing temperature from 600° C. to 650° C. and to 700° C. The peak intensity then decreased with increasing temperature to 750° C. The XRD peaks nearly disappeared at 800° C. In this case, Fe 2 O 3 was also found in several samples prepared at 650° C., 700° C., and 750° C.
[0038] For the highest concentration samples (Case 2, dilution ratio 1:2.5), the crystalline peaks were detected from samples prepared at 600° C. Both CO 3 O 4 and CoO crystals were detected from the sample prepared at 700° C. Fe 2 O 3 phase was also detected from the sample prepared at 750° C. The calculated crystalline size by XRD line broadening was about 17.4 nm for the sample prepared at 700° C., and 14.8 nm for the sample prepared at 750° C.
[0039] X-Ray Fluorescence (XRF)
[0040] XRF was used to measure the amount of Co and Fe inside the glass surface. The results are shown in FIGS. 2 and 3 . XRF results indicated that at 550° C. and 600° C., the incorporation of Co and Fe was very similar regardless of dilution ratio and precursor ratio. With the same dilution ratio, the high precursor Co:Fe ratio gave rise to slightly higher Co and Fe incorporation at temperatures above 600° C. The dilution ratio, however, had a dramatic effect on the incorporation of Co and Fe inside the glass surface. The samples with dilution ratio of 1:5 had higher amount of both Co and Fe inside the glass surface than the sample with dilution ratio of 1:20. The samples with dilution ratio of 1:2.5 had the maximum amount of Co (reaching 36 μg/cm 2 ) and Fe (reaching 5 μg/cm 2 ).
[0041] X-Ray Line Scan
[0042] X-ray line scan was performed on cross-sectioned samples in order to examine the depth of oxide nanoparticles incorporated inside the glass surface. At 700° C., both Co and Fe could penetrate into the glass surface up to 1.8 um. By contrast, at 800° C., both Co and Fe could penetrate into the glass surface up to 4.22 um.
[0043] Haze
[0044] Haze was measured to monitor whether the glass sample had light scattering due to the incorporation of oxide nanoparticles. The results are shown in FIGS. 4 and 5 . All haze data were measured from samples after polishing the backside of the glass piece. The haze was similar for samples prepared at 550° C. and 600° C., regardless of precursor Co:Fe ratio, and dilution ratio. For samples with 1:20 dilution ratio, haze increased with temperature up to 650° C., and then decreased. For both 1:5 and 1:2.5 dilution ratios, haze increased rapidly, reaching a peak at 700° C. preparation temperature, and then dropped. The maximum haze was seen at around 20% from a case two sample with a dilution ratio of 1:2.5 prepared at 700° C.
[0045] Color Change
[0046] FIG. 6 shows the color change of all samples after polishing the backside, as compared to the untreated Solex® glass. It appears that samples with 600° C. and 650° C. treatment move towards positive a* and positive b*. The samples prepared at 700° C. move towards positive a* while keeping b* relatively the same. The samples with 750° C. and 800° C. treatment move towards positive a* and negative b*. This may be a result of forming nanocrystals and/or dissolving of nanocrystals at different temperatures.
[0047] Optical Transmittance
[0048] Optical transmittance was measured on all samples after polishing the backside ( FIG. 7 ). The results show that the optical transmittance decreases with increasing temperature up to about 700° C. (for 1:20 dilution at 650° C.), and then increases with increasing temperature. The optical transmittance changes slightly with precursor Co:Fe ratio. However, the optical transmittance decreases significantly with dilution ratio, from 1:20, to 1:5, to 1:2.5. This change corresponds well with haze, and amount of Co and Fe by XRF for various samples.
Example 3
[0049] This example illustrates the combination of iron and manganese nanoparticles (1:1 ratio) on the color of a glass sheet. Samples of Solex® glass were coated as described above in Example 1.
[0000]
TABLE 2
Transmittance
and Haze (After
Grinding)
Sample
L*
a*
b*
T %
H %
Fe + Mn, 650° C.
31.53
3.58
−1.24
35.1
62.3
Fe + Mn, 700° C.
32.90
3.49
−1.42
53.6
36.8
Fe + Mn, 750° C.
34.35
2.91
−2.59
79.2
11.2
[0050] It will be readily appreciated by those skilled in the art that modifications may be made to the invention without departing from the concepts disclosed in the foregoing description. Accordingly, the particular embodiments described in detail herein are illustrative only and are not limiting to the scope of the invention, which is to be given the full breadth of the appended claims and any and all equivalents thereof.
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A method of making colored glass in a float glass process includes the steps of: melting glass batch materials in a furnace to form a glass melt; transporting the glass melt into a float glass chamber having a flame spray device, the glass melt forming a float glass ribbon; supplying at least one coating material to the flame spray device to form a spray having coating particles; and directing the spray onto the float glass ribbon to diffuse the particles into the surface of the float glass ribbon to form a glass sheet of a desired color.
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FIELD
[0001] The present disclosure relates to a capacitive proximity sensor for mounting to a body such as, for example, the rear side and/or bumper of a vehicle, to sense external objects.
BACKGROUND
[0002] Capacitive proximity sensors have been used in various industrial applications for sensing the presence of objects or materials. Various forms of capacitive proximity sensors are known and are suitable for use in different environments and applications including, for example, touch-operated systems, collision-prevention systems, occupancy-detection systems, and security/warning systems. In one field of application, capacitive proximity sensors have been fitted to the rear side and/or bumpers of vehicles so that, when a vehicle is reversed, a warning signal is provided if it approaches an object so that a collision can be safely avoided while still allowing the driver to conveniently position the vehicle close to the object.
[0003] WO 01/08925 (AB Automotive Electronics Ltd.) describes a capacitive proximity sensor for a vehicle, which consists of two strips of metal, or other conductive material, insulated from each other and provided on the inside of the bumper of a vehicle. One strip, which faces outwardly from the vehicle, is referred to as the sensor plate and the other strip, which faces inwardly towards the vehicle, is called the guard plate. Both plates are connected to a control unit. The control unit monitors the change that occurs in the capacitance between the sensor plate and (electrical) ground as the vehicle approaches an external object and provides an indication to the driver of the distance between the sensor plate (and, hence, the vehicle) and the object. Various geometries for the sensor plate are described, to increase the sensitivity of the proximity sensor at the corners of the vehicle.
[0004] GB-A-2 374 422 (of the same Applicant) describes a modified form of such a capacitive proximity sensor, in which an extra conductive plate is provided to reduce the effect of rainwater on the sensitivity of the sensor. That extra conductive plate, which can be arranged above or below the sensor plate (with respect to ground level), is often referred to as the superguard conductor. More generally, a superguard conductor can be used to address the problem of reducing the sensitivity of a capacitive proximity sensor to very close objects that the sensor is not required to detect.
[0005] GB-A-2 400 666 (also of the same Applicant) mentions the manufacture of a capacitive proximity sensor of the type described in WO 01/08925 by screen-printing the sensor and guard plates with conductive ink onto opposite sides of a plastic film substrate. GB-A-2 400 666 also describes that the sensor and guard plates may, as an alternative, be formed from aluminium foil that is laminated to the plastic film substrate.
[0006] The present disclosure is concerned with capacitive proximity sensors of the type comprising a dielectric substrate, for example a film, having a sensor conductor on one of its major surfaces and a guard conductor on at least one of its major surfaces to provide an electrical shield for the sensor conductor. Electrical connection of a sensor of that type to an electronic control unit often requires the use of a coaxial cable, to ensure that signals transmitted from the sensor to the control unit are electrically screened against external interference. For example, in the case of a capacitive proximity sensor located on the bumper of a vehicle, the signals transmitted from the sensor need to be electrically screened especially from the grounded body of the vehicle. Conventional coaxial cables are, however, comparatively expensive and, because they tend to be somewhat bulky and rigid, are not always well suited to use with capacitive proximity sensors or to the locations (such as vehicle bumpers) in which the sensors are employed. In the particular case in which a sensor is positioned on a vehicle bumper, it is also important that the physical connection between the coaxial cable and the sensor should be robust enough to withstand shocks, exposure to the weather, and blows from objects thrown up from the road.
[0007] In some embodiments, the present disclosure provides a capacitive proximity sensor of the above-mentioned type, a cable that can provide the required electrical screening for signals transmitted from the sensor but is comparatively straightforward and inexpensive to manufacture, is compatible with the sensor as regards its physical characteristics, and can be reliably connected to the sensor in a comparatively simple manner.
[0008] In some embodiments, the present disclosure provides a capacitive sensor assembly comprising:
[0009] (i) a capacitive proximity sensor for mounting to a body for sensing external objects, the sensor comprising a dielectric substrate having front and rear major surfaces which, in use of the sensor, face respectively outward from and towards the body; a sensor conductor on the front major surface; and a guard conductor on at least one of the major surfaces to provide an electrical shield for the sensor conductor; and
[0010] (ii) a cable for transmitting electrical signals from the sensor to an electronic control unit; the cable comprising a dielectric film substrate having, on a first major surface thereof, a first electrical conductor that is connected to the sensor conductor for transmitting electrical signals therefrom and, on both major surfaces thereof, an electrically-conductive layer that is connected to the guard conductor to provide an electrical shield for the said first conductor.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] Embodiments of the disclosure will be described below, by way of example only, with reference to the accompanying drawings, in which:
[0012] FIG. 1 is a diagrammatic plan view of a major surface of a proximity sensor;
[0013] FIG. 2 shows an enlarged diagrammatic cross-section on the line 2 - 2 of FIG. 1 ;
[0014] FIG. 3 is a diagrammatic plan view of a blank that is used in the assembly of a cable for use with the sensor of FIGS. 1 and 2 ;
[0015] FIG. 4 shows an enlarged diagrammatic cross-section on the line 4 - 4 of FIG. 3 ;
[0016] FIG. 5 is a diagrammatic plan view of a cable made using the blank of FIGS. 3 and 4 ;
[0017] FIG. 6 is an enlarged diagrammatic cross-section on the line 6 - 6 of FIG. 5 ;
[0018] FIG. 7 illustrates the use of the cable of FIGS. 5 and 6 with the sensor of FIGS. 1 and 2 ;
[0019] FIGS. 8 , 9 and 10 are cross-sections, similar to FIG. 6 , of modified forms of cable (the cross-section of FIG. 10 being viewed in the opposite direction to those of FIGS. 8 and 9 ).
DETAILED DESCRIPTION OF EMBODIMENTS
[0020] The term “film substrate” as used herein refers to an article having an extension in two directions which exceed the extension in a third direction, which is essentially normal to said two directions, by a factor of at least 5 and more preferably by at least 10. More generally, the term “film” is used herein to refer to a flexible sheet-like material, and includes not only films but also sheetings, foils, strips, laminates, ribbons and the like.
[0021] The term “dielectric” as used herein refers to materials having a specific bulk resistively as measured according to ASTM D 257 of at least 1×10 12 Ohm·centimeter (Ωcm) and more preferably of at least 1×10 13 Ωcm. The term “electrically-conductive” as used herein refers to materials having a surface resistivity as measured according to ASTM B193-01 of less than 1 Ohm per square centimeter (Ω/cm 2 ).
[0022] The capacitive proximity sensor 1 of FIGS. 1 and 2 comprises a dielectric film substrate layer 2 , the peripheral shape of which is determined mainly by the intended location of the sensor as described further below. In FIG. 1 , for the purposes of the present description, the substrate layer 2 is shown diagrammatically as being generally rectangular in shape.
[0023] The major surface of the substrate layer 2 shown in FIG. 1 carries a sensor conductor 3 and a superguard conductor 4 that are spaced apart on the surface of the substrate layer, and electrically-isolated from one another by the intervening substrate material. The superguard conductor 4 comprises a flat, electrically-conductive track extending essentially along the length of the substrate layer 2 . The sensor conductor 3 exhibits a more complicated design and comprises four, optionally-flattened, conductive tracks 3 a extending parallel to one another essentially along the length of the substrate layer 2 and, adjacent both ends of the tracks 3 a, three additional parallel (but shorter), optionally-flattened, electrically-conductive tracks 3 b forming lobe type regions. The tracks 3 a, 3 b of the sensor conductor are connected together in both lobe regions by electrically-conductive tracks 3 c extending at an angle across the whole array of tracks 3 a, 3 b.
[0024] The opposite major surface of the substrate layer 2 , not visible in FIG. 1 , carries a guard conductor 5 in the form of an electrically-conductive layer that preferably covers an area of the substrate corresponding in size at least to that occupied, on the other side, by the sensor conductor 3 . In the sensor illustrated in FIGS. 1 to 3 , the guard conductor 5 essentially fully covers the surface of the main part of the substrate layer 2 to which it is attached. The guard conductor 5 is electrically-isolated from the sensor and superguard conductors 3 , 4 by the intervening dielectric substrate layer 2 .
[0025] In FIG. 2 , the sensor, superguard and guard conductors 3 , 4 , 5 are shown as being attached to the substrate layer 2 by respective adhesive layers 6 , 7 , 8 although, as described below, that is not essential.
[0026] The entire sensor 1 may be encased in a protective cover film (not shown).
[0027] The substrate layer 2 , with the sensor conductor 3 , the guard conductor 5 and the superguard conductor 4 , can be attached to any suitable surface, for example the inside of a bumper of a vehicle, to function as a capacitive proximity sensor. To that end, in the case of a vehicle bumper, the substrate layer is positioned with the major surface of FIG. 1 (i.e. the surface carrying the sensor and superguard conductors 3 , 4 ) directed outwardly from the vehicle and the other major surface (i.e. the surface carrying the guard conductor 5 ) directed inwardly towards the vehicle. The conductors 3 , 4 , 5 are connected to an electronic control unit (not shown) that can monitor the change that occurs in the capacitance between the sensor conductor 3 and (electrical) ground as the vehicle approaches an external object, and thereby provide an indication to the driver of the distance between the sensor conductor (and, hence, the vehicle) and the object. During the monitoring process, the guard conductor 5 acts as a shield to reduce the sensitivity of the sensor conductor 3 to anything behind it in the direction of the body of the vehicle, while an electrical signal is applied to the superguard conductor 4 to make the guard conductor 5 appear even bigger and so minimize the effect, on the signal from the sensor conductor 3 , of water drops running over the bumper in rainy weather conditions. Further information on the operation of a capacitive proximity sensor of that type can be obtained from, for example, WO 01/08925, GB-A-2 374 422, and GB-A-2 400 666 mentioned above. The measurement and processing of signals from a capacitive proximity sensor are described, for example, in WO 02/19,524 of the same Applicant.
[0028] The electrical control unit that receives signals from the sensor 1 is typically located within the vehicle, and a coaxial cable would typically be used to establish the electrical connection between the sensor conductors 3 , 4 , 5 and the control unit, to ensure that the signals transmitted to the control unit are screened from external interference. As already described, however, conventional coaxial cables are not particularly well suited to being used in this type of environment and an alternative type of cable that is more appropriate will now be described with reference to FIGS. 3 to 5 .
[0029] FIGS. 3 and 4 show a blank 10 for use in forming the cable. The blank 10 comprises a dielectric film substrate 11 , which, in some embodiments, is formed from the same material as the substrate layer 2 of the sensor 1 . The main part 11 a of the substrate 11 is of rectangular form and has a length corresponding to the required length of the cable. The major surface of this part 11 a, shown in FIG. 3 , carries two parallel electrically-conductive tracks 12 , 13 each of which extends substantially along the whole length of the substrate part, with one track ( 13 ) being slightly longer than the other at one end ( 11 b ) of the substrate part. The conductive tracks 12 , 13 are electrically-isolated from one another by the intervening substrate material. The substrate also has an extension 11 c that is shorter than the main part 11 a and extends outwardly from one of the longer sides 11 d of the latter. Finally, the opposite major surface of the substrate 11 (not visible in FIG. 3 ) carries an electrically-conductive screen layer 14 that covers the whole area of the main part 11 a and the extension 11 c. The screen layer 14 is electrically-isolated from the conductive tracks 12 , 13 by the intervening material of the substrate 11 .
[0030] To form the cable, a layer of adhesive 15 (shown in FIG. 6 ) is applied to the extension 11 c of the substrate 11 , on the side visible in FIG. 3 , and the extension is then folded over to cover the conductive tracks 12 , 13 . However, because the extension 11 c is shorter than the main part 11 a of the substrate, the ends of the conductive tracks 12 , 13 will remain exposed. The cable 16 , which thus has a generally-flat appearance, is then prepared for attachment to the sensor 1 by applying electrically-conductive adhesive pads 17 to the ends of the conductive tracks 12 , 13 and covering the extra length of the track 13 with a piece of electrically-insulating adhesive tape 18 , as shown in FIG. 5 . Finally, the cable 16 is encased in a protective cover film (not shown), leaving the ends of the conductive tracks 12 , 13 exposed.
[0031] The cable 16 is attached at the end 11 b to the sensor 1 , by adhering the pad 17 at the end of the longer conductive track 13 to the sensor conductor 3 , and the pad 17 at the end of the shorter conductive track 12 to the superguard conductor 4 , as shown in FIG. 6 . Although the conductive track 13 passes over the superguard conductor 4 , the electrically-insulating adhesive tape 18 ensures that they are electrically-isolated from one another. Finally, on the other side of the sensor 1 , an electrical connection is established between the guard connector 5 of the sensor and the screen layer 14 of the cable 15 by means of a conductive metal foil tab 19 extending between the two and secured in position by an electrically-conductive adhesive.
[0032] The sensor 1 can now be installed in a desired location such as the interior of the bumper of a vehicle. The sensor 1 can be easily attached, for example by an adhesive, to the bumper, and the installation is further assisted by the flexibility of the substrate 2 , which facilitates its attachment to a curved surface. It will be understood that the rectangular shape of the substrate 2 shown in the drawings is an example only, and that the substrate would normally be cut to a suitable shape, for example by die-cutting, punching, or laser cutting, having regard to the surface on which it is intended to be mounted. The substrate 2 can also be provided as appropriate with features such as cuts and darts to enable it to be attached to a three-dimensionally curved surface, such as the inner surface of a vehicle bumper, without forming undesirable creases. The attached cable 16 , being formed from similar materials to the sensor 1 , is equally flexible and can be bent as required to enable it to be connected, at the other end, to the electronic control unit in the vehicle without putting undue strain on the electrical connections at either end. In addition, the electrical characteristics of the cable 16 , when formed as described above from similar materials to the sensor 1 , have been found sufficient to ensure the integrity of electrical signals transmitted from the sensor to the electronic control unit at frequencies typically employed in capacitive proximity sensors for automotive applications (normally around 25 kHz).
[0033] It will be apparent that various modifications could be made to the method of forming the cable 16 without substantially altering its construction. For example, the extension 11 c of the cable substrate could be made wider so that it will wrap around the opposite edge of the main part 11 a of the substrate as illustrated in FIG. 8 , thereby completely enclosing the conductive tracks 12 , 13 over most of the length of the cable. Alternatively, the extension 11 c of the cable substrate could be omitted, and the cable formed by adhering an equivalent length of a dielectric/screen laminate 20 over the conductive tracks 12 , 13 as illustrated in FIG. 9 . In that case, the conductive metal foil tab 19 should be adhered to the screen layer 14 ′ of the laminate 20 as well as to the screen layer 14 .
[0034] As a further modification, instead of applying a protective cover film to the sensor 1 and the cable 16 separately as described above, the cover film can be applied to the sensor and cable at the same time, after the cable has been electrically-connected to the sensor. In that case, the electrical connection points will also be enclosed within the cover film, reducing the risk of damage.
[0035] Suitable materials for use in the sensor 1 and cable 16 , and methods in which they can be employed, will now be described.
[0036] Suitable materials for the substrate layer 2 of the sensor 1 and the substrate 11 of the cable 16 include, for example, polymeric films and layers, paper films and layers, layers of non-wovens, laminates (such as, for example, polyacrylate foams laminated on both sides with polyolefin films, and papers laminated or jig-welded with polyethylene terephthalate) and combinations thereof. Useful polymeric films and layers include, for example, polyolefin polymers, monoaxially oriented polypropylene (MOPP), biaxially oriented polypropylene (BOPP), simultaneously biaxially oriented polypropylene (SBOPP), polyethylene, copolymers of polypropylene and polyethylene, polyvinylchloride, copolymers having a predominant olefin monomer which may be optionally chlorinated or fluorinated, polyester polymers, polycarbonate polymers, polymethacrylate polymers, cellulose acetate, polyester (e. g. biaxially oriented polyethylene terephthalate), vinyl acetates, and combinations thereof. Useful substrate materials may be subjected to an appropriate surface modification technique including, for example, plasma discharge techniques including corona discharge treatment and flame treatment, mechanical roughening and chemical primers.
[0037] The conductive tracks of the sensor conductor 3 , and the conductive tracks 12 , 13 of the cable 16 may be formed from any suitable electrically-conductive material, for example copper, and may be applied to the substrate 2 , 11 by an adhesive as already described. As an alternative, they may be formed by vapour deposition of a suitable metal onto the substrate 2 , 11 , or by printing/die coating an electrically-conductive ink onto the substrate, or from a foil that is bonded to the substrate. As yet a further alternative, the sensor conductor 3 and the conductive tracks may be formed by removing zones of material from an electrically-conductive layer on the substrate 2 , 11 , as described in our copending European patent application No. 06001155.8 of 19 Jan. 2006. The sensor conductor 3 may assume a variety of shapes, although a discontinuous arrangement of conductive areas, such as the arrangement of conductive tracks described above, exhibits an especially advantageous sensitivity and may be preferred. It will be appreciated that the number of conductive areas in the sensor conductor 3 , and the way in which they are arranged, can be altered as required.
[0038] The thickness of the sensor conductor 3 and the conductive tracks 12 , 13 (i.e. their height above the substrate 2 , 11 on which they are located) may vary widely depending on the method by which they are manufactured. A conductor comprising flattened metal track may have a thickness of between 20 and 200 micrometers (μm), in some case between 25 and 100 μm. A conductor obtained by vacuum metal vapour deposition may be as thin as 200-800 Angstroms (Å) and, in some cases, 300-500 Å. When using an aluminum foil for the conductor, it may have a thickness of from 1-100 μM, in some cases 2-50 μm and, in some cases, 3-30 μm.
[0039] The superguard conductor 4 of the sensor 1 may be formed from any suitable electrically-conductive material in any of the ways described above for the sensor conductor 3 , and will have a similar resulting thickness. The superguard conductor 4 is not an essential component of the sensor 1 but, if present, may assume a variety of shapes and, in automotive applications, may be arranged (relative to the road level) above or below the sensor conductor 3 .
[0040] The guard conductor 5 of the sensor 1 and the screen layer 14 of the cable may be formed from any suitable electrically-conductive material, for example aluminium. They may be formed, for example, by adhesively-bonding a metal foil to the relevant substrate 2 , 11 , or by applying a metallic layer directly to the substrate, for example by vacuum metal vapour deposition. In an advantageous embodiment, in which the guard conductor 5 and screen layer 14 comprise aluminium foil, the substrate material is a filled polypropylene (FPO) film having a thin layer of EVA bonded to it by coextrusion: the EVA layer facilitates the bonding of the aluminium foil to the substrate by heat-lamination.
[0041] The thickness of the guard conductor 5 and the screen layer(s) 14 , 14 ′ may vary widely depending on the method by which they are formed on the substrate 2 . A metallic layer obtained by vacuum vapour deposition may be as thin as 200-800 Å and, in some cases, 300-500 Å. A metal foil, on the other hand, may have a thickness of from 1-100 μm, in some cases 2-50 μm and, in some cases, 3-30 μm.
[0042] The protective cover film (not shown in the drawings) that encases the sensor 1 and the cable 16 is a polymeric film that is applied to the sensor and the cable by, for example, an adhesive or heat-lamination. In some embodiments, the dimensions of the film exceed those of the substrates 2 , 11 to provide a border that will form an edge seal around the sensor 1 and cable 16 to protect, in particular, the edges of the guard conductor 5 and the screen layers 14 , 14 ′ against corrosion. The border may have a width of 1-50 mm, in some cases 1-40 mm and, in some cases, 2-20 mm.
[0043] Reference is made above to our European patent application No. 06001155.8 of 19 Jan. 2006 entitled “Capacitive sensor film and method for manufacturing the same”, in which the sensor conductor and the superguard conductor (when present) are at least partly surrounded by a front conductor on the same major surface of the substrate layer, being electrically isolated against the front conductor by zones where the front conductor is removed (for example, by laser ablation). If that method is applied to the cable 16 , as mentioned above, the conductive tracks 12 , 13 are likewise surrounded by a front conductor on the same major surface of the substrate 11 , being electrically isolated against the front conductor by zones where the front conductor is removed (for example, by laser ablation). The cable may then have the configuration illustrated in the cross-sectional view of FIG. 10 , in which the front conductor is indicated by the reference numeral 60 . The conductive tracks 12 , 13 are defined within, and electrically isolated from, the surrounding front conductor 60 by zones 61 where the front conductor has been removed e.g. by laser ablation. The cable is completed by the provision of an electrical shield for the conductive track 13 (i.e. the track that, in use, is connected to the sensor conductor 3 of the sensor 1 ), comprising a layer 14 a of conductive material laminated over the strip with an intervening layer of dielectric material 62 and a corresponding layer 14 b of conductive material on the opposite side of the substrate layer 11 . The electrical shield layers 14 a, 62 , 14 b could extend over the second conductive track 13 also (in the manner illustrated in FIG. 9 , but that is not essential. The cable of FIG. 10 may be encased in a protective film (not shown) as described above.
[0044] A capacitive proximity sensor as described above with reference to the drawings can be easily installed due to its flexible nature and that of the connector cable, and is especially suited for use in the automotive industry. The use of similar materials and similar manufacturing methods for the sensor and the cable is also advantageous, but is not essential. It will be appreciated, for example, that the cable could be used with other types of capacitive proximity sensors, and is not restricted to use with sensors in which the dielectric substrate is a film material.
[0045] It will be understood that the particular configurations shown in the drawings for the sensor and guard conductors and the optional superguard conductor are for the purposes of illustration only and are not an essential feature of the invention. The proximity sensors described herein with reference to the drawings are particularly appropriate for use on vehicle bumpers but the manner in which electrical connection is made between the sensor and guard conductors (and, when present, the superguard conductor) and an electronic control unit, using the flexible cable 16 , is applicable to capacitive proximity sensors intended for use in other applications and to capacitive proximity sensors with differently-configured conductors including, for example, those with a sensor conductor of serpentine or spiral form or with two interdigitated sensor conductors, or with a multiplicity of guard conductors.
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A capacitive proximity sensor assembly comprises: (i) a capacitive proximity sensor ( 1 ) for mounting to a body for sensing external objects, the sensor comprising a dielectric substrate ( 2 ) having front and rear major surfaces which, in use of the sensor, face respectively outward from and towards the body; a sensor conductor ( 3 ) on the front major surface; and a guard conductor on at least one of the major surfaces to provide an electrical shield for the sensor conductor; and (ii) a cable ( 16 ) for transmitting electrical signals from the sensor ( 1 ) to an electronic control unit; the cable comprising a dielectric film substrate having, on a first major surface thereof, a first electrical conductor ( 13 ) that is connected to the sensor conductor ( 3 ) for transmitting electrical signals therefrom and, on both major surfaces thereof, an electrically-conductive layer ( 14 ) that is connected to the guard conductor to provide an electrical shield for the said first conductor ( 13 ).
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the priority, under 35 U.S.C. §119, of German application DE 10 2015 221 187.8, filed Oct. 29, 2015; the prior application is herewith incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
Field of the Invention
[0002] A hearing aid serves to supply a hearing impaired person with acoustic signals from the surroundings, which have been appropriately processed for compensating the respective hearing impairment and, in particular, amplified. To this end, a hearing aid usually contains one or more acoustoelectric input transducers, for example in the form of a microphone, a signal processing unit with an amplifier, and an electro acoustic output transducer. The output transducer is generally realized as a miniaturized loudspeaker and is also referred to as receiver. It produces acoustic output signals which are forwarded to the ear of a patient and produce the desired audio perception for the patient.
[0003] There are various embodiments of hearing aids. In the case of so-called in-the-ear (ITE) hearing aids, a housing which contains all functional components, including the microphone and the receiver, is worn at least partly in the auditory canal. Completely-in-canal (CIC) hearing aids are similar to ITE hearing aids, but are worn completely in the auditory canal. In the case of behind-the-ear (BTE) hearing aids, a housing with components such as a battery and the signal processing unit is worn behind the ear. A flexible sound tube, also referred to as tube, guides the acoustic output signals of the receiver from the housing to the auditory canal, where a corresponding earpiece is usually provided on the sound tube for positioning the end of the sound tube in the auditory canal.
[0004] Irrespective of the configuration of the respective hearing aid, hearing aids which, in addition to the conventional function thereof as a sound amplifier for ambient noises, are also usable for different purposes are being developed ever more frequently in the meantime. Thus, modern hearing aids may, for example, be coupled without problems to telephones, televisions and/or audio systems in order to directly play-in the audio signals thereof.
[0005] Monitoring and recording vital functions of the hearing aid wearer also represents a further field of interest. In principle, such monitoring of biological data, in particular data relating to the metabolism or vital functions, by use of so-called “wearables” is known. These include e.g. armbands, watches, pieces of clothing or headphones which are used by sensors to measure blood pressure, heartbeat or the like. Then, for example during physical exercise, the vital functions may be monitored directly (in the case of watches or armbands) or (in the case of items of clothing or headphones) by of e.g. a (wirelessly) coupled smartphone (or the corresponding application).
[0006] Using the hearing device together with a system for monitoring the activities of the user, for example during physical exercise, is known from U.S. Pat. No. 8,655,004 B2. The monitoring system may be arranged in the vicinity of the head or the ear of the user and is able to measure user-specific biological data, such as the body temperature, the heartbeat or sweating. To this end, the monitoring sensor contains a sensor which may be either integrated into the corresponding hearing device or fastened thereto.
[0007] U.S. Pat. No. 5,721,783 A discloses an option for recording signals from the surroundings or biological data of the hearing aid wearer by an external apparatus such as e.g. a watch or a piece of jewelry, amplifying or improving said signals or biological data and subsequently transferring these wirelessly to a hearing aid or an earpiece of a hearing aid.
[0008] What is common to both systems described above is that the signal processing of the biological data recorded by the sensor is carried out by separate signal processing units provided specifically for this purpose, which are appropriately coupled to the respective hearing device. This is complicated and expensive.
SUMMARY OF THE INVENTION
[0009] A first object underlying the invention is that of specifying a hearing aid system which allows a technically simplified connection of the sensor for capturing biological data to a hearing aid.
[0010] Specifying a method by which a correspondingly simplified connection of the sensor for capturing biological data to a hearing aid is possible is a second object underlying the invention.
[0011] According to the invention, the first object of the invention is achieved by a hearing aid system containing a hearing aid with an acoustoelectric input transducer for recording a sound signal and converting the latter into an electrical input signal, with a signal processing unit, connected to the input transducer, for processing the input signal, and with an electro acoustic output transducer, connected to the signal processing unit, for converting the processed input signal into an acoustic output signal, and containing a sensor for capturing a measurement value of at least one biological measured variable and for outputting an electrical information signal carrying information about the measurement value. Here, the signal processing unit used to process the input signal is also signal-connected to the sensor and additionally configured and embodied to process the information signal.
[0012] In a first step, the invention is based on the consideration that the previously required external devices for signal processing, monitoring and transfer of vital functions, medical data or, in general, biological data of a hearing aid wearer reduce the user comfort for the hearing aid wearer since he must carry further separate components on him for coupling to the hearing aid. Technically, a multiplicity of additional electronic components is required, making the coupling of the corresponding sensor unnecessarily more expensive.
[0013] In a second step, the invention considers the fact that a signal processing unit is installed in each hearing device. The signal processing unit is used for processing and amplifying the electrical input signals generated from the sound signals.
[0014] Finally, in a third step, the invention recognizes that the signal processing units used in the hearing aid in principle have the potential to be additionally used for processing further data and, in particular, for processing signals from sensors for capturing biological data. By way of example, the frequency range below or above the faculty of hearing typically remains unconsidered when processing audio signals, even though processing of such signals is possible due to the parameters of the components used in the signal processing unit of a hearing device.
[0015] Taking this into account, the invention provides for the signal processing unit of the hearing aid to also be used for processing the electrical information signals of the sensor for capturing biological data in addition to the processing of audio signals. To this end, the corresponding sensor, by which the respective biological data are captured, is signal-connected to the signal processing unit of the hearing aid such that the signal processing unit is enabled to process both the electrical input signal from the acoustoelectric input transducer and an electrical information signal from the biosensor.
[0016] In other words, an electrical information signal from the biosensor is processed by using a signal processing unit already available in the hearing device. Previously unused capacities of the signal processing unit could be effectively used in this manner. It is possible to dispense with additional electronic components and/or a separate signal processing unit for connecting a biosensor to a hearing aid.
[0017] The sensor or biosensor captures a measurement value of the biological measured variable. By way of example, the pulse or the heartbeat, the body temperature or sweating are able to be captured as measured variables. It is also possible to measure oxygen saturation, blood sugar levels, blood pressure or further medical parameters. The electrical information signal of the sensor carrying the information about the measurement value may be a voltage, a current, a resistance, a capacitance, an inductance or the like. The sensor outputs the electrical information signal carrying information about the measurement value, the electrical information signal being processed further accordingly in the signal processing unit of the hearing device. In a particularly preferred configuration, the sensor is connected to a voltage supply unit in the hearing aid.
[0018] In an advantageous variant, the sensor is arranged on the hearing aid or integrated into the hearing aid. In particular, the hearing is embodied as an ITE hearing aid in this case. Biological data of the hearing aid wearer can be captured immediately on or in the ear by way of a sensor arranged on a concha hearing aid or on a CIC hearing aid. In another preferred configuration, the biosensor is line-connected to the hearing aid. In particular, in that case, the sensor is assembled in an earpiece of the hearing aid which is able to be inserted into the ear, the hearing aid being connected by way of e.g. a sound tube to a BTE hearing aid in such a case. In the variant of the BTE hearing aid, the receiver or the electro acoustic transducer is inserted into the earpiece and coupled in a wired manner by way of a connection tube. Then, this is also referred to as a receiver-in-canal (RIC) hearing aid. These variants have the advantage of a very simple placement of the sensor. The sensor is simply arranged with the hearing aid or with the earpiece on the position on the body of the hearing aid wearer suitable for tapping the biological data. A complicated separate attachment of the sensor at another position is dispensed with.
[0019] In an advantageous configuration of the invention, the signal processing unit contains an amplifier, in particular preamplifier, and a processor unit disposed downstream of the amplifier, with the actual processing of the amplified signal being carried out in the processor unit on an analog and/or digital basis. An amplifier unit and a processor unit are conventional components of a signal processing unit typically installed in a hearing aid. In this case, the amplifier may be embodied for digital and/or analog amplification of the signal. Accordingly, an analog-to-digital converter is implemented where necessary. If the hearing aid contains a telecoil for inductive coupling of audio signals or for inductive coupling with a second hearing aid, e.g. in the case of the binaural hearing system, the hearing aid generally contains a separate preamplifier which lifts the coupled-in signals to the signal level of the input signals coupled in by way of the acoustoelectric input transducer. In a preferred variant, the information signal of the biosensor is conducted via the preamplifier of the telecoil before it is further amplified by an amplifier and processed in the processor unit. This is particularly advantageous in the case of a biosensor which supplies very weak information signals.
[0020] In principle, it is possible for the information signal and the input signal to be supplied independently of one another to the signal processing unit, in particular to the amplifier and/or the processor unit. However, it is advantageous for the information signal from the biosensor to be applied to the input signal from the acoustoelectric input transducer on the input side or for both signals to be coupled such that the signal processing unit is used for common processing, in particular for common amplification, of both signals. Preferably, at least both signals are amplified together. This is possible since the frequency components of the audio signal and of the information signal of the biosensor typically differ. Optionally, as mentioned above, the information signal is initially conducted via the preamplifier of the telecoil before it is applied to the input signal.
[0021] Expediently, a separation unit for separating the common amplified signals is interposed between the amplifier and the processor unit in the signal processing unit. The separation unit is configured and embodied to separate the signals amplified together by means of the amplifier. After separating the signals amplified together, the audio signal and the information signal from the biosensor are subsequently processed separately.
[0022] Preferably, the processor unit contains an audio processor unit for processing the input signal and/or a bio-processor unit for processing the information signal for the purposes of separate processing of the audio, or input, signal and the information signal. The audio processor unit assumes the preparation of the audio signal for the hearing aid wearer. The prepared audio signal is accordingly output to the electro acoustic output transducer for the purposes of outputting a sound signal. The electrical information signals which are established by the biosensor and optionally amplified are processed by the bio-processor unit in such a way that they are usable for a hearing aid wearer. Thus, in a preferred configuration, the information signals are e.g. prepared so as to be displayed on an external output unit, for example a smartphone or the like. By way of example, the vital functions of the respective user are displayed graphically (for example on the basis of a heart rate symbol on the display of the smartphone) after a corresponding transfer of the prepared information signals. Warnings may also be prepared, output and transmitted. Here, the connection between the bio-processor unit and the respective output unit is preferably realized in a wireless manner, in particular by way of Bluetooth or by way of WLAN. To this end, the bio-processor unit is coupled to an antenna of the hearing aid in an advantageous variant, the antenna facilitating a corresponding wireless connection to an external device.
[0023] Warning messages, sounds or else voice announcements in relation to the measurement values of the biosensor or in relation to evaluations may also be output in the output transducer of the hearing aid. To this end, it is preferable for the bio-processor unit to be connected to the audio processor unit for the purposes of an acoustic signal output in one configuration variant. The electrical information signals processed in the bio-processor unit are appropriately prepared for the audio processor unit, processed further by the latter and forwarded to the electro acoustic output transducer of the hearing aid for outputting an acoustic signal. Thus it is possible, for example on a permanent basis or when necessary, to output the heart tone to a hearing aid wearer by way of the hearing aid, to state the heart rate or other biological parameters, or to directly provide information or a warning by way of a signal tone or a corresponding announcement in the case of physical overexertion or when a normal range is left.
[0024] The use of the amplifier for common amplification of the electrical information signal from the sensor and the electrical input signal from the acoustoelectric input transducer is possible, in particular, if the audio signal and the information signal from the bio-sensor have frequency ranges that differ from one another. Here, the information signal from the sensor is expediently variable over time and substantially contains frequencies from a frequency range lying below the frequency range of the input signal. Preferably, the information signal of the sensor contains frequencies in a frequency range below 10 Hz. The input signal typically contains frequencies in a frequency range above 100 Hz.
[0025] The different frequency ranges firstly facilitate a common amplification in the signal processing unit of the hearing aid, without requiring additional measures. Secondly, a separation of the signals by frequency selection is possible after amplification has been carried out. To this end, the separation unit used for separation is preferably embodied for frequency-selective splitting of the common amplified electrical signals. By way of example, the separation unit is embodied as a crossover and divides the signal into various frequency ranges, i.e. into the information signal and the audio signal. The separated signals are then processed separately in the signal processing unit, in particular by the audio processor unit and the bio-processor unit.
[0026] The sensor or biosensor is preferably embodied as an optical sensor and, in this case, expediently contains at least one light source and a detection unit. An LED is preferably used as light source. The light emitted by the LED is detected by the detection unit, which is preferably embodied as a photodiode. The signal detected by the optical sensor is preferably a voltage or current signal. Expediently, a filter is disposed downstream of the sensor, the filter serving to pre-filter the signals for separating out disturbance, noise or background signals before said signals are supplied to the signal processing unit.
[0027] The sensor is particularly preferably configured and embodied to capture a heartbeat of a hearing aid wearer. A sensor embodied to capture the heartbeat contains e.g. an infrared-emitting diode (IR-LED), by which the signals reflected by a pulsating artery are measured. The capillaries expand and contract again with each heartbeat due to changes in the blood volume. The light of the IR-LED reflected by the skin captures these changes. By way of example, the reflected light is detected by a photodiode. Then, as described above, the information signals are amplified and processed further. In the case of the heartbeat, the information signal of the sensor is a periodic or time-varying signal.
[0028] In another configuration, the oxygen saturation in the blood of the hearing aid user is captured by an optical sensor. In particular, a sensor embodied to capture the oxygen saturation in the blood has two light-emitting diodes (LEDs) which differ in terms of the emission wavelengths thereof. In particular, a light-emitting diode (R-LED) emitting red in the visible spectral range and an infrared light-emitting diode (IR-LED) serve as light sources for the measurement. The pulsation of the arterial blood flow is also used to determine the arterial oxygen saturation, the pulsation changing the blood volume during the systole (contraction phase and hence blood outflow phase of the heart) and the diastole (relaxation phase and hence blood inflow phase) and hence acting on the light absorption. A change in the light absorption is captured by way of a change in the back-reflected light. Since it is only the change in the light absorption that is evaluated, non-pulsating absorbing substances such as tissue, bones and venous blood have no effect on the measurement. In particular, in the back reflection, the sensor measures the ratio of the red pulsating absorption and infrared pulsating absorption, which is directly related to the oxygen saturation, and the sensor moreover expresses the oxygen saturation thereby.
[0029] In a further advantageous configuration of the invention, the sensor is configured and embodied to capture the skin moisture and/or the body temperature of the hearing aid wearer. The resistance of the skin changes in the case of a change in temperature or increased sweating. This change in resistance is measured, converted into an electrical signal by an appropriate transducer and finally amplified and processed further. In this case, the information signal is static. It is preferably modulated onto a periodic carrier signal with a suitable frequency for further processing or amplification.
[0030] According to the invention, the second object of the invention is achieved by a method for establishing biological data of a hearing aid wearer by a hearing aid system, a sound signal being recorded by an acoustoelectric input transducer of a hearing aid, the sound signal being converted into an electrical input signal by means of the acoustoelectric input transducer, the electrical input signal being forwarded to a signal processing unit of the hearing aid and processed there, the processed electrical input signal being forwarded to an electro acoustic output transducer of the hearing aid and being converted into an acoustic output signal there, a measurement value of at least one biological measured variable being captured by a sensor, and the sensor outputting an electrical information signal carrying information about the measurement value. Here, additionally, the information signal of the sensor is also processed in the signal processing unit used to process the input signal.
[0031] Here, the advantages specified for the hearing aid system and the advantageous configurations thereof may analogously be transferred to the method. Further advantageous variants become apparent from the dependent claims directed to the method.
[0032] Preferably, the information signal is applied to the input signal on the input side of the signal processing unit, or of an amplifier, and both signals are amplified together in an amplifier of the signal processing unit. Optionally, the information signal is initially pre-amplified in a preamplifier of a telecoil before it is applied to the input signal. Naturally, a separate supply of the two signals into the amplifier is also possible.
[0033] The, in particular amplified, electrical input signal and the, in particular amplified, electrical information signal are expediently processed in a processor unit. Here, the processor unit preferably contains an audio processor unit and a bio-processor unit, the audio processor unit processing the input signal and the bio-processor unit processing the information signal.
[0034] In an advantageous configuration, the input and information signals, amplified together, are separated from one another by the processor unit, with the input signal being processed in an audio processor unit and the information signal being processed in a bio-processor unit. The electrical input signal processed in the processor unit is preferably forwarded to the electro acoustic output transducer. The processed electrical information signal is preferably output to an, in particular external, output unit. An alternative preferred configuration provides for the processed electrical information signal to be forwarded or output from the bio-processor unit, in particular via the audio processor unit, to the electro acoustic output transducer for the purposes of outputting acoustic information.
[0035] Other features which are considered as characteristic for the invention are set forth in the appended claims.
[0036] Although the invention is illustrated and described herein as embodied in a hearing aid system and method containing a sensor for capturing biological data, 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.
[0037] 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 SEVERAL VIEWS OF THE DRAWING
[0038] FIG. 1 is an illustration showing a hearing aid system containing a sensor for capturing a heart rate of a hearing aid wearer according to the invention; and
[0039] FIG. 2 is an illustration showing the hearing aid system containing a sensor for capturing oxygen saturation of blood of the hearing aid wearer.
DETAILED DESCRIPTION OF THE INVENTION
[0040] Referring now to the figures of the drawings in detail and first, particularly to FIG. 1 thereof, there is shown a hearing aid system 1 containing a hearing aid 3 and an optical sensor 5 for capturing the heart rate of a hearing aid wearer. The hearing aid 3 contains an acoustic electric input transducer 7 with three microphones 9 , by which sound signals are recorded, in particular in a directionally selective manner, and converted into electrical input signals.
[0041] Furthermore, the hearing aid 3 has a signal processing unit 11 , connected to the input transducer 7 , with an amplifier 13 disposed upstream thereof and a processor unit 15 connected to the amplifier 13 . The electrical input signals which, as audio signals, typically have frequencies in a frequency range above 100 Hz are initially amplified by the amplifier 13 for further processing. In the processor unit 15 , the amplified electrical input signals are processed further, in particular amplified e.g. in a frequency-selective and/or directionally dependent manner in view of the hearing ability of the hearing aid wearer, and e.g. freed from background noise and noise. A component 33 with the amplifier unit 13 simultaneously contains an analog-to-digital converter, a transceiver for wireless coupling by way of an antenna 18 and a voltage supply unit in the present case. A preamplifier 22 , in particular, is integrated in the case of a telecoil 20 .
[0042] On the output side, the signal processing unit 11 is connected to an electro acoustic output transducer 17 , which converts the processed electrical input signal into an acoustic output signal which is then conducted to the ear of a hearing aid wearer.
[0043] Like the acoustic electric input transducer 7 of the hearing aid, the optical sensor 5 belonging to the hearing aid system 1 is also signal connected, in particular in a wired manner, to the signal processing unit 11 . In this case, the sensor 5 is also placed directly on or in the ear of the hearing aid wearer. In particular, the hearing aid 3 is embodied as an ITE hearing aid, with the sensor 5 being arranged directly on the hearing aid. This is indicated in FIG. 2 . In another configuration, which is indicated in FIG. 1 , the sensor 5 is arranged in an earpiece 24 , with the earpiece 24 being line-connected to the hearing aid 3 and the latter being embodied as a BTE hearing aid. In a further alternative configuration, the sensor 5 is coupled to the signal processing unit 11 , for example by way of a radio link. By way of example, this is possible by way of a corresponding antenna 18 , which is connected to the amplifier 13 . The sensor 5 is embodied with a light source 19 embodied as an IR-LED and a photodiode as detection unit 21 . In the present case, the heartbeat of the hearing aid wearer is captured by the sensor 5 . For the purposes of actuating the LED, the sensor 5 contains a power management unit 26 , which is supplied by way of the voltage supply unit in the component 33 of the hearing aid 3 .
[0044] For the purposes of capturing the heartbeat, the LED as light source 19 emits light in the infrared spectral range, which reaches into the skin of the hearing aid wearer up to a certain penetration depth and which is partly reflected. Here, the reflection varies with the heartbeat since the blood volume of the capillaries changes periodically with the heartbeat. The reflected light is detected by the photodiode 21 . The photodiode 21 outputs an electrical signal which varies periodically with the heartbeat, the electrical signal being pre-filtered in a filter 23 . Here, an electrical information signal with frequencies below 10 Hz, i.e. with the frequency of the heartbeat, is filtered out.
[0045] In the present case, the electrical information signal is applied to the electrical input signal on an input side 25 of the signal processing unit 11 . Both signals are amplified together by the amplifier 13 of the signal processing unit 11 . In another variant, the information signal is applied to the preamplifier 22 before it is amplified together with the input signal. This is indicated by dashed lines in FIG. 1 . After amplification, the two signals are separated from one another in a separation unit 27 , embodied as a crossover, interposed between the amplifier 13 and the processor unit 15 . Here, the separation unit separates the information signal with frequencies of less than 10 Hz from the audio signal with frequencies above 100 Hz.
[0046] After the frequency-selective split of the electrical signals are amplified together in the amplifier 13 , the amplified electrical input signals with frequencies in a frequency range above 100 Hz are supplied to an audio processor unit 29 of a processor unit 15 . Here, the audio signals are processed and forwarded for an acoustic output to the electro acoustic output transducer 17 .
[0047] The amplified electrical information signals from the sensor 5 with frequencies in a frequency range below 10 Hz are supplied to bio-processor unit 31 of the processor unit 15 . Here, the information signals of the sensor 5 are processed and forwarded wirelessly by means of an antenna 18 to an external output unit 34 via a transceiver in the component 33 . By way of example, the external output unit 34 is a smartphone, on which the heart rate is made visible on the display, for example on the basis of the heart rate symbol with the measured or evaluated value.
[0048] Alternatively, or additionally, acoustic information about the heart rate is output by means of the electro acoustic transducer 17 of the hearing aid 3 . To this end, the bio-processor unit 31 is connected to the audio processor unit 29 . The signal processed in the bio-processor unit 31 is accordingly forwarded to the audio processor unit 29 and, from there, likewise forwarded to the electro acoustic output transducer 17 . The latter also converts the processed electrical information signal into acoustic output signals, which are then conducted to the ear of a hearing aid wearer. The acoustic information signal may be the heart rate as a periodic signal. However, there may also be a voice output about the heart rate. Additionally, or alternatively, a warning message may also be output if, for example, the heart rate departs from a normal or wellness range which the hearing aid wearer preset. The hearing aid wearer will then hear warning messages or voice announcements in respect of his heart rate directly by way of the hearing aid.
[0049] FIG. 2 shows a further hearing aid system 51 . The hearing aid system 51 contains the hearing aid 3 in accordance with FIG. 1 , and so the detailed description in relation to FIG. 1 may analogously be transferred to FIG. 2 . In the present case, the employed sensor 53 is an optical sensor for capturing the oxygen saturation of the blood of the hearing aid wearer.
[0050] In contrast to the sensor 5 in accordance with FIG. 1 , the present sensor 53 comprises two light sources 55 , 57 . A light-emitting diode 55 emitting red in the visible spectral range and an infrared light-emitting diode 57 serve as light sources for the measurement. For the purposes of determining the arterial oxygen saturation, use is made of the pulsation of the arterial blood flow which changes the blood volume during the systole and the diastole and hence acts on the light absorption. Since only the change in the light absorption is evaluated, non-pulsating absorbing substances such as tissue, bones and venous blood have no effect on the measurement.
[0051] Measured by way of the reflection is the respective difference in the absorptions during the diastole and the peak value during the systole. Here, it is postulated that the absorption increase during the systole is only caused by arterial blood. The measurement principle is based on the fact that deoxygenated hemoglobin (Hb) in the infrared range (≈940 nm−infrared light-emitting diode 57 ) is absorbed less than oxygenated Hb or oxygenated hemoglobin in the red range (≈660 nm−red light emitting diode 55 ).
[0052] The detection unit 59 of the sensor 53 embodied as a photodiode measures the reflected light from both LEDs 55 , 57 . The oxygen saturation is established from the ratio of the red and infrared pulsating absorption.
[0053] The further processing of the signals in the signal processing unit 11 of the hearing aid 3 , and the output to an output unit and/or the speech output in the electro acoustic output transducer 17 is carried out analogously to this description in accordance with FIG. 1 .
[0054] The following is a summary list of reference numerals and the corresponding structure used in the above description of the invention:
1 Hearing aid system 3 Hearing aid 5 Biometric sensor 7 Acoustoelectric input transducer 9 Microphone 11 Signal processing unit 13 Amplifier 15 Processor unit 17 Electro acoustic output transducer 18 Antenna 19 Light source 20 Telecoil 21 Detection unit 22 Preamplifier 23 Filter 24 Earpiece 25 Input side 26 Power management unit 27 Separation unit 29 Audio processor unit 31 Bio-processor unit 33 Component 34 Output unit 51 Hearing aid system 53 Biometric sensor 55 Light source 57 Light source 59 Detection unit
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A hearing aid system contains a hearing aid having with an acoustoelectric input transducer for recording a sound signal and converting the latter into an electrical input signal, a signal processing unit, connected to the input transducer, for processing the input signal, and an electro acoustic output transducer, connected to the signal processing unit, for converting the processed input signal into an acoustic output signal. A sensor is provided for capturing a measurement value of a biological measured variable and for outputting electrical information signal carrying information about the measurement value. The signal processing unit used to process the input signal is also signal-connected to the sensor and additionally configured and embodied to process the information signal. Furthermore, a method for establishing biological data of a hearing aid wearer by a corresponding hearing aid system is possible.
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CLAIM OF PRIORITY
The present invention claims priority from Japanese application JP 2004-357539 filed on Dec. 10, 2004, the content of which is hereby incorporated by reference on to this application.
FIELD OF THE INVENTION
The present invention relates to an electron beam apparatus, such as an electron microscope, which measures an electromagnetic field in a matter or vacuum using interference of electron beams.
BACKGROUND OF THE INVENTION
The electron holography, or the electron interference microscopy, is a technique of quantitatively measuring an electromagnetic field in a matter or vacuum by measuring a phase shift of an electron beam caused by a specimen, and specifically a technique in which an electron beam generated in an electron source is splitted into a plurality of electron beams by an electron biprism, a splitted electron beam is made to enter the specimen, and the electron beam having transmitted through the specimen is detected, whereby an interference image is acquired. Such a scanning interference electron microscope is disclosed in, for example, Japanese Patent Application Laid-Open No. 8-45465 and Japanese Patent Application Laid-Open No. 9-134687.
The electron beam holography method is classified in terms of its system into an interference electron microscopy of the scanning transmission electron microscope (STEM; Scanning Transmission Electron Microscope) type and an interference electron microscopy of the transmission electron microscope (TEM; TranSmission Electron Microscope) type. The interference electron microscopy of the STEM type has the following merits as compared with the interference electron microscopy of the TEM type: (1) The STEM type interference electron microscopy can display a phase image on-line and real-time; (2) It can display simultaneously an analytical image, such as detection of a characteristic X-ray etc. generated by scanning illumination of an electron beam, and an interference image; and (3) Since a spatial resolution is determined by a spot size of a focused electron beam, controllability of spatial resolution is excellent; and the like.
An electromagnetic field in the specimen can be estimated by measuring the amount of phase shift of interference fringes by image analysis of a detected interference image, namely the amount of positional shift between positions of constructive interference and of destructive interference. As a technique of measuring the amount of phase shift of interference fringes, for example, there is the method of Leuthner et al. In addition, in the invention disclosed in Japanese Patent Application Laid-Open No. 9-134687, the amount of phase shift is calculated with the method of Leuthner et al. In the Leuthner' method (Th. Leuthner, H. Lichte, and K-H. Herrmann: “STEM-Holography Using the Electron Biprism” Phys. Stat. Sol. A 116, 113. (1989)), a phase image of the specimen is acquired by detecting an electron beam having passed through a grating-type slit with an electron beam intensity detector, and converting an intensity signal of the detected electron beam into phase information. Hereafter, the Leuthner's method will be explained in detail using FIG. 2A and FIG. 2B .
FIGS. 2A and 2B are schematic diagrams each showing a comparative relation among interference fringes of electron beams, a slit, and an electron beam intensity detector. In FIGS. 2A and 2B , the reference numeral 46 denotes a slit and 50 denotes an electron beam intensity detector. The numerals 48 and 49 each denote interference fringes of the electron beams which reach the slit. FIG. 2A corresponds to a case where an aperture of the slit coincides with a position of constructive interference and FIG. 2B corresponds to a case where the aperture of the slit coincides with a position of destructive interference. The vertical axis of the interference fringes 48 and 49 corresponds to the intensity of the electron beams. When performing the method of Leuthner et al., first a direction of the interference fringes and a direction of the slit are set in the same direction. Usually, the apparatus user observes the image of interference fringes by visual inspection, and manually adjusts the direction of the interference fringes obtained, the direction of the slit apertures, and a position of the grating-type slit itself.
When the interference fringes are detected in a state where the direction of the interference fringes agrees with the direction of the slit, the intensity of the detected electron beam varies depending on positions of constructive interference and of destructive interference relative to the slit. In the case of FIG. 2A , the amount of the electron beams passing through the slit 46 becomes a maximum, and in the case of FIG. 2B , the amount of the electron beams passing through the slit 46 becomes a minimum. Therefore, if the amount of the electron beams detected with the detector 50 is normalized using its maximum and minimum, the amount of the detected electron beams could be converted to a cosine of the amount of phase shift. That is, when the amount of the electron beams of the interference fringes passing through the slit 46 assumes a maximum, the phase shift by the specimen is 0□}2π□Λn, and when the amount of the electron beams of the interference fringes passing through the slit 46 assumes a minimum, the phase shift by the specimen is π□}2□Λn. Generally, a direction of the apertures of the slit 46 and a position of the slit 46 are so adjusted that detected constructive interference and destructive interference assume detection intensities of those formed under the condition that there is no specimen or both of the splitted electron beams pass through a vacuum. Therefore, it becomes possible to display an image having phase information of the specimen by displaying the amount of the electron beams having passed through the slit 46 which is normalized to be a value between a maximum and a minimum as a cosine of the amount of phase shift or further converting the value so obtained into the amount of phase shift between zero and π.
SUMMARY OF THE INVENTION
An S/N ratio of a scanning phase information image obtained with the scanning interference electron microscope becomes higher with increasing intensity of the detected electron beam intensity. Therefore, it is essential to make the electron interference fringes enter a detector effectively in order to achieve a clear scan image. The conventional scanning interference electron microscope using the method of Leuthner et al. has the following problems.
(1) Setting and adjustment are complex and difficult to do. (2) Simultaneous display of a phase image and an amplitude image cannot be performed. (3) The detection efficiency of the electron beams is low.
The above (1) problem arises from a fact that a relative direction between the slit and the interference fringes and positions thereof are adjusted manually. Specifically, adjustment to equalize a spacing of apertures of the slit and a spacing of interference fringes and make directions of both spacings agree with each other is done by observing the interference fringes magnified by about 1000 times with imaging lenses with an eye using a fluorescent screen and moving the position and direction of the slit manually. Since the magnification weakens the intensity of interference fringes, the adjustment requires skills and experience and accurate adjustment is difficult.
Regarding a problem described in the above (2), since only one detector is used, it is essential to select and display either the amplitude image corresponding to a normal electron microscope image or the phase image, thus simultaneous display being impossible. If the observer is enabled to observe simultaneously structure information obtained from the normal electron microscope image and electromagnetic field information obtained from the phase image, it will give the observer an extra convenience.
The above (3) results from a fact that, since electron beams passing through the slit are allowed to enter the detector, a part of the electron beam blocked by the slit is not used. Since the electron beams blocked the slit cannot be used effectively, there is a limit in improving detection sensitivity or detection precision. Although it is possible to capture the whole image of the interference fringes, namely, to detect all the electrons, and process them with a high-speed processor, a time to transfer data to the processor, a time required for arithmetic computing, a time to transfer the data to memory, etc. will become huge, which deprives the STEM type interference electron microscopy of its advantage that a phase image can be displayed real-time. The present invention has its object to provide a scanning interference electron microscope which is easy to set up and adjust and yet highly sensitive.
The present invention solves the above-mentioned problems by detecting interference fringes of electron beam with an electron beam detector that consists of one pair of multi pixels. That is, an output of this detector is a 1-dimensional interference fringe image such that a value of each pixel is an integration value of 2-dimensional pixels along one 1-dimensional direction. Moreover, in the present invention, by mounting this detector on an externally controllable rotationable stage, a magnification of the interference fringes and a rotation direction of the detector are automatically adjusted, so that the interference fringes can be detected under conditions of highest efficiency.
According to the present invention, the apparatus can detect interference fringes of the electron beams with an asymmetric 2-dimensional detector with integration capability, and adjust them at high-speed and easily, thereby being able to detect them under optimum conditions. Therefore, a scan image of a high S/N ratio can be obtained. Moreover, the use of one pair of detectors enables simultaneous display of the amplitude image and the phase image. Furthermore, unlike the conventional microscopes, this microscope uses no slit, and accordingly the whole electrons constituting the interference fringes can be used, achieving high detection efficiency.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagram explaining a method of carrying out the present invention.
FIGS. 2A and 2B are diagrams explaining a detection technique that is being carried out conventionally. FIG. 2A corresponds to a case where an aperture of the slit coincides with a position of constructive interference. FIG. 2B corresponds to a case where the aperture of the slit coincides with a position of destructive interference.
FIG. 3 is a flowchart explaining procedures of optimally adjusting the direction of interference fringes and the direction of a detector in the present invention.
FIG. 4 explains procedures of optimally adjusting the direction of interference fringes and the direction of a detector in the present invention.
FIG. 5 is a diagram explaining variation of spacing and contrast of interference fringes with magnification.
FIG. 6 is a diagram explaining a detection principle in the present invention.
FIG. 7 is a diagram explaining a display method in the present invention.
FIG. 8A is a diagram explaining a step of one embodiment of semiconductor dopant profile observation in the present invention.
FIG. 8B is a diagram explaining a step of the one embodiment of semiconductor dopant profile observation in the present invention.
FIG. 8C is a diagram explaining a step of the one embodiment of semiconductor dopant profile observation in the present invention.
FIG. 8D is a diagram explaining a step of the one embodiment of semiconductor dopant profile observation in the present invention.
FIG. 9A is a diagram explaining a step of one embodiment of magnetic domain observation in a magnetic thin film in the present invention.
FIG. 9B is a diagram explaining a step of the one embodiment of magnetic domain observation in the magnetic thin film in the present invention.
FIG. 9C is a diagram explaining a step of the one embodiment of magnetic domain observation in the magnetic thin film in the present invention.
FIG. 9D is a diagram explaining a step of the one embodiment of magnetic domain observation in the magnetic thin film in the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
First Embodiment
In this embodiment, an example where the present invention is applied to STEM will be described. FIG. 1 shows an example of a configuration of an STEM of this embodiment. The STEM of this embodiment comprises an electron gun 38 , an illumination system 39 , a specimen chamber 40 , an imaging system 41 , a detection system 42 , a control system, etc., as a rough breakdown of the STEM.
The electron gun 38 of the STEM of this embodiment consists of an electron source 1 , a first anode 2 , a second anode 3 , an acceleration anode 4 , etc. The illumination system 39 consists of an electron biprism 7 , a condenser aperture 8 , a first condenser lens 19 , a second condenser lens 10 , a scanning coil 11 , an objective lens pre-field 13 , an objective lens post-field 16 , etc. In addition, although not illustrated specifically, the electron biprism 7 is equipped with an electron biprism fine positioning system 35 , and is made movable by this. The imaging system 41 and the detection system 42 consist of a secondary electron detector 12 , the stigmator 19 , single or multiple imaging lenses 20 , a detector 23 , a rotationable stage 24 , a rotation mechanism 37 of the rotationable stage, etc. In addition to the secondary electron detector 12 , the STEM may be equipped with a reflected electron detector.
The control system consists of a CPU 25 , memory 26 , a display 27 , D/A converters 28 , 29 , a signal processor 32 , etc. The D/A converter 28 is connected with constituents of the electron optical system and the imaging system through signal transmission line, and a control signal from the CPU 25 is transferred to each constituent through the signal transmission line. Moreover, although not illustrated in the figure, the display 27 is equipped with information input means, such as a keyboard and a mouse, and the system user enters desired information into the system using the information input means as an input interface. There is a case where the CPU 25 , the D/A converter 28 , and the signal processor 32 may be housed in a single enclosure, each as a part of a control computer. The reference numerals 30 and 31 denote a specimen stage fine positioning system and a specimen stage fine positioning sensor, both of which are attached to the rotationable stage 24 . The numeral 37 denotes the rotation mechanism of the rotationable stage for moving the detector 23 and the rotationable stage 24 used in the present invention and replacing the detector 23 to another detector. The numeral 15 denotes a specimen stage, which is movable in an X-Y plane and in a Z-direction by stage drive means indicated by an arrow.
First, operations of the electron optical system will be explained. The electron biprism 7 is inserted between the electron source 1 and a first condenser lens 9 and a voltage is applied to this, whereby the electron beam is splitted into two which apparently come from two virtual electron sources 6 . The two splitted electron beams are focused with the first condenser lens 9 , a second condenser lens 10 , and further the objective lens pre-field 13 , respectively, to form two micro spots 14 on a plane of a specimen 15 . At this time, the two beams are so adjusted that one of the two micro spots transmits through the specimen and the other passes through a vacuum in proximity to the specimen. Note here that a distance of separation of the two micro spots becomes larger in proportion to a voltage applied to the electron biprism 7 .
In this embodiment, the voltage applied to the electron biprism 7 and the voltage applied to an electron beam deflection coil 11 are gang controlled in response to a magnification of an image to be observed. Although this gang control is automatically done by the CPU 25 , naturally the both voltages can be set manually. This gang control is realized by setting up the voltage of the electron biprism in such a way that the distance of separation of the two micro spots on the plane of the specimen which is calculated with both a deflection angle of the electron beam by the electron biprism and the electron optical system assumes either a comparative value of the spot size of the focused electron beam in each magnification power multiplied by a predetermined multiplier or an absolute value in proportion to an inverse of each magnification value.
Now, the electron beam having transmitted through the specimen and the electron beam passing though a vacuum overlap on an arbitrary plane below the specimen to generate interference fringes 17 , which is magnified with the imaging lenses 20 . The magnified interference fringes are recorded by the detector 23 disposed on an observation plane 22 . Generally, if the electron beam is scanned with the electron beam deflection coil 11 , the whole interference fringes will move. However, if the object plane of the imaging lenses 20 is adjusted to be on a pivot plane 18 of the electron beam, the interference fringes will not move even with electron beam scanning. Here, the “pivot plane” means an electron optics plane that remains immovable even when the electron beam is scanned at a fulcrum of deflection of the electron beam.
Here, the imaging lenses 20 may be of one stage or a combination of multi-stage lenses according to resolution of the detector. In this embodiment, the detector 23 is placed on the externally controllable rotationable stage 24 . Moreover, the electron biprism 7 , the detector 23 , and the rotationable stage 24 can be removed from the passage of the electron beam with the help of the fine positioning system 35 and the rotationable stage movement mechanism 37 , respectively, so that these components do not hinder operations of the system as a normal scanning transmission electron microscope. Naturally, this microscope can also be used as a special purpose apparatus of the scanning interference electron microscope. Furthermore, the use of the stigmator 19 consisting of a multipole is desirable because an image of the interference fringes is compressed in a direction parallel to the interference fringes and the intensity of the electron beams is enhanced.
Next, a method for observing the interference fringes by using the STEM shown in FIG. 1 will be explained using FIG. 3 . First, in Step 300 , the specimen is placed and held on the specimen stage 15 and carried into the vacuum chamber. Next, in Step 301 , a predetermined voltage is applied to the acceleration anode 4 to accelerate the electron beam generated in the electron source 1 . In Step 302 , field emission current is pulled out by applying suitable voltages to the first anode 2 and the second anode 3 .
In Step 303 , the electron biprism fine positioning system 35 is driven to move the electron biprism 7 to a predetermined position. In Step 304 , the electron biprism is adjusted by using a rotational mechanism of the electron biprism and a rotational mechanism of the specimen so that the edge of the specimen becomes parallel to the direction of the electron biprism.
In Step 305 , the monitor 27 shows a screen used to specify observation magnification, and the apparatus user enters the observation magnification into the apparatus by input means, such as a GUI and a keyboard. The CPU 25 determines a voltage to be applied to the biprism and transfers it to the electron biprism 7 based on the entered observation magnification. The applied voltage determined by the CPU 25 is converted into an analog control signal by the D/A converter 28 , and inputted into an unillustrated drive power supply for the electron biprism. Then, Step 306 is executed.
Next, in Step 307 , adjustment of the magnifying lens and the stigmator 19 is executed. That is, the magnification of the imaging lens 20 is suitably adjusted, the interference fringes 17 on the pivot plane 18 are converted into interference fringes 21 suitably magnified, and further these interference fringes 21 are compressed in a direction parallel to the fringes by adjusting the stigmator 19 .
In Step 308 , formation of the interference fringes 21 is completed in this way, and in Step 309 , the interference fringes 21 are grabbed by the apparatus through the detector 23 . Since the present invention uses one pair of detectors, what is inputted into the apparatus is a 1-dimensional image 33 or a 1-dimensional image 34 . In Step 310 , the inputted interference-fringes image is 1-dimensional-Fourier transformed by the processor 32 . From the results, the CPU 25 finds a current rotational speed and a peak position of the rotationable stage 24 , namely, a spatial frequency giving a peak and a peak intensity, and stores them in the storage device 26 . The rotation angle of the rotationable stage 24 is obtained by inputting an output of the specimen stage fine positioning sensor 31 provided in the rotationable stage 24 into the CPU 25 through the A/D converter 29 .
In Step 311 , whether or not the current rotation angle of the rotationable stage 24 is optimum is evaluated. That is, peak intensities corresponding to the respective rotation angles which cover up to 180 degrees are called from the storage device 26 , and whether or not a peak intensity corresponding to the current rotation angle is a maximum among them is evaluated. If data corresponding to rotation angles which cover up to 180 degrees is not obtained or if the current rotation angle is not optimum, the flow proceeds to Step 312 , where the rotation angle is varied by a previously set angle. This operation is done by the CPU 25 by inputting a signal to the specimen stage fine positioning system 30 provided in the rotationable stage 24 through the D/A converter 28 . Here, the flow returns to Step 310 again, and Step 311 and Step 312 are repeated until the rotation angle becomes optimum.
If the rotation angle of the detector is determined optimum, whether or not the magnification is optimum is determined in Step 313 . That is, the peak positions stored in Step 310 are scanned over a range of previously set spatial frequencies, and whether or not the peak position gives a maximum peak intensity among them is evaluated. If either of the two criteria is not satisfied, the flow goes back to Step 307 , where the magnification of the magnifying lens is varied by a previously set value, and Steps 308 to 313 are repeated.
If it is determined that the magnification is optimum in Step 313 , the flow proceeds to Step 314 , where the specimen is observed and the observation is finished in Step 315 . FIG. 4 is a diagram showing the imaging system and a main part of the control system of the STEM of FIG. 1 , and the operation flow shown in FIG. 3 is executed by constituents shown in FIG. 4 . In FIG. 4 , the drawing-out reference numeral 63 denotes interference fringes of the electron beam that passes through imaging lenses 62 and reaches a rotationable stage 66 . On the rotationable stage 66 , one pair of asymmetric 2-dimensional detectors with integration capability 64 , 65 are placed and held. Here the “asymmetric 2-dimensional detector with integration capability” means a detector which is made up of a 2-dimensional array of multi-pixels such that a ratio of the number of pixels in one dimension and the number of pixels in the other dimension is equal to or more than two and a value obtained by integrating values of pixels along a dimension having a smaller number of pixels is outputted as a value of each pixel being arrayed along the dimension having a larger number of pixels. This function may be realized with hardware or may be realized with software.
The asymmetric 2-dimensional detectors with integration capability 64 , 65 are each made up of a large number of electron sensing elements, wherein signals detected by the elements are integrated in a direction along a direction of integration sequentially and is outputted finally as a 1-dimensional image. In this embodiment, the output signal from the asymmetric 2-dimensional detector with integration capability 64 and the output signal from the asymmetric 2-dimensional detector with integration capability 65 are intended to be used for phase detection and for amplitude detection, respectively, and they are designated by symbols P and A in the figure, respectively.
The asymmetric 2-dimensional detectors with integration capability 64 , 65 are connected with signal transmission lines 67 , 68 , respectively, being connected to a signal processor 69 . A signal which transmits through the transmission line 67 is a signal for phase detection and a signal which transmits through the transmission line 68 is a signal for amplitude detection, and they are designated by DP and DA in FIG. 4 , respectively. The signal passing through the signal processor 69 is finally inputted into a CPU 70 , subjected to a predetermined operational processing, and subsequently displayed by display means 76 . A D/A converter 71 is provided in order to convert the rotation angle information of the rotationable stage 66 from the CPU 70 into an analog control signal and transfer it to a fine rotation mechanism 73 for the rotationable stage 66 , and also serves for a stigmator 61 and the imaging lenses 62 . An A/D converter 72 is provided in order to convert a signal from a sensor 74 for detecting rotation of the rotationable stage into digital data which the CPU 70 can process.
Next, a position adjustment flow of the detector will be explained in detail. Prior to observation of the specimen, it is necessary to form interference fringes first on the detector placed in the center of this scanning interference microscope, i.e., on the electron optical axis. This can be done by mechanical adjustment of the imaging lenses and adjustment of the electron beam deflection coil built in the illumination system. After this was completed, it is necessary to adjust the detector so that the interference fringes may be formed along a longitudinal direction of the detector used in the present invention. (It is necessary to adjust relatively a direction of the interference fringes and a direction of the asymmetric 2-dimensional detector with integration capability.) Here, the direction of the interference fringes of the electron beams and the direction of the detector are defined as follows. That is, the interference fringes of the electron beams are of a pattern in which an intense part and a weak part of the intensity of the electron beams are repeated in a 1-dimensionally direction in a sinusoidal manner. The 1-dimension direction in concern is defined as a direction of the interference fringes. The direction of the asymmetric 2-dimensional detector with integration capability is defined as its longitudinal direction. Adjusting the direction of the interference fringes and the direction of the detector thus defined can be achieved precisely by performing procedures as described below. These procedures will be explained using FIG. 4 similarly.
First, the interference fringes 63 are made to be incident on the detector 64 and the detector 65 , under appropriate conditions. The 1-dimensional image signal DA 67 which is an output of the phase detecting detector 64 or the 1-dimensional image signal DP 68 which is an output of the amplitude detecting detector 65 is subjected to 1-dimensional fast Fourier transform, namely converted to a spatial frequency spectrum, by the signal processor 69 . When the spectrum is displayed on the display 76 , if the direction of the interference fringes and the direction of the detector agree with each other, a clear peak 77 is observed in the spectrum. The signal processor 69 may be realized with hardware using a special board, or may be realized by executing software of Fourier transform on the CPU 70 .
In line with this, rotational angle detection means, such as the angle sensor 74 , is provided in the rotationable stage 66 , and a rotational angle of the rotationable stage 66 counting from the start of rotation is outputted as an angle signal, which is inputted into the CPU 70 though the A/D converter 72 . The CPU 70 displays a phase signal inputted from the signal converter 69 on the display means 76 in synchronization with the angle signal from the A/D converter 72 . Then, data showing a dependence of the peak intensity of the spectrum on the rotational angle of the rotationable stage, as shown in a graph 78 , on the display means 76 . Observing the height of the peak while rotating the detector, the peak intensity assumes a maximum when the angle of the rotation agrees with a best matched direction. The angles at which the peak intensity becomes maximums are determined as optimum arrangement angles of the asymmetric 2-dimensional detectors with integration capability 64 , 65 , respectively. Determination of the optimum arrangement angle may be selected by the apparatus user, or the apparatus may control adjustment of rotation angle so that the optimum peak is automatically selected.
In the case where the apparatus user itself selects the optimum peak, the apparatus is so controlled that, when rotation of the rotationable stage is ended in a range of horizontal direction of the graph 78 , the apparatus becomes a state of waiting an entry from the user. When the apparatus becomes the state of waiting an entry, the apparatus allows the apparatus user to select a peak which is considered optimum from the graph 78 displayed on the display screen 76 with input means, such as a mouse and as key board, entering information of the optimum peak into the apparatus. The information of the optimum peak entered by the apparatus user is transferred to the CPU 70 , and the CPU 70 reads a rotation angle of the optimum peak from the display image (graph 78 ) based on the inputted information and forwards the information of the optimum angle to the D/A converter 71 . The optimum angle is fed back to the fine rotation mechanism 73 installed in the rotationable stage 66 . The control means of the rotationable stage rotates the rotationable stage based on the angle information fed back thereto, and optimizes the arrangement angle of the asymmetric 2-dimensional detectors with integration capability 64 , 65 .
In the case where the apparatus optimizes the arrangement angle of the asymmetric 2-dimensional detectors with integration capability in a fully automatic manner, the CPU 70 automatically reads an optimum peak from the graph 78 and feeds it back to the fine rotation mechanism 73 for the rotationable stage through the D/A converter 71 . In this case, it is not necessary to control the apparatus to be in the state of waiting for the user's entry after the end of the rotation of the rotationable stage; automatic reading of the optimum peak may be started just after the end of the rotation. It is needless to say that the apparatus needs to be adjusted in advance so that the center of the detector coincides with the center of the interference fringes before the adjustment of the optimum arrangement angle of the interference fringes described above.
Note here that, since the interference fringes are integrated in a direction parallel to the interference fringes in the case of the asymmetric 2-dimensional detector with integration capability used in this embodiment, a clear peak can be obtained only when the direction of the interference fringes agrees with the direction of the detector in a highly precise manner; therefore, the direction of the two can be adjusted precisely. Moreover, integration of the interference fringes enhances the ratio excellently, and consequently the directions can be adjusted further accurately. By such procedures, it becomes possible to bring the direction of the interference fringes and the direction of the detector into agreement with each other with high precision.
A next important adjustment subject is adjustment between a fringe spacing of the interference fringes, or a magnification of the interference fringes, and a pixel size of the detector. FIG. 5 shows several electron interference fringes formed under fixed conditions recorded on a high-resolution film while varying only the magnification. A film whose resolution allows interference fringes having a fringe spacing of about 3 μm at a minimum to be recorded was used. When the magnification is so reduced that the interference fringe spacing becomes 33 μm, 13 μm, 9 μm, 5.5 μm, and 3.8 μm on the film, an exposure time necessary to achieve the same optical density becomes smaller as 240 sec, 120 sec, 60 sec, 8 sec, and 4 sec, respectively. Observing a profile ( FIG. 5 , right row) obtained by integrating the interference fringes recorded under these conditions in a direction parallel to the fringe of the interference fringes, it is found that a highest contrast is achieved with an interference fringe spacing of 5.5 μm and an exposure time of 8 sec. As shown in this example, it is preferable to record the interference fringes with as small a magnification as possible. However, when the interference fringe spacing comes close to a resolution limit of a detector (in this case, the film), the contrast blurs because constructive interference and destructive interference cannot be recorded.
The above fact teaches that in order to detect the interference fringes, it is recommended to magnify the interference fringes so as to have a best fringe spacing which complies with the resolution of the detector. So, in this embodiment, the magnifying lens 62 and the stigmator 61 are controlled by the CPU 70 and the D/A converter 71 , as shown in FIG. 4 , and a position and the height of the peak in the 1-dimensional Fourier conversion of the interference fringes are adjusted by the same procedures as was used in adjusting a direction of the detector. The adjustment is done by the following procedures.
First, the magnifying lens 62 is so adjusted that the electron beam is incident on the center of the detector under a condition that the spacing of the interference fringes 63 is sufficiently large as compared to a size of a pixel of the detector 64 or detector 65 . Then, the stigmator 61 is so adjusted that the interference fringes are compressed in a direction parallel to the interference fringes. After that, the direction of the detectors is optimized with respect to the direction of the interference fringes by the procedures described above. At this time, a peak value in a spatial frequency spectrum of the interference fringes under the optimum conditions is stored in a storage device 75 . Next, the magnification of the magnifying lens 62 is made small, the same procedures are repeated, and a peak in the spectrum corresponding to a current value of the magnifying lens 62 is stored sequentially. Subsequently, the current value of the magnifying lens 62 is plotted on the horizontal axis and the peak value in the spectrum is plotted on the vertical axis. Since the peak value in the spectrum becomes a maximum at an optimum magnification of the magnifying lens 62 , the magnifying lens 62 and the stigmator 61 are set to this condition and the adjustment is finished.
By the above procedures, the interference fringes can be detected under the optimum conditions. Naturally, these adjustment procedures can be put in a program and be performed automatically. It goes without saying that the procedures of matching the direction of the interference fringes described above can be realized by finely tuning a mechanism for rotating the electron biprism in a plane vertical to the direction of the electron beam, except for the rotation of the detector.
Now, procedures of obtaining both the amplitude image and the phase image simultaneously after setting detection of the interference fringes to be under the optimum conditions in this way will be explained using FIG. 6 . Note that, in FIG. 6 , a rectangular pattern that is hatched is a conceptual image of a digital output signal. First, for the amplitude image, an output signal by the asymmetric 2-dimensional detector with integration capability is obtained in the absence of specimen or under a condition that both of the two spots splitted by the electron biprism pass through a vacuum on the plane of specimen and stored in the storage means, which is designated as D A-in 80 . Next, under a condition that one of the spots transmits through the specimen and the other passes through a vacuum, an output signal D A-in 79 of the asymmetric 2-dimensional detector with integration capability is obtained. The two output signals are added by an adder 81 to obtain an output signal, which is designated as D A-n+A0-in 82 .
Further, this is integrated for all the pixels to obtain an output signal, which is designated as I A-out 83 . This output signal I A-OUT 83 is equivalent to an amplitude image of a normal electron microscope. In this embodiment, in parallel to the acquisition of the amplitude image, a phase image is obtained simultaneously using another asymmetric 2-dimensional detector with integration capability. That is, under conditions that there is no specimen or the two spots splitted by the electron biprism both pass through a vacuum on the plane of specimen as in the case of the acquisition of the amplitude image, an output signal of the asymmetric 2-dimensional detector with integration capability is obtained and recorded as D P0-in 85 .
Next, under conditions that one of the spots transmits through the specimen and the other spot passes through a vacuum, an output signal D P-in 84 of the asymmetric 2-dimensional detector with integration capability is acquired, and the two signals are added by an adder 86 to obtain a 1-dimensional image D P-in+P0-in 87 . Using a processor 89 which keeps values equal to or larger than a certain threshold of the pixels among the pixels constituting the 1-dimensional image D P-in+P0+in 87 and sets the values of other pixels to zero, a 1-dimensional image D P-OUT 90 composed of values of the pixels each having a value equal to or larger than the certain threshold is obtained. Here, for the threshold, a 1-dimensional image D P-TH 88 that is set arbitrarily by the user may be used. Alternatively, a 1-dimensional image D P-TH 88 each of whose pixels has an average value of the output signal I A-OUT 83 of the amplitude image. Each pixel value of the 1-dimensional image D P-OUT 90 thus set up is integrated over all the pixels to obtain an output signal, which is designated as I P-OUT 91 . The two kinds of output signals I A-OUT 83 and I P-OUT 91 obtained in the above may be displayed, as they are, as the amplitude image and the phase image on the screen, respectively. Alternatively, as shown in the bottom of FIG. 6 , another signal I P-NORMALIZED 92 may be generated from the two signals and displayed as a new phase image. Here, a computing equation used to covert the signal is given by the following expression.
I P-NORMALIZED =( I P-OUT −I A-OUT ) /I A-OUT
This signal I P-NORMALIZED 92 becomes an output signal of the image corresponding to the cosine of a phase. Naturally, the output signal may be further converted to obtain an output signal of an image that corresponds to a value of the phase. Incidentally, the storage device, the adder 86 , and the processor 89 correspond to the storage device 26 , the CPU 25 , and the signal processor 32 , respectively, in the configuration of the STEM shown in FIG. 1 .
In this way, in this embodiment, the amplitude image and the phase image can be acquired simultaneously. In order to display the two images simultaneously, the two may be displayed independently on the screen of the display. Alternatively, a signal I A-OUT 94 of the amplitude is brought into correspondence with a Lightness value, as shown in FIG. 7 , a signal I P-OUT 95 corresponding to the cosine of a phase or a signal obtained by further converting it into a phase value is brought into correspondence with a Hue value of the HLS color model, and this is converted to the RGB model with a converter 96 to be displayed in a display 97 . Thus, the phase image and amplitude image are simultaneously displayed, overlaying one image on the other in the same display. The simultaneous display of the two images makes possible for the user to observe both a structure which is recognizable from the amplitude image and a potential distribution or a magnetic field distribution of the sample which is recognizable from the phase image, thereby making it easy to observe the both images being correlated with each other.
Second Embodiment
FIGS. 8A to 8D show another example of this embodiment. In this example, this embodiment is applied to dopant profile evaluation of a semi-conductor transistor. First, a voltage is applied to the electron biprism in the absence of specimen, the interference fringes magnified with an imaging lens is made to be incident on the asymmetric 2-dimensional detector with integration capability. After that, the electron beams are deflected with a deflection coil, and thereby the electron beams take an arrangement as shown in FIG. 8A . Here, one of two splitted electron beam spots 98 , 99 is adjusted to pass through a vacuum and the other is adjusted to transmit through the specimen. Next, the two splitted electron beam spots are scanned in a direction of scanning 100 , and at each predetermined scanning distance, the interference fringes are acquired. FIG. 8B shows a comparative relation between the specimen and the electron beam spot at the time when the electron beam is scanned as far as the central portion of a semiconductor thin film specimen. Further the scanning is continued so as to complete the scanning of the electron beam as far as a desired range ( FIG. 8C ), and subsequently an image corresponding to a dopant profile in an area 107 can be obtained from an image which corresponds to sequentially acquired cosine values of phases of the electron beam or values obtained by converting them into phases.
Third Embodiment
FIGS. 9A to 9D show further another example of the embodiment. In this, the STEM is applied to magnetic domain structure evaluation of a magnetic thin film. First, in the absence of specimen, a voltage is applied to the electron biprism and interference fringes magnified with an imaging lens are made to be incident on the asymmetric 2-dimensional detector with integration capability. After that, by deflecting the electron beam with a deflection coil, the electron beams take an arrangement as shown in FIG. 9A . Here, two splitted electron beam spots 108 , 109 are so adjusted that one of them passes through a vacuum in proximity to the specimen and the other transmits through the specimen.
Next, while the two splitted electron beam spots are being scanned in a direction of scanning 110 , the interference fringes are acquired at each predetermined scanning distance. FIG. 9B shows a comparative relation between the specimen and an electron beam spot at a time when the electron beam is scanned as far as the central part of a semiconductor thin film specimen. Further the scanning is continued so as to complete the scanning of the electron beam as far as a desired range ( FIG. 9C ), and subsequently contour line displays 119 , 120 which correspond to a magnetic domain structure 113 in a magnetic thin film 112 and a stray magnetic field in a vacuum 111 in proximity to the specimen can be obtained. Note that, in this embodiment, the apparatus outputs cosine values of phases rather than values obtained by converting the cosine values of phases into phases, whereby a display corresponding to magnetic lines of force can be obtained directly.
The present invention relates to a scanning interference electron microscope used for evaluation of electric and magnetic characteristics of a micro domain.
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The conventional detection technique has the following problems in detecting interference fringes: (1) Setting and adjustment are complex and difficult to conduct; (2) A phase image and an amplitude image cannot be displayed simultaneously; and (3) Detection efficiency of electron beams is low. The invention provides a scanning interference electron microscope which is improved in detection efficiency of electron beam interference fringes, and enables the user to observe electric and magnetic information easily in a micro domain of a specimen as a scan image of a high S/N ratio under optimum conditions.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a filing under 35 U.S.C. 371 of International Application No. PCT/GB2007/004320 filed Nov. 13, 2007, entitled “Process for the Synthesis of Moxifloxacin Hydrochloride,” claiming priority of Indian Patent Application No. 1879/MUM/2006 filed Nov. 13, 2006, which applications are incorporated by reference herein in their entirety.
FIELD OF THE INVENTION
The present invention relates to a process for the preparation of moxifloxacin, and more particularly relates to a process for the preparation of moxifloxacin which uses a novel Borate intermediate. The present invention relates to a novel crystalline form of moxifloxacin hydrochloride and process to prepare the same.
BACKGROUND OF THE INVENTION
Moxifloxacin hydrochloride {1-cyclopropyl-7-[S,S]-2,8-diazabicyclo-[4,3,0]non-8-yl)6-fluoro-1,4-dihydro-8-methoxy-4-oxo-3-quinoline carboxylic acid hydrochloride} is known from EP 350733 & EP 550903 and has the following chemical structure.
Moxifloxacin is a fluoroquinolone broad spectrum antibacterial agent, shown to be clinically active against Gram-positive microorganisms including staphylococcus aureus, streptococcus pneumonia , and streptococcus pyogenes ; significantly better than those of Sparfloxacin and Ciprofloxacin that was disclosed in EP No 350,733 and EP No 550,903. Moxifloxacin also has activity against Gram-negative microorganisms including haemophilus influenzae, haemophilus parainfluenzae, klebisiella pneumoniae , and moraxella catarrhalis.
The prior art disclosed in European patent No's EP 350,733, EP 550,903 and EP 657,448 describes the preparation of moxifloxacin hydrochloride involving the condensation of 1-cyclopropyl-6,7-difluoro-8-methoxy-4-oxo-1,4-dihydro-3-quinoline carboxylic acid or its esters with (S,S)2,8-diazabicyclo[4.3.0]nonane in presence of a base and its conversion to hydrochloride at higher temperatures leading to the desired moxifloxacin along with its potential isomer namely (4aS-Cis)-1-cyclopropyl-6-(2,8-diazabicyclo[4.3.0]non-8-yl)-7-fluoro-8-methoxy-4-oxo-1,4-dihydro-3-quinoline carboxylic acid as a major impurity. As the impurity and moxifloxacin are positional isomers they are difficult to separate. Further, purification of moxifloxacin to remove this isomer results in lower yields thereby increasing the product cost.
U.S. Pat. No. 5,849,752 discloses the monohydrate of moxifloxacin hydrochloride{1-cyclopropyl-7-[S,S]-2,8-diazabicyclo-[4,3,0]non-8-yl)-6-fluoro-1,4-dihydro-8-methoxy-4-oxo-3-quinoline carboxylic acid hydrochloride} (CDCH) and its preparation by treating the anhydrous crystalline form with ethanol/water mixtures.
Moxifloxacin hydrochloride exhibits polymorphism. WO 2004/091619 discloses a new crystalline Form III of moxifloxacin monohydrochloride and processes for making the crystalline form using an alkanol and an antisolvent for precipitation. This patent discloses X-ray powder diffraction patterns, 13 C solid state NMR spectra, Differential scanning calorimetry (DSC) thermogram and IR spectrum of the crystalline form III.
However, it is known that polymorphic forms of the same drug may have substantial difference in certain pharmaceutically important properties such as dissolution characteristics and bioavailability as well as stability of the drug. Furthermore, different crystalline form may have different particle size, hardness and glass transition temperature. Thus, one crystalline form may provide significant advantages over other crystalline forms of the same drug in solid dosage form manufacture processes, such as accurate measurement of the active ingredients, easier filtration, or improved stability during granulation or storage. Furthermore, a particular process suitable for one crystalline form may also provide drug manufacturers several advantages such as economically or environmentally suitable solvents or processes, or higher purity or yield of the desired product.
U.S. Pat. No. 5,157,117 discloses (1-cyclopropyl-6,7-difluoro-8-methoxy-4-oxo-1,4-dihydro-3-quinoline carboxylic acid-O 3 ,O 4 )bis(acyloxy-O)borate and a process for its preparation by reacting ethyl-1-cyclopropyl-6,7-difluoro-8-methoxy-4-oxo-1,4-dihydro-3-quinoline carboxylate with Boric acid and acetic anhydride in presence of zinc chloride and its conversion to Gatifloxacin hydrochloride.
WO 2005/012285 discloses the process for the preparation of moxifloxacin hydrochloride using a novel intermediate namely (4aS-Cis)-(1-cyclopropyl-7-(2,8-diazabicyclo[4,3,0]non-8-yl)-6-fluoro-8-methoxy-4-oxo-1,4-dihydro-3-quinoline carboxylic acid-O 3 ,O 4 )bis(acycloxy-O)borate. The disclosure further refers to the preparation of moxifloxacin hydrochloride pseudohydrate and conversion to moxifloxacin hydrochloride monohydrate. The fingerprinting of the novel intermediate, moxifloxacin hydrochloride pseudohydrate and moxifloxacin hydrochloride anhydrous and moxifloxacin hydrochloride monohydrate forms are substantiated using NMR, FTIR and X-ray diffraction analysis.
Prior art processes for the preparation of the Borate complex without use of catalyst has its limitations owing to higher exothermicity during acetylation thereby reducing the reaction purity which is indicated in the lower yields obtained when further converted to moxifloxacin after condensation with nonane and subsequent hydrolysis. Also prior art makes use of triethyl amine as a base required for the condensation step with nonane.
Hence it is a long felt need of the industry to provide a simple, safe and cost effective process that produces moxifloxacin hydrochloride with high product yield and quality.
SUMMARY OF THE INVENTION
In one aspect, invention relates to a new crystalline form of moxifloxacin hydrochloride designated herein as Form C. The invention also relates to a method of making the new form and to pharmaceutical compositions containing it.
In another aspect the invention relates to new intermediates for use in making moxifloxacin and salts thereof, of formulas (1) and (2):
The invention also relates to method of making the intermediates (1) and (II).
According to an aspect of the invention there is provided a method of making a compound of formula (I), comprising reacting propionic anhydride and boric acid with Ethyl-1-cyclopropyl-6-7-difluoro-8-methoxy-4-oxo-1,4-dihydro-3-quinolone carboxylate, preferably without the use of any catalyst, to obtain the compound of formula (I).
According to an aspect of the invention there is provided a method of making a compound of formula (II), as defined in claim 20 , comprising condensing a compound of formula (I), as defined in claim 18 , with (S,S)-2,8-Diazabicyclo[4.3.0]nonane in an organic solvent, preferably in the absence of a base, to obtain the compound of formula (II).
BRIEF DESCRIPTION OF THE DRAWINGS
Reference is made to the accompanying drawings, in which:
FIG. 1 is an X-ray diffraction pattern of moxifloxacin hydrochloride Form C.
FIG. 2 is a FTIR of moxifloxacin hydrochloride Form C.
FIG. 3 is a differential scanning calorimetry (DSC) of moxifloxacin hydrochloride Form C.
FIG. 4 is a Raman Spectra of moxifloxacin hydrochloride Form C.
DETAILED DESCRIPTION OF THE INVENTION
The present invention provides an improved process for the preparation of moxifloxacin base, or a salt thereof, especially the hydrochloride salt, using a novel intermediate (I) and (II).
In one embodiment of the present invention the process comprises first reacting boric acid and propionic anhydride with ethyl 1-cyclopropyl-6,7-difluoro-8-methoxy-4-oxo-1,4-dihydro-3-quinolinecarboxylate (A) without using any catalyst to give a novel borate complex of formula (I), 1-cyclopropyl-6,7-difluoro-8-methoxy-4-oxo-1,4-dihydro-3-quinoline carboxylic acid-O 3 ,O 4 )bis(propyloxy-O)borate.
In another embodiment of the present invention the novel borate complex (I) may be condensed with (S,S)-2,8-Diazabicyclo[4.3.0]nonane (B) in absence of any base using an organic polar solvent to give novel intermediate of formula (II).
The intermediate (II) may be subjected to hydrolysis to get moxifloxacin base. The base may be treated with hydrochloric acid in the presence of a suitable solvent to give moxifloxacin hydrochloride.
Surprisingly, it was found that use of propionic anhydride without the use of any catalyst during the preparation of Borate complex follows a nonexothermic pathway resulting in lesser impurity formation and hence better recovery of the product. Also reaction of the propionate complex with the nonane (B) without the use of a base results in moxifloxacin with excellent yields. In general, we prefer that a base is used if the temperature of the reaction is less than or equal to about 100° C. We prefer that a base is used if the temperature of the reaction is above 100° C.
The process of present invention wherein the novel borate complex (I) is condensed with (S,S)-2,8-Diazabicyclo[4.3.0]nonane (B) can be optionally carried out in using sodium methoxide, triethyl amine as base in an organic polar solvent to give novel intermediate of formula (II).
The yield of moxifloxacin hydrochloride is much higher compared with the yields from prior art processes: 100.0 g of nonane yields 260.0 g of moxifloxacin hydrochloride using the process of the present invention whereas; 100.0 g of nonane yields 187.0 g of moxifloxacin hydrochloride as per prior art process.
In yet another aspect the present invention provides a novel crystalline form of moxifloxacin hydrochloride herein designated Form C, and a process for the preparation of Form C which comprises the step of: dissolving or suspending the moxifloxacin base in methanol treating with methanolic hydrochloric acid, preferably at a temperature range of 0° C. to 30° C., and isolating moxifloxacin hydrochloride form C from methanol.
It is preferred that the methanol is substantially pure, i.e., it has a water content less than 0.5 wt %.
It is preferred that the methanolic hydrochloride comprises 10-15% HCl gas dissolved in methanol.
The moxifloxacin base may be formed according to the processes described above, specifically:
i) Reacting Propionic anhydride and boric acid with Ethyl-1-cyclopropyl-6-7-difluoro-8-methoxy-4-oxo-1,4-dihydro-3-quinolone carboxylate (A) to obtain 1-cyclopropyl-6,7-difluoro-8-methoxy-4-oxo-1,4-dihydro-3-quinoline carboxylic acid-O 3 ,O 4 bis(propyloxy-O)borate (I); ii) Condensing the borate complex (I) with nonane (B) in the absence of a base and in an organic solvent to obtain a novel intermediate (4aS-Cis)-(1-cyclopropyl-7-(2,8-diazabicyclo[4.3.0]non-8-yl)-6-fluoro-8-methoxy-4-oxo-1,4-dihydro-3-quinoline carboxylic acid-O 3 ,O 4 )bis(propyloxy-O)borate (II); and iii) hydrolysing the intermediate (II) to get moxifloxacin base
Moxifloxacin Hydrochloride Form C according to the present invention is further characterized by X-ray powder diffraction spectrum as obtained by X-ray powder diffraction spectrum measured on a Rigaku D-maz-2200 advance X-ray powder diffractometer having a copper-k-α radiation as shown in FIG. 1 .
Moxifloxacin Hydrochloride Form C is further characterized by having characteristic peaks (2 θ°) at least at 15.080, 27.86, and 28.221±0.2 θ°. The peaks are shown in more detail in Table 1.
TABLE 1
2 THETA VALUES
I/I 0
5.72
21.3
7.139
68.6
8.499
100
8.779
23.7
10.24
85.8
12.20
10.9
13.139
45.4
13.98
23.5
14.50
31.6
14.799
61.8
15.08
46.6
16.52
49.8
17.04
59.6
17.219
41.1
17.74
54.4
19.239
87.5
19.679
37.3
21.54
92.6
22.22
29.8
24.60
20.9
25.06
37.2
25.72
31.4
26.42
65.7
26.88
61
27.260
64.4
27.86
27.9
28.221
23.2
28.882
30.5
29.859
30.1
31.461
7.5
32.101
16.7
33.420
5.6
33.879
10.8
34.860
15.3
36.659
7.8
37.299
12.2
37.638
9.8
38.981
21.8
Furthermore, the following Table 2 shows in more detail the data for the XRPD shown in FIG. 1 .
TABLE 2
[RD-MOXIHCl-28.raw] MOXIFLOXACIN - RD-MOXIHCl-28
Peak Search Report
#
2-Theta
d(Å)
Height
Height %
FWHM
1
5.720
15.4388
381
21.3
0.216
2
6.504
13.5794
120
6.7
0.489
3
7.139
12.3714
1225
68.6
0.332
4
8.499
10.3947
1786
100.0
0.294
5
8.779
10.0639
423
23.7
0.442
6
10.241
8.6305
1532
85.8
0.269
7
12.201
7.2482
195
10.9
0.153
8
13.139
6.7329
810
45.4
0.238
9
13.980
6.3297
420
23.5
0.662
10
14.501
6.1035
564
31.6
1.105
11
14.799
5.9811
1104
61.8
0.611
12
15.080
5.8703
821
46.0
0.458
13
16.522
5.3610
889
49.8
0.564
14
17.040
5.1991
1064
59.6
0.542
15
17.219
5.1456
734
41.1
0.987
16
17.740
4.9957
972
54.4
0.303
17
19.239
4.6097
1563
87.5
0.367
18
19.679
4.5075
666
37.3
0.401
19
21.540
4.1221
1654
92.6
0.391
20
22.220
3.9975
533
29.8
0.708
21
24.601
3.6156
374
20.9
0.455
22
25.060
3.5505
665
37.2
0.376
23
25.720
3.4609
560
31.4
0.371
24
26.420
3.3707
1174
65.7
0.606
25
26.880
3.3141
1089
61.0
0.813
26
27.260
3.2688
1150
64.4
1.072
27
27.860
3.1997
499
27.9
0.843
28
28.221
3.1596
414
23.2
0.273
29
28.882
3.0888
545
30.5
0.222
30
29.859
2.9899
538
30.1
0.327
31
31.003
2.8821
43
2.4
0.584
32
31.461
2.8412
134
7.5
1.031
33
32.101
2.7860
298
16.7
0.707
34
33.420
2.6790
100
5.6
0.509
35
33.879
2.6437
193
10.8
0.684
36
34.860
2.5716
273
15.3
0.522
37
36.659
2.4494
140
7.8
0.933
38
37.299
2.4088
217
12.2
0.837
39
37.638
2.3879
175
9.8
1.534
40
38.981
2.3086
390
21.8
0.415
SCAN: 3.0/40.0/0.02/0.6(sec), Cu(40 kV, 30 mA), I(max) = 1933. Sep. 20, 2006 16:33
PEAK: 15-pts/Parabolic Filter, Threshold = 2.0, Cutoff = 1.5%, BG = 4/2.0, Peak − Top = Summit
NOTE:
Intensity = Counts, 2T(0) = 0.0(deg), Wavelength to Compute d-Spacing = 1.54056 Å (Cu/K-alpha1)
Moxifloxacin Hydrochloride Form C according to the present invention is further characterized by IR, DSC, and Raman as shown respectively in FIGS. 2 , 3 and 4 .
In the IR spectrum of moxifloxacin hydrochloride Form C, the wave number of several distinctive peaks may help to identify the crystalline nature of the compound. These IR peaks measured on IR Thermo Nicolet instrument includes absorption bands at about 3367 cm −1 ; 2931 cm −1 ; 2885 cm −1 ; 2728 cm −1 ; 2691 cm −1 ; 1733 cm −1 ; 1311 cm −1 ; 1242 cm −1 ; 1104 cm −1 ; 923 cm −1 .
Moxifloxacin Hydrochloride Form C according to the present invention is further characterized by DSC having a melting endotherm peak at 253° C. The DSC spectrum was measured on Perkin Elmer Diamond DSC.
Moxifloxacin Hydrochloride Form C according to the present invention is further characterized by Raman Spectra having Raman peaks at 3094.48, 3079.19, 3052.84, 3038.86, 3012.81, 2997.21, 2964.58, 2934.40, 2879.86, 1741.20, 1618.72, 1547.70, 1490.01, 1462.68, 1430.60, 1393.53, 1372.62, 1354.07, 1337.13, 13124.47, 1302.62, 1277.88, 1226.72, 1207.46, 1189.47, 1164.50, 1104.89, 1030.51, 957.69, 939.73, 888.57, 831.46, 783.78, 723.06, 687.13, 541.70, 477.11, 425.87, 389.22, 306.92, 271.51, 228.03, 207.24, 140.22, 103.95, 75.76. cm −1 . The Raman spectra is done on the instrument Bruker RFS-100S.
The invention also relates to pharmaceutical compositions comprising moxifloxacin hydrochloride Form C. It can be formulated with one or more pharmaceutically acceptable carriers, also known as excipients, which ordinarily lack pharmaceutical activity, but have various useful properties which may, for example, enhance the stability, sterility, bioavailability, and ease of formulation of a pharmaceutical composition. These carriers are pharmaceutically acceptable, meaning that they are not harmful to humans or animals when taken appropriately and are compatible with the other ingredients in a given formulation. The carriers may be solid, semi-solid, or liquid, and may be formulated with the compound in bulk. The resulting mixture may be manufactured in the form of a unit-dose formulation (i.e., a physically discrete unit containing a specific amount of active ingredient) such as tablet or capsule.
In another aspect, the invention also provides methods of treating infections caused by susceptible strains of staphylococcus aureus, streptococcus pneumoniae , and streptococcus pyogenes, haemophilus influenzae, haemophilus parainfluenzae, klebisiella pneumoniae , and moraxella catarrhalis which includes administering a mammal in need thereof an effective amount of the moxifloxacin hydrochloride Form C.
EXAMPLES
The examples which will follow will further illustrate the preparation of the compound of the invention, according to different process routes and including new intermediates. These examples are not intended to limit the scope of the invention as defined hereinabove or as claimed below in any way.
Example 1
Propionic anhydride (200.0 g) was heated to 80-85° C. and boric acid (30.0 g) was added at a temperature range of 80-90° C., refluxed for 2 hours, and later cooled to 70° C. Ethyl-1-cyclopropyl-6-7-difluoro-8-methoxy-4-oxo-1,4-dihydro-3-quinolone carboxylate (100 g) was added under stirring. The reaction mass temperature was raised to 100° C. and maintained for 4 hours at 100° C. After the completion of reaction the reaction mass was cooled to 0° C., purified water (1000.0 ml) was slowly added at 0° C. and maintained for 1 hour at 0-5° C. The product was filtered, washed with water (400.0 ml) and dried at 45-50° C. in Fluid bed drier to get 135.0 g (96.0%) of 1-cyclopropyl-6,7-difluoro-8-methoxy-4-oxo-1,4-dihydro-3-quinoline carboxylic acid-O 3 ,O 4 bis(propyloxy-O)borate.
Example 2
1-cyclopropyl-6,7-difluoro-8-methoxy-4-oxo-1,4-dihydro-3-quinoline carboxylic acid-O 3 ,O 4 bis(propyloxy-O)borate (100.0 g) was suspended in n-butanol (500.0 ml) to which (S,S)-2,8-diazabicyclo(4,3,0)nonane (29.0 g) diluted with 100.0 ml n-butanol was added slowly at 10-15° C. The contents were heated to 100° C. and maintained for 3 hours. After the completion of reaction it was cooled to 25-30° C. 200.0 ml methanol was added and pH was adjusted 1.0-2.0 using methanolic hydrochloric acid. The contents were stirred at 25-30° C. for 2 hours. After completion of reaction the reaction mass was distilled to residue. Purified water 500 ml was added and pH was adjusted to 7.5-9.0 using liquor ammonia. The reaction mass was then extracted with dichloromethane. The organic layer was dried using sodium sulphate and concentrated to residue. The residue was stripped with 100 ml methanol. 300 ml methanol was charged and pH was adjusted to 1.0-2.0 using methanolic hydrochloric acid, the contents were further cooled to 0-5° C. and maintained for 1 hour. The solid was filtered and washed with chilled methanol (50.0 ml) and dried under vacuum at 85-90° C. to yield 75.0 g (75%) of moxifloxacin hydrochloride.
Example 3
1-cyclopropyl-6,7-difluoro-8-methoxy-4-oxo-1,4-dihydro-3-quinoline carboxylic acid-O 3 ,O 4 bis(propyloxy-O)borate (100.0 g) was suspended in acetonitrile (445.0 ml). (S,S)-2,8-diazabicyclo(4,3,0)nonane (29.0 g) diluted with 50.0 ml acetonitrile. The contents were heated to reflux temperature optionally in presence of triethyl amine and maintained for 2 hours. The reaction mass was distilled under vacuum to residue. Diisopropyl ether (500.0 ml) was added and the contents were cooled to 25-30° C. The resulting product was filtered and washed with diisopropyl ether (50.0 ml) and dried at 45-50° C. under vacuum to yield 120.0 g (93.8%) of (4aS-Cis)-1-Cyclopropyl-7-(2,8 diazabicyclo[4.3.0]non-8-yl)-6-fluoro-8-methoxy-4-oxo-1,4-dihydro-3-quinoline carboxylic aid-O 3 ,O 4 ) bis(propyloxy-O)borate.
Example 4
(4aS-Cis)-1-Cyclopropyl-7-(2,8 diazabicyclo[4.3.0]non-8-yl)-6-fluoro-8-methoxy-4-oxo-1,4-dihydro-3-quinoline carboxylic aid-O 3 ,O 4 )bis(propyloxy-O)borate (100.0 g), was suspended in 500.0 ml methanol and pH was adjusted to 1.0-2.0 using hydrochloric acid. The reaction mass was maintained at 10-15° C. for 2 hours. The reaction mass was distilled to obtain a residue. Purified water 500.0 ml was added and pH was adjusted to 7.5-8.0 using liquour ammonia. The contents were stirred for 15 minutes and heated to 70-75° C. The reaction mass was then cooled to 25-30° C. and stirred for 1 hour. The resulting solid were filtered and washed with purified water and dried under vacuum at 55-60° C. to obtain 65.0 g (90%) moxifloxacin base.
Example 5
The (4aS-Cis)-1-Cyclopropyl-7-(2,8 diazabicyclo[4.3.0]non-8-yl)-6-fluoro-8-methoxy-4-oxo-1,4-dihydro-3-quinoline carboxylic acid-O 3 ,O 4 )bis(propyloxy-O)borate (100.0 g), was suspended in about 500.0 ml methanol and pH was adjusted to 1.0-2.0 using hydrochloric acid and stirred at 10-15° C. for 2 hours. The reaction mass was distilled to residue. Purified water 500.0 ml was added and pH was adjusted to 7.5-8.0 using liquour ammonia. The reaction mass was extracted with 500.0 ml methylene chloride and organic layer was washed with 70.0 ml purified water, dried over sodium sulphate. The organic layer was distilled under vacuum, stripped off with 200.0 ml methanol. Methanol 200.0 ml was added and chilled to 0-5° C. and stirred for 1 hour. The resulting solid was filtered and washed with chilled methanol and dried under vacuum at 55-60° C. to obtain 65.0 g (90%) moxifloxacin base.
Example 6
Moxifloxacin base 50.0 g was stirred in 200.0 ml methanol for 10-15 minutes at 25-3-° C. The pH was adjusted to 1.0-2.0 using methanolic hydrochloric acid. The reaction mass was chilled to 0-5° C. and maintained for 1 hour. The solids were filtered and dried under vacuum at 85-90° C. to yield 52.5 g (105%) of moxifloxacin hydrochloride.
Example 7
1-cyclopropyl-6,7-difluoro-8-methoxy-4-oxo-1,4-dihydro-3-quinoline carboxylic acid-O 3 ,O 4 bis(propyloxy-O)borate (100.0 g) was suspended in acetonitrile (445.0 ml). (S,S)-2,8-diazabicyclo(4,3,0)nonane (29.0 g) diluted with 50.0 ml acetonitrile was slowly added at 10-15° C. followed by triethyl amine (25.0 g). The contents were heated to reflux temperature for 2 hours. Cooled to 25-30° C. Methanol (200.0 ml) was added and pH was adjusted to 1.0-2.0 using hydrochloric acid and stirred at 10-15° C. for 2 hours. After the completion of reaction, the reaction mass was concentrated to residue. Purified water 500.0 ml was added and pH was adjusted to 7.5-9.0 using liquour ammonia under stirring. The contents were heated to 70-75° C. and ammonia is expelled off by purging Nitrogen gas to the reaction mass. The reaction mass was cooled to 25-30° C. and stirred for 1 hour. The resulting solid was filtered and washed with purified water and dried under vacuum at 55-60° C. to obtain 75.0 g moxifloxacin base. 70.0 g of moxifloxacin base was stirred with 350.0 ml of methanol at 25-30°. The pH was adjusted to 1.0-2.0 using methanolic hydrochloric acid and contents were chilled to 0-5° C. and stirred for 1 hour at the same temperature. The solid was filtered and dried under vacuum at 85-90° C. to yield 78.0 g (77%) of moxifloxacin hydrochloride.
Example 8
Moxifloxacin hydrochloride 100.0 gm was stirred with methanol 800.0 ml and triethyl amine 25-30° C. The reaction mass was concentrated partially. Further 300.0 ml of methanol was added and the pH was adjusted to 1.0-2.0 using hydrochloric acid gas dissolved in methanol at 20-25° C. The contents were cooled to 0-5° C. and maintained at 0-5° C. for 2 hours. The resulting solids were filtered and washed with 50.0 ml chilled methanol. The product was dried under vacuum at 80-90° C. to obtain 90-95.0 gm of moxifloxacin hydrochloride Form C.
It will be appreciated that the invention described above may be modified within the scope of the claims.
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A new polymorph of moxifloxacin hydrochloride is described, together with a method for making the polymorph. In addition, new intermediates in the formation of moxifloxacin hydrochloride are described, having formulas (1) and (II):
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TECHNICAL FIELD
[0001] The present invention relates to solar modules. More specifically, the present invention relates to a system for deploying these solar modules and for adjusting their deployment such that the exposure of the solar modules to the sun is maximized by maintaining the solar modules as close to perpendicular as possible to the sun to ensure high output.
BACKGROUND OF THE INVENTION
[0002] The increasing price of energy, whether it be from fossil fuels, nuclear energy, or other alternative forms of energy, has been a constant fact of life in the late 20 th and early 21 st centuries. This has led to a renewed interest in cheaper, more abundant sources of energy.
[0003] While solar energy has been harnessed for generations, recent technology has made it possible to make solar arrays feasible and viable for a greater clientele. Currently in the northern hemisphere, the optimal direction to arrange a stationary solar array is with a southward facing direction and vice-versa for the southern hemisphere. The closer to the equator that a solar array is located, the less there is of a need for dual axis tracking as the sun moves more overhead. As an example, while sunlight may be plentiful in some areas (such as the American southwest), the nature of the sun is that solar panels which harvest solar energy are not always at or near their peak efficiency. This is caused by the restriction in mounting options which current solar arrays offer.
[0004] It should be noted that solar modules that track the sun are known in the art and are actually in use in large solar energy farms and medium sized rural establishments. However, these current devices are inaccurate and far from optimal because of their simple software, their expensive installation fees, and they are not conducive to being deployed by residential homeowners, commercial and industrial buildings and rural establishments. Previously, solar trackers and solar positioners were required to be either ground mounted or mounted on the flat roof of a steel frame commercial/industrial building.
[0005] To address the growing energy needs of the early 21 st century, the market penetration of solar energy will need to be increased as this will reduce dependency on fossil fuel based energy. This may be fostered by having a lightweight, easy to assemble, effective, and accessible solar module assembly that maximises the solar exposure of the module regardless of the time of day.
[0006] There is therefore a need to mitigate if not overcome the shortcomings of the prior art.
SUMMARY OF INVENTION
[0007] The present invention provides systems and devices for deploying solar modules. A ladder frame having multiple solar modules is hinged with a base. The ladder frame is coupled to the base and is rotatable about an edge axis. Each one of the multiple solar modules is connected to the ladder frame by a panel frame, with the panel frame joining the solar modules to the ladder frame. Each panel frame can be independently rotatable about its own panel axis. The ladder frame is actuated by at least one base motor, with the inclination of the ladder frame being determined by the at least one base motor. Each panel frame (and the solar module attached to it) can be rotated by at least one panel motor. In one implementation, a plurality of solar modules and panel frames can be run from a single base motor. The ladder frame may be angled with the base using the base motor while each panel frame/solar module may be angled about its panel axis using its panel motor. One implementation uses a plurality of panel frames and solar modules conjoined by means of gearing. In this implementation, any means of applying a force which can directly or indirectly transferred to the rotational frames on the invention may be used. Alternatively, the solar modules, if each is running on at least one base motor, may all be synchronised so that all the solar panels are uniformly angled about their respective panel axes. The system may be controlled by a control computer that, throughout the day, adjusts the deployment of the ladder frame and the angle of the solar modules to maximize the exposure of the solar modules to sunlight.
[0008] In a first aspect, the present invention provides a system for mounting at least one solar module, the system comprising:
a base a ladder frame comprising at least one solar module, said ladder frame being hinged with said base at a base edge of said ladder frame, said ladder frame being rotatable about an edge axis adjacent and parallel to said base edge
[0011] wherein
each of said at least one module comprises a solar module coupled to a panel frame, said solar panel and panel frame being rotatable about a panel axis, said panel axis being parallel to an edge of said solar panel.
[0013] In a second aspect, the present invention provides a mounting system for mounting a plurality of movable panels, the system comprising:
a base; a ladder frame comprising a plurality of panels, said ladder frame being hinged with said base at a base edge of said ladder frame, said ladder frame being rotatable about an edge axis adjacent and parallel to said base edge;
[0016] wherein
each of said plurality of panels comprises a panel coupled to said ladder frame by a panel frame, said panel and panel frame being rotatable about a panel axis, said panel axis being parallel to an edge of said panel.
[0018] Each of the panels may be equipped with poster style advertising and/or digital advertising. The digital advertising may be light emitting diodes (LEDs), liquid crystal displays (LCDs), plasma displays, or any other means for projecting images, video and/or audio.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] The embodiments of the present invention will now be described by reference to the following figures, in which identical reference numerals in different figures indicate identical elements and in which:
[0020] FIGS. 1 and 2 are diagrams illustrating a mounting system according to one aspect of the invention;
[0021] FIG. 3A is a back view of a non-deployed panel frame according to one aspect of the invention;
[0022] FIG. 3B is a back view of a deployed panel frame from FIG. 3A ;
[0023] FIG. 4 is a block diagram of a control scheme for the system according to another aspect of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0024] Referring to FIGS. 1 and 2 , diagrams of the system 10 according to one aspect of the invention are presented. A ladder frame 20 is illustrated as being hinged to a base 30 . The ladder frame 20 has a number of solar modules 40 A, 40 B, 40 C, each solar module being mounted to the ladder frame by a panel frame 45 . The ladder frame 20 is rotatable about an edge axis 50 while each solar module 40 is rotatable about a panel axis 60 . As can be seen from the Figures, each panel axis 60 may be perpendicular to the edge axis 50 . It should be noted that in FIG. 1 , solar module 40 A has its working or front side facing the base while solar modules 40 B and 40 C have their front or working sides facing away from the base. The panel frame 45 for solar module 40 A is shown for illustration.
[0025] The ladder frame's deployment (i.e. its angle with the base) may be adjusted using a direct drive motor or by using a cable and motor system. For the cable and motor system, a cable is attached to the top of the ladder frame and is also tensioned with a motor. Activating the motor pulls on the cable and thereby causes an angle θ between the base and the ladder frame to increase. Increasing the angle between the ladder frame and the base thereby “raises” the frame while decreasing the angle “lowers” the ladder frame. The cable 65 can be seen in FIGS. 1 and 2 .
[0026] The ladder frame's deployment may also be adjusted using hydraulic, pneumatic or electric linear actuators as illustrated in FIGS. 3A and 3B . FIG. 3A shows a back view of a non-deployed ladder frame with the base. Hydraulic actuators 70 can be seen in the Figure. Each hydraulic actuator is coupled to the base and the ladder frame at hinge points 80 . Actuating the hydraulic actuators raises the ladder frame. As the hydraulic actuators lengthen, the ladder frame pivots about the edge axis and is raised, thereby increasing the angle defined by the ladder frame and the base. Referring to FIG. 3B , a back view of the deployed ladder frame is illustrated, clearly showing the hydraulic actuators 70 . When not deployed, it is preferable that the ladder frame, with the solar modules aligned and flat as well, be able to lay substantially flat on the base. The solar modules mounted with the panel frames are not only able to lay flat but are able to be inverted, allowing the working area of the solar module to face the base to minimise unwanted debris and to aid in maximising output. This feature also helps in keeping the solar modules clear of snow in the winter.
[0027] Systems other than the hydraulic actuators or the motor and cable systems noted above may be used to raise or lower the frame. Preferably, such systems provide a smooth, controllable travel from a lowered frame to a raised frame. As well, it is preferable that the deployment (i.e. the angle between the base and the frame) be controllable so that the solar modules' exposure to the sun may be increased if not maximized.
[0028] Regarding the base, the base is preferably of heavy enough construction or it may be weighted down so that the system does not tilt over when the frame is deployed. Alternatively, the base may be of the same construction of the ladder frame and may be securely bolted down to the floor or roof where the system is located. When the system is installed on a residential sloped roof, the base should be securely attached to the trusses in the roof to maintain building integrity.
[0029] Regarding the solar modules 40 , each solar module is mounted on a panel frame 45 which rotates about its panel axis. The panel axis may be longitudinally in the middle of the module or, alternatively, the panel axis may be latitudinally in the middle of the module. Other configurations for the panel axis may be used but it has been found that placing the panel axis approximately in the middle of the module provided the best results. Offsetting the panel axis from the middle may also be tried but this may not yield the best results.
[0030] Preferably, each panel frame is rotatable by 360 degrees (both clockwise and anticlockwise) about its panel axis. Such a configuration would allow for the greatest freedom in terms of tilting the module. The module can thus be tilted properly so that solar exposure is maximized regardless of where the sun is. As well, if desired, the solar module may be rotated so that the solar module side (or the working side) is facing the base as is the case with module 40 A in FIG. 1 . Once the solar panel side is facing the base, the frame's deployment may be set so that the solar module side is protected from damage by the elements. This may be useful in the event meteorological occurrences which can damage the panel, such as snow, hail, sand or dust storms, are about to occur.
[0031] To rotate or tilt each panel/module assembly, a direct drive motor may be used with a single motor for each module. By properly controlling the rotation of the motor, the angle at which the module tilts can be carefully controlled. This control of the module's tilt angle allows for an increase or a maximization of the module's exposure to the sun. Using a single motor for each module allows for tilting each module independently of the other modules.
[0032] Alternatively, the solar modules may be tilted as a group. Use of a worm drive and a low rpm (revolution per minute) single drive motor, with suitable gearing at each panel axis, can simultaneously turn all the modules to the same tilt angle. Again, it would be preferable if the solar modules and panel frames can be rotated by about 360 degrees both clockwise and anticlockwise to allow for the varying positions of the sun. Such an arrangement can maximize the solar exposure of each group of modules.
[0033] Other means for tilting/rotating the solar panels may, of course, be used. Different types of gearing mechanisms, using helical, worm, spur, bevel, etc. gears may be used. Depending on the implementation, chains, cables, and other means for translating one type of motion into rotational motion for the panels may be used.
[0034] Referring to FIG. 4 , a block diagram of a control scheme for the system is illustrated. A control computer 100 controls the rotation of ladder frame and the panel frame(s). The computer determines the deployment of the ladder frame and the rotation or tilt of the various panel frames to maximize the solar exposure of the modules. The various deployment settings for the ladder frame and the panel frame(s) can be pre-programmed into the control computer and may be time dependent and season/date dependent. As such, the control computer 100 can adjust the deployment angle for the frame and the tilt of the modules depending on the time of day and on the date. Alternatively, the control computer can be programmed to search for the optimum mix of settings for the ladder frame and the panel frame every few seconds to maximize the solar exposure of the solar modules given the current weather conditions and position of the sun.
[0035] As can be seen from FIG. 4 , the control computer 100 separately controls the panel frame(s) and the ladder frame. In one variant, the control computer 100 can be two computers, each separately controlling the frame or the panels. Also as can be seen in FIG. 4 , a weather station 110 can be coupled to the control computer 100 . The weather station 110 can determine the prevailing conditions and, based on these conditions, the control computer 100 can deploy the panels accordingly. As an example, if the prevailing weather conditions are not conducive to the deployment of a solar array (e.g. rain, hail, night time, clouds), the control computer can ensure that the ladder frame, panel frames and solar modules are properly configured to minimize the possibility of damage to the panels and to not waste valuable electricity. Preferably, the control computer can operate using either DC or AC current. Also, if the weather conditions, as sensed by the weather station (e.g. wind speed), are not conducive to the use of the solar panels in that the panels may get damaged, the control computer can lower the ladder frame and retract the modules so that their working surface is configured to face the base to prevent damage to the modules.
[0036] It should be noted that the weather station may be equipped with various instruments and devices which may be useful in determining the prevailing weather condition and which may be useful in communication with the control computer. To this end, hygrometers, barometers, thermometers, anemometers, and other weather measuring and detecting devices may be placed on the weather station. As well, a wireless connection between the weather station and the control computer may be used to transfer data between the two devices.
[0037] With the weather station coupled or in communication with the computer, this allows for real-time monitoring of weather data as well as the crossed-referencing of this data by software. This enables the automatic interaction of the ladder frame and the panel frame(s) depending on wind speeds, snow loads, levels of sunlight and other factors that are not optimal for the harnessing of solar energy.
[0038] The weather station 110 in FIG. 4 may take the form of a sun tracking control subsystem that tracks the passage of the sun through the sky and accordingly adjusts the tilt of the various panels and the deployment of the ladder frame to increase or maximize the solar exposure of the modules. As an alternative to the existing sun tracking systems currently available, instead of tracking the hottest spot in the sky (presumably the sun), the sun tracking control subsystem may track the brightest spot in the sky. As such, even with cloudy skies, the sun positioning subsystem will track the sun.
[0039] The control computer 100 may control the various motors used in the system by means of suitable A/C or D/C control devices. The control computer 100 can, using a feedback loop, sense the speed of each motor and, depending on the speed, adjust the speed or torque accordingly to arrive at the correct tilt angle or deployment angle for the ladder frame or the relevant module.
[0040] Again referring to FIG. 4 , the control computer 100 may also be coupled to or in communication with position sensors 115 . These position sensors 115 may sense the tilt angle of the various modules or the deployment angle of the ladder frame. The position sensors can provide a feedback path for the control computer so that the deployment angle between the ladder frame and the base or the tilt angle of the various modules can be more accurately controlled.
[0041] Also shown in FIG. 4 is a connection between the control computer and a network 120 . The network 120 may include any known types of networks (wired, wireless, etc.) and may encompass a connection to the Internet. The network 120 serves as a communications conduit between the control computer and a weather mapping database 130 . The readings from the weather station 110 may be entered into the weather database 130 by way of the control computer. Alternatively, the control computer may retrieve weather readings from the database 130 and, based on these readings, the control computer may retract the ladder frame and the modules. As an example, if weather readings from the database indicate an impending wind storm, the control computer may retract ladder frame and modules to prevent damage.
[0042] It should be noted that control computers for controlling various devices and motors are currently available and may be adapted to control the ladder frame and the panel frames of the system by a person skilled in the art.
[0043] Regarding the construction of the frames, the frames may be constructed from any suitable material that can withstand the shearing forces applied to the frames when being deployed. As well, the material used should also be able to withstand prolonged exposure to the elements. Finally, it would be preferred if the material was relatively light so as not to need an overly powerful motor to be used for raising or lowering the frame. It has been found that aluminum may be used as well as stainless steel and any suitable composite materials in the construction of the frame.
[0044] Regarding the panel frames, these panel frames may be framed using the same material as that for the construction of the ladder frame. The panel frames and solar modules are then coupled to the ladder frame so that the panel frames and their associated solar modules are rotatable about each panel's panel axis as noted above. As can be seen in FIG. 1 , the panel frame may have a T-shaped construction to provide support for the solar module. Other configurations for the panel frame may be used in place of the T-shaped configuration in FIG. 1 .
[0045] Again regarding the panels, any suitable solar panel may be used including solar photovoltaic (electric), thermal liquid, thermal air, and water heating. Depending on the size of the solar modules, the framing for the solar modules may be adjusted accordingly and, as well, the sizing of the frame may be adjusted to accommodate the modules.
[0046] It should, however, be noted that, while the above description relates to the use of the system with solar panels, other panels may be used as well. As an example, advertising panels may be used in place or along with solar panels. Since each panel has two sides, each side may be used for advertising while the other side may be used for another advertiser or for solar energy generation. Depending on the programming of the control computer, when the sun is out the solar modules can be harnessing electricity and when the sun is not out the solar module can be inverted to reveal advertising. In another embodiment, one advertiser may be given exposure for a certain portion of the day while the other advertiser may be given exposure for the rest of the day. The frame can thus be deployed to provide public exposure to one or the other side of the panels. At a certain time of the day, each panel can be automatically rotated to provide exposure to the other side of the panel.
[0047] For implementations which use advertising panels, the advertising panels may be equipped with poster style advertising and/or digital advertising. The digital advertising may be light emitting diodes (LEDs), liquid crystal displays (LCDs), plasma displays, or any other means for projecting images, video and/or audio.
[0048] While the above description describe a single frame with multiple solar modules, multiple frames can be placed together to obtain better power generation capabilities and can all be controlled using a single control computer. It should also be noted that the frame may have as few as a single solar panel and perhaps as many as 15 or more solar panels. Of course, the actual configuration may be dependent on the size of the solar module used as well as the motors or actuators used to tilt and deploy the frame and panels.
[0049] A person understanding this invention may now conceive of alternative structures and embodiments or variations of the above all of which are intended to fall within the scope of the invention as defined in the claims that follow.
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Systems and devices for deploying solar modules. A ladder frame having multiple solar modules is hinged with a base. The ladder frame is coupled to the base and is rotatable about an edge axis. Each one of the multiple solar modules is connected to the ladder frame by a panel frame, with the panel frame joining the solar modules to the ladder frame. Each panel frame can be independently rotatable about its own panel axis. The ladder frame is actuated by at least one base motor, with the inclination of the ladder frame being determined by the at least one base motor. Each panel frame (and the solar module attached to it) can be rotated by at least one panel motor. The system may be controlled by a control computer that, throughout the day, adjusts the deployment of the ladder frame and the angle of the solar modules to maximise the exposure of the solar modules to direct sunlight. The system may also be used for advertising by deploying advertising panels in place of or in addition to the solar modules.
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TECHNICAL FIELD
[0001] The present invention relates to a tire having a plurality of recessed portions formed on a buttress portion along a tire circumferential direction.
BACKGROUND ART
[0002] Conventionally, in a tire mounted on a vehicle such as a passenger vehicle, various methods have been used to reduce tire noise generated when the tire rolls on a road surface having irregular recesses and bumps, such as a paved road with a rough road surface. For example, there is known a tire using rubber with high stiffness in the shoulder portion of a tread (refer to Patent Literature 1). According to such a tire, deformation of the tread can be suppressed when the bumps, of the recesses and bumps of the road surface, wedge into the tread. Due to this, the increase of the contact pressure of the tread is suppressed, and the increase of tire noise when the tire rolls on a rough road surface can be suppressed.
[0003] Incidentally, nowadays, as a result of progress in the intensive study on the mechanism of tire noise generated, it has been made clear that the vibration of the buttress portion due to recesses and bumps of the road surface is also a cause of tire noise. In other words, when the road surface is smooth, normally, the buttress portion does not contact the road surface. On the other hand, when there are small recesses and bumps on the road surface, such as a paved road with a rough road surface, the buttress portion does contact the road surface, and due to these recesses and bumps, the buttress portion vibrates. Vibration of the buttress portion like this increases tire noise. In order to suppress the generation of such tire noise, it is considered to form small recessed portions on the buttress portion. However, there is a problem that, when such small recessed portions are formed on the buttress portion that is severely deformed, cracks originating from the recessed portions easily progress.
CITATION LIST
Patent Literature
[0004] [Patent Literature 1] Japanese Patent Application Publication No. 2008-24048.
SUMMARY OF INVENTION
[0005] A first feature is summarized as a tire comprising: a tread that contacts a road surface; a side wall provided on an inner side of the tread in the tire radial direction; and a buttress portion provided between the tread and the side wall, wherein a plurality of recessed portions are formed on the buttress portion along a tire circumferential direction, each of the recessed portions has: a first outer edge that bulges inward in a tread widthwise direction; and a second outer edge that continues to the first outer edge and bulges outward in the tread widthwise direction with respect to the first outer edge, and the distance between a deepest portion of the recessed portion and a grounding end of the tread varies as proceeding along the tire circumferential direction.
BRIEF DESCRIPTION OF DRAWINGS
[0006] FIG. 1 is a perspective view of a part of a segmented pneumatic tire 10 according to an embodiment.
[0007] FIG. 2 is a view schematically showing a first recessed row 210 and 220 configured by recessed portions 100 according to the embodiment.
[0008] FIG. 3 is an enlarged view of the recessed portions 100 within an F 3 frame shown in FIG. 2 .
[0009] FIG. 4 is a sectional view of a buttress portion 70 , which is taken along a line F 4 -F 4 shown in FIG. 3 .
[0010] FIG. 5 is a sectional view of the buttress portion 70 , which is taken along a line F 5 -F 5 shown in FIG. 3 .
[0011] FIG. 6 is a sectional view of the buttress portion 70 , which is taken along a line F 6 -F 6 shown in FIG. 3 .
[0012] FIG. 7 is a view showing a shape of a recess according to modifications.
DESCRIPTION OF EMBODIMENTS
[0013] Next, an embodiment of a tire (a pneumatic tire) according to the present invention is described with reference to drawings. It is noted that, in the following description of the drawings, the same or similar reference numerals are used to designate the same or similar portions. It should be appreciated that the drawings are schematically shown and the ratio and the like of each dimension are different from the real ones.
[0014] Accordingly, specific dimensions and the like should be determined in consideration of the explanation below. Further, among the drawings, the respective dimensional relations or ratios may differ.
[0015] (1) Schematic Configuration of Pneumatic Tire
[0016] FIG. 1 is a perspective view of a part of a segmented pneumatic tire 10 . As shown in FIG. 1 , the pneumatic tire 10 is provided with a tread 50 which contacts the road surface, a side wall 60 provided on the inner side, in a tire radial direction D R , of the tread 50 , and a buttress portion 70 provided between the tread 50 and the side wall 60 . It is noted that the pneumatic tire 10 may be filled with, instead of air, an inert gas such as nitrogen gas. The tread 50 is configured by a plurality of land blocks 51 , a plurality of circumferential grooves 52 , and a shoulder land portion 53 . Further, a plurality of recessed portions 100 are formed on the buttress portion 70 along a tire circumferential direction D C .
[0017] (2) Shape of Recessed Portion 100
[0018] Next, the shape of each recessed portion 100 formed on the buttress portion 70 will be described. Specifically, description will be given for the schematic shape and the cross-sectional shape of the recessed portion 100 .
[0019] (2.1) Schematic Shape of Recessed Portion 100
[0020] FIG. 2 is a view schematically showing a first recessed row 210 and 220 configured by the recessed portions 100 . FIG. 3 is an enlarged view of the recessed portions 100 within an F 3 frame shown in FIG. 2 .
[0021] As shown in FIG. 2 , the recessed portion 100 is in an elliptical shape and a plurality of the recessed portions 100 continue in the tire circumferential direction D C . In the present embodiment, the first recessed row 210 configured by the plurality of recessed portions 100 formed along the tire circumferential direction D C , and the second recessed row 220 configured by the plurality of recessed portions 100 formed along the tire circumferential direction D C and disposed outside the first recessed row 210 in the tread widthwise direction D T , are provided.
[0022] A distance d between a deepest portion 150 of the recessed portion 100 and a grounding end 50 e of the tread 50 (specifically, the shoulder land portion 53 ) varies in the tire circumferential direction D C . That is, the distance d varies as proceeding along the tire circumferential direction D C , and the variation in the distance d is repeated with the recessed portion 100 as a unit.
[0023] Further, the deepest portion 150 of the recessed portion 100 is curved in side view of the pneumatic tire 10 . It is noted that the grounding end 50 e means an outer end in the tread widthwise direction D T on the ground contact surface of the tread 50 in a state where a normal load is applied to the pneumatic tire 10 set to have a normal internal pressure regulated by the Japan Automobile Tire Manufacturers Association (JATMA) and the like.
[0024] (2.2) Cross-Sectional Shape of Recessed Portion 100
[0025] FIG. 4 is a sectional view of the buttress portion 70 , which is taken along a line F 4 -F 4 shown in FIG. 3 . FIG. 5 is a sectional view of the buttress portion 70 , which is taken along a line F 5 -F 5 shown in FIG. 3 . FIG. 6 is a sectional view of the buttress portion 70 , which is taken along a line F 6 -F 6 shown in FIG. 3 .
[0026] As shown in FIG. 4 to FIG. 6 , the recessed portion 100 has a first outer edge 110 that bulges inward in the tread widthwise direction D T . Further, the recessed portion 100 has a second outer edge 120 that is continuous with the first outer edge 110 and that bulges outward in the tread widthwise direction D T with respect to the first outer edge 110 .
[0027] In the present embodiment, the first outer edge 110 is in an arc-like shape that is curved so as to bulge inward in the tread widthwise direction D T . Similarly, the second outer edge 120 is in an arc-like shape that is curved to bulge outward in the tread widthwise direction D T with respect to the first outer edge 110 . That is, the recessed portion 100 is in an elliptical shape. Further, the recessed portion 100 has a first bottom surface 130 that extends from the first outer edge 110 to the deepest portion 150 and a second bottom surface 140 that extends from the second outer edge 120 to the deepest portion 150 . The first bottom surface 130 is formed so as to be point-symmetrical to the second bottom surface 140 .
[0028] Further, in the present embodiment, the recessed portion 100 included in the second recessed row 220 is formed between the two recessed portions 100 adjacent to each other in the tire circumferential direction D C included in the first recessed row 210 . The deepest portion 150 has a first curved portion 151 that is curved so as to be closer to the first outer edge 110 in side view (viewpoint from the side wall 60 ) of the pneumatic tire 10 and a second curved portion 152 that continues to the first curved portion 151 and is curved so as to be closer to the second outer edge 120 in side view of the pneumatic tire 10 .
[0029] Further, as described above, the distance d between the deepest portion 150 and the grounding end 50 e of the tread 50 varies in the tread widthwise direction DT (see FIG. 2 ). Therefore, as shown in FIG. 4 to FIG. 6 , the position of the deepest portion 150 in the tread widthwise direction D T varies as proceeding along the tire circumferential direction D C . Specifically, positions, in the tread widthwise direction D T , of the deepest portion 150 of the recessed portion 100 that forms the first recessed row 210 and the deepest portion 150 of the recessed portion 100 that forms the second recessed row 220 vary, respectively, in the tire circumferential direction D C . Further, the distance between the deepest portion 150 and the first outer edge 110 and the distance between the deepest portion 150 and the second outer edge 120 also vary in the tire circumferential direction Dc.
[0030] (3) Advantageous Effect
[0031] According to the pneumatic tire 10 , the plurality of recessed portions 100 formed along the tire circumferential direction have the first outer edge 110 that bulges inward in the tread widthwise direction D T , and the second outer edge 120 that continues to the first outer edge 110 and bulges outward in the tread widthwise direction D T with respect to the first outer edge 110 . Further, the distance d between the deepest portion 150 of the recessed portion 100 and the grounding end 50 e of the tread 50 varies in the tire circumferential direction D C .
[0032] In general, a buttress portion does not contact a smooth road surface, but contacts a road surface with small recesses and bumps, such as a paved road with a rough road surface. Due to such recesses and bumps, the buttress portion vibrates, and road noise resulting from the vibration of the buttress portion is increased. However, in the embodiment, the recessed portion 100 is formed on the buttress portion and the distance d between the deepest portion 150 of the recessed portion 100 and the grounding end 50 e of the tread 50 varies in the tire circumferential direction D C , thus it is possible to suppress the road noise resulting from the vibration of the buttress portion.
[0033] Further, the distance d between the deepest portion 150 of the recessed portion 100 and the grounding end 50 e of the tread 50 varies in the tread widthwise direction D T , thus the progression of cracks resulting from the shape of the recessed portions 100 along the tire circumferential direction D C is suppressed.
[0034] That is, according to the pneumatic tire 10 , it is possible to suppress, by the recessed portion 100 formed on the buttress portion 70 , the generation of tire noise resulting from a vibration of the buttress portion 70 and progression of cracks originating from the recessed portions 100 .
[0035] Further, since the distance d between the deepest portion 150 of the recessed portion 100 and the grounding end 50 e of the tread 50 varies in the tire circumferential direction D C , curvature itself is suppressed, and generation of cracks is suppressed. Further, even when cracks are generated, progression of cracks is suppressed.
[0036] In the present embodiment, the first outer edge 110 and the second outer edge 120 are in an arc-like shape, and the deepest portion 150 is curved in the pneumatic tire 10 . Further, the recessed portion 100 has a first bottom surface 130 that extends from the first outer edge 110 to the deepest portion 150 and a second bottom surface 140 that extends from the second outer edge 120 to the deepest portion 150 . Thus, progression of cracks resulting from the shape of the recessed portion 100 along the tire circumferential direction D C is further suppressed.
[0037] In the present embodiment, the deepest portion 150 has the first curved portion 151 that is curved so as to be closer to the first outer edge 110 and the second curved portion 152 that continues to the first curved portion 151 and is curved so as to be closer to the second outer edge 120 . Further, the first bottom surface 130 is formed so as to be point-symmetrical to the second bottom surface 140 . Therefore, progression of cracks in the recessed portion 100 can be suppressed.
[0038] In the present embodiment, the first recessed row 210 and the second recessed row 220 are formed and the recessed portion 100 included in the second recessed row 220 is formed between the two recessed portions 100 adjacent to each other in the tread widthwise direction D T included in the first recessed row 210 . Therefore, vibration resulting from contact of the buttress portion 70 with the road surface is effectively reduced and progression of cracks resulting from the shape of the recessed portions 100 along the tire circumferential direction D C is suppressed.
[0039] (4) Other Embodiments
[0040] As described above, the contents of the present invention are disclosed through the embodiment of the present invention. However, it should not be interpreted that the statements and drawings constituting a part of this disclosure limit the present invention. From this disclosure, a variety of alternate embodiments, examples, and applicable techniques will become apparent to one skilled in the art. For example, the shape of the recessed portion 100 may not necessarily be in an elliptical shape as described in the above-described embodiment. FIGS. 7( a ) to ( c ) are views showing shapes of recessed portion according to modifications of the present invention. As shown in FIGS. 7( a ) to ( c ), a recess formed on the buttress portion 70 may be a polygonal recessed portion 100 A as shown in FIG. 7( a ). Alternatively, as shown in FIGS. 7( b ) and ( c ), the recessed portion may be rhomboidal recessed portions 100 B and 100 C. Further, the shape of the deepest portion of the recess may be a combination of straight lines like the recessed portion 100 B or in a curved shape like the recessed portion 100 C.
[0041] As described above, needless to say, the present invention includes various embodiments and the like not described here. Therefore, the technical range of the present invention is to be defined only by the inventive specific matter according to the adequate claims from the above description.
[0042] In addition, the entire content of Japanese Patent Application No. 2011-171170 (filed on Aug. 4, 2011) is incorporated in the present specification by reference.
INDUSTRIAL APPLICABILITY
[0043] According to a characteristic of the present invention, it is possible to provide a tire with which it is possible to suppress, by recessed portions formed on a buttress portion, the generation of tire noise resulting from vibration of the buttress portion and the progression of cracks originating from the recessed portions.
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This tire has a buttress section to which a plurality of depressions ( 100 ) have been formed along the tire peripheral direction (D C ). The depressions ( 100 ) have: a first outer edge ( 110 ) that bulges inward in the tread width direction (D T ); and a second outer edge ( 120 ) that is continuous with the first outer edge ( 110 ) and that bulges outward in the tread width direction (D T ) with respect to the first outer edge ( 110 ). The distance between the deepest section ( 150 ) of the depressions ( 100 ) and the ground-contact end of the tread varies along the tire peripheral direction (D C ).
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BACKGROUND OF THE INVENTION
(1) Field of the Invention
The present invention relates to a system for injecting liquid chemical into a subsea well and to pumps designed for use in such a system. Although the term “subsea” is used for convenience to indicate the location of wells to which the system relates, this should be understood to include reference to any substantial body of water beneath which a well may be located. Furthermore pumps of the character to be more particularly disclosed herein are not restricted to use in such systems and may also find application in, for example, automotive fuel injection systems, hydraulic actuator systems, or in other areas where high fluid pressures need to be generated by electrically-powered pumps with a minimum of moving parts.
(2) Description of the Art
It is a well known practice, in order to maintain the efficient operation of a production oil or gas well, to inject certain chemicals in liquid form into the well at selected times and positions, for example corrosion inhibitors to inhibit corrosion of downhole equipment and wax inhibitors to inhibit the formation of waxy substances that block the flow of product. For high pressure, high temperature (HPHT) wells and extremely high pressure, high temperature (XHPHT) wells, pressures typically in the range of 15,000-25,000 PSI (100-170 MPa) need to be generated by the pumps in such systems. In the case of subsea wells it is not always practical to have pumps at the surface platform (or only at the surface platform) due to the cost of running high pressure umbilicals down to the wellheads (which can involve umbilical lengths of some thousands of meters) and the pressure drop across such long umbilicals, meaning that control of the delivery pressures and flow rates at the wellheads can be quite problematic. It is therefore common to employ the pumps (or additional pumps) for such systems underwater in the vicinity of the wellheads. However, a subsea environment presents particularly serious challenges to the reliability of such chemical injection pumps due to the aggressive conditions under which they are required to operate and the difficulty of accessing and effecting any required maintenance or repair of the equipment located underwater. Current systems typically employ hydraulically-actuated pumps, requiring hydraulic control lines to be run down to the sea bed, and regular maintenance, and are therefore both complex and costly to operate. The present invention therefore aims to provide an alternative pumping system for such service, which can be electrically operated, has a minimum of moving parts and in particular avoids the need for any rotating parts and attendant high performance bearings and seals; in other words an essentially “solid state” solution.
SUMMARY OF THE INVENTION
In one aspect the present invention accordingly resides in a system for injecting liquid chemical into a subsea well comprising:
a source of liquid chemical;
a pump located in the subsea environment comprising a pumping chamber, an inlet and an outlet opening to said chamber, a reciprocal plunger adapted to compress and expand the effective volume of said chamber, and a piezoelectric actuator for reciprocating said plunger;
conduit means for leading liquid chemical from said source to said inlet of said pump; and
conduit means for leading liquid chemical from said outlet of said pump to said well.
The invention also resides per se in various features of the pump to be more particularly described and illustrated herein.
DESCRIPTION OF THE DRAWINGS The invention will now be more particularly described, by way of example only, with reference to the accompanying drawings in which:
FIG. 1 is a schematic diagram of a subsea chemical injection system according to the invention;
FIG. 2 is a longitudinal section through one embodiment of a pump according to the invention for use in the system of FIG. 1 ;
FIG. 3 shows the plunger and head portion of the pump of FIG. 2 , to an enlarged scale;
FIG. 4 is a scrap section showing the sealing arrangement of the plunger to the head in the pump of FIG. 2 , to a further enlarged scale;
FIG. 5 illustrates schematically a control system for the pump of FIG. 2 ;
DESCRIPTION OF THE INVENTION
Referring to FIG. 1 , this illustrates schematically one example of a system according to the invention. There is shown an oil or gas wellbore 1 extending down from the sea floor and equipped with a wellhead 2 from which product flows through tubing 3 to a production platform 4 at the surface. Although the platform 4 is shown as a floating (off-shore) platform in the Figure, depending on the topography of the oil or gas field it could alternatively be a land-based platform serving the subsea well 1 / 2 . Adjacent to the wellhead there is a unit 5 housing one or more—and in practice most likely to be a multiplicity acting in series and/or parallel—of pumps of the kind described below, for use in injecting liquid chemical into the well. The chemical or chemicals to be injected are stored on the platform 4 and supplied to the unit 5 , partially pre-pressurised if required, through an umbilical 6 which also carries electrical power and any required data and/or control signals to the pumping unit. Tubing 7 conveys the chemical for injection from unit 5 to the wellhead whence it is distributed as required.
FIGS. 2 and 3 illustrate the structure of one embodiment of a pump 10 for use in the unit 5 . It has a barrel-like body part 11 typically of stainless steel, closed by a monolithic head 12 typically of a nickel-based alloy such as Hastelloy® for resistance to the chemicals which will be handled by the pump. The head 12 is attached to the body part 11 through mating fine pitched screw threads 13 and secured in place by a set of, say, six clamping bolts 14 A pressing on a ring 14 B on top of the body part 11 , as will be more particularly explained hereafter. The head 12 has inlet and outlet fittings 15 and 16 for the chemical to be pumped, fitted with respective micro non-return valves 17 , 18 and leading to/from the pumping chamber referred to below.
Within body part 11 is mounted an elongate piezoelectric actuator 19 , being fixed at its base by a screw 20 . In this respect the actuator 19 sits in a cradle 21 at its base equipped with flats to prevent rotation of the actuator as the screw 20 is tightened. This actuator comprises a stack of piezoelectric ceramic discs (not individually shown) within a housing, preloaded by an internal spring (also not shown), which when energized expand in the longitudinal direction of the stack with a maximum strain rate of around 0.1% of the length of the stack, and return to their unstrained condition, with assistance from the spring, when the energising voltage is removed. By applying voltage pulses to the actuator, therefore, its free end (upper end as viewed in the Figures) can be caused to reciprocate at the frequency of the pulses. Leads carrying the energising voltage to the actuator are routed through a radial bore in the body part 11 (not shown). Actuators of this kind are commercially available and typically used for generating mechanical vibrations at sonic frequencies e.g. for sonar equipment.
Rigidly screwed to the free end of the actuator 19 is a plunger 22 , typically of Hastelloy®, which consequently also reciprocates in use in accordance with the energisation of the actuator. The plunger 22 is formed at its upper and lower ends with narrower and wider cylindrical surfaces 23 and 24 , joined by a frustoconical surface 25 . The surfaces 23 and 24 are a close sliding fit in correspondingly bored portions 26 and 27 of the head 12 and the bores 26 and 27 are joined by an internal frustoconical surface with clearance around the surface 25 of the plunger to define a small space 28 and accommodate the reciprocation of the plunger. A small pumping chamber 29 is defined between the topmost surface of the plunger 22 and the facing surface of the head 12 , through which ports 30 and 31 open from the valves 17 and 18 . As the plunger is reciprocated by energisation of the actuator 19 , therefore, its upper end acts as a piston to alternately compress and expand the volume of the chamber 29 . More particularly movement of the plunger to the top of its stroke compresses the volume of the chamber 29 , causing the valve 18 to open and expelling the contents of the chamber towards the outlet 16 . As the plunger 22 returns to the bottom of its stroke the volume of the chamber 29 is expanded so that the valve 18 closes, the valve 17 opens and a fresh quantity of chemical enters the pumping chamber from the inlet 15 .
In this respect the upper end (piston) of the plunger 22 is sealed against the bore 26 of the head 12 as shown in FIG. 4 (from which the ports 30 and 31 are omitted for simplicity). That is to say the plunger surface 23 is formed with a groove in which is located an “O” ring 32 e.g. of Viton® which is slightly compressed in the radial direction when fitted in the head 12 and forms a sliding seal against the bore 26 as the plunger reciprocates. This ring is supported on each side by a PTFE back up ring 33 , 34 of substantially the same effective radial thickness as the compressed “O” ring 32 so there is no danger of the “O” ring becoming damaged by extrusion against any sharp edges in use. The fit of the plunger surface 24 ( FIGS. 2 and 3 ) in the bore 27 of the head 12 ensures that the piston portion of the plunger remains centralised in the bore 26 and further assures that the piston is evenly sealed around the head as it reciprocates. The head 12 is itself machined from a monolithic block and provides no leakage path for liquid from the pumping chamber 29 .
In use the pump 11 will be immersed in a bath of hydraulic fluid and bores (not shown) through the body part 11 convey this fluid to the space 35 around the piezoelectric stack 19 for cooling the same. Circulation of this fluid to enhance cooling may occur through natural convective flow or an additional small conventional circulating pump (not shown) may be provided for this purpose. Bores (not shown) through the head 12 also convey this fluid to the space 28 around the plunger 22 for lubricating the movement of the plunger, the seal 32 also serving to keep this fluid out of the pumping chamber 29 .
It will be appreciated that by virtue of the limited stroke length of the actuator 19 and corresponding size of the pumping chamber 29 only a small volume of liquid will be pumped in each cycle, although the total flow rate is of course a function of the actuation frequency. By way of example, a single pump substantially as illustrated, with an actuator length of 200 mm and stroke of 0.2 mm, has been found to be capable of pumping liquid at a rate of up to 5 liters per hour at an outlet pressure of up to 20,000 PSI (140 MPa) from an inlet pressure of up to 10,000 PSI (70 MPa) when actuated at between 30 and 70 Hz, and substantially higher rates and/or pressures should be achievable by ganging a plurality of such pumps together. The ratio of the swept volume of the pumping chamber 29 to its total volume (including the volume of the ports 30 , 31 and any “dead” space between the valves 17 , 18 ) will be at least 1:7.
A typical control system for the pump 10 within a unit 5 is illustrated in FIG. 5 . The pump is shown connected to the chemical supply line (umbilical) 6 through an inline filter system 36 for removing any debris that may accumulate from the long umbilical, and to the chemical output line 7 . The pump is energised from an electrical power supply 37 via a driver unit 38 under the control of a driver control unit 39 which is itself linked by a two way data and control line 40 to a topside control unit 41 using any standard serial communication technique (e.g. RS422/RS485). Transducers 42 and 43 monitor the pressures in the supply and output lines, from which the flow rate can also be computed. The control unit 39 controls the driver 38 to energise the pump 10 to inject the chemical as demanded by the topside controller, to achieve a desired flow rate by control of the applied voltage amplitude, duty cycle and/or frequency.
The assembly of the pump shown in FIGS. 2-4 is achieved as follows. First the plunger 22 is fitted to the actuator 19 , the actuator is slid into the cradle 21 in the body part 11 , with its leads routed as required, and the bolt 20 is loosely fitted Next the “O” ring 32 and back up rings 33 , 34 are fitted to the plunger 22 and the clamping ring 14 B is placed on the body part 11 . The inside surfaces of the head 12 are then lubricated and the head is screwed onto the body part 11 ensuring that it is correctly located over the plunger 12 but not screwed all the way down. The bolt 20 is then tightened and the head 12 is screwed further until it abuts the top surface of the plunger 22 . The clamping bolts 14 A are fitted into the head 12 and turned to engage loosely in respective cups 44 formed in the ring 14 B. The head 12 is then backed off from the top of the plunger by turning it in the reverse direction through a specified arc to define the required depth of the pumping chamber 29 —to facilitate which the clamping ring 14 B (which now turns on the body part 11 with the head 12 by virtue of its engagement with the bolts 14 A) is provided with a series of markings around its periphery which can be related to an index mark on the body part 11 . Finally the bolts 14 A are tightened to take up any play in the screw threads 13 and to clamp the head 12 against the body part 11 in the relative rotational position to which it has been set. This process ensures that the volume of the pumping chamber 29 is consistent from pump to pump notwithstanding any variations which may exist in the axial lengths of the actuators 19 or other engineering tolerances on the plunger and head profiles.
A feature of the pump 10 described and illustrated herein is that the plunger 22 is connected directly to the actuator 19 and avoids the use of any lever or the like force —or movement-amplifying means. In the described chemical injection system the pump also acts directly on the liquid to convey it towards the injection point(s) in the well as distinct from a system where, say, a piezoelectric pump is used to pressurise a hydraulic fluid for operation of a ram or the like.
The pump 10 , being a positive displacement pump, can also usefully function as a metering unit by controlling the frequency or other characteristic of operation of the piezoelectric actuator, meaning that separate orifice plates or the like devices need not be employed for this purpose. Indeed such a pump can be used as a metering unit even in the case where it is not required to provide, or boost, the pressure of the system, then simply controlling the rate of flow of fluid though it under a separately-generated pressure differential.
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A high pressure pump for use in the injection of liquid chemicals into subsea oil or gas wells, and intended to be positioned in the subsea environment adjacent to the wellhead, comprises a piezoelectric actuator ( 19 ) for reciprocating a plunger ( 22 ) which acts to compress and expand the effective volume of a pumping chamber ( 29 ) having a valved inlet ( 15 ) connected to a source of the liquid and a valved outlet ( 16 ) to lead the liquid to the well. The device has a minimum of moving parts and in particular avoids the need for any rotating parts and attendant high performance bearings and seals.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention is concerned with the separation of monovalent anions in a basic medium with respect to their relative basicity.
More especially this invention relates to a process that separates the liquors used in the kraft pulping process into two streams; one stream that is rich in alkali metal sulphide and another that is poor in alkali metal sulphide.
2. Description of Prior Art
The kraft pulping process is the most widely used to produce chemical pulps and as such has been the focus of much research and development. In the production of bleached kraft pulp, a low lignin content is desirable (both after pulping and after oxygen delignification), in order to decrease the consumption of expensive bleaching chemicals and to reduce the effect of bleaching effluents on the environment. Various modifications to the basic kraft pulping method have been suggested. The objective of these modifications has generally been to improve the selectivity of the pulping process. Improving selectivity in a pulping process means that the rate of delignification is high compared to the rate of cellulose and hemicellulose degradation. Two such processes are MCC--modified continuous cooking (B. Johansson et al., Svensk Papperstidning nr 10, 30-35, 1984) and EMCC--extended modified continuous cooking (J. E. Jiang et al., APPITA, 45 (1), 19, 1992). It is recognized that the selectivity of the process could be improved further by applying a high sodium sulphide to sodium hydroxide ratio at the beginning of the delignification phase (S. Norden and A. Teder, Tappi, 62( 7), 49-51, July 1979, A. Teder and L. Olm, Paperi ja Puu 63 (4a), 315-322, 1981, B. Mao and N. Hartler, Paperi ja Puu--Paper and Timber, Vol. 74, No. 6, 491-494, 1992).
In a continuous digester system using MCC or EMCC, it is standard practice to divide the total effective alkali (EA) charge into three or four portions. It is simultaneous control of this EA distribution and the dissolved lignin profile that makes selective extended delignification possible. Dividing the total EA addition into three charges results in a slower pulping rate; this effect can be minimized by adding all of the sodium sulphide to the first EA charge in the impregnation stage. This improvement in pulping seems to be additive to that of modified and extended modified cooking (J. E. Jiang et al., CTAPI, Proceedings of 7th Int. Symp. on Wood and Pulping Chemistry, Vol. 1, 337-347, Beijing, P. R. China, May 25-28, 1993). A low concentration of dissolved lignin and a high alkali concentration in the final delignification phase increases the lignin removal (K. Sjoblom et al., Paperi ja Puu--Paper and Timber, 5, 452-460, 1988, B. Mao and N. Hartler, Nordic Pulp and Paper Research Journal, No. 4, 168-173, 1992). A process that generates a sulphide-rich and a sulphide-poor liquor while maintaining the sulphur balance in the kraft process would help in improving the pulping process.
Extended modified cooking has also been examined in the presence of polysulphide which increases pulp yield. Extended modified cooking and polysulphide pulping are two compatible processes that offer complementary advantages (J. E. Jiang, Tappi, 77(2), 120-124, February 1994). A process that provides a high polysulphide concentration in the presence of a decreased concentration of hydroxide would allow further improvements of the pulping process.
At present, there are three published methods of producing liquors with different sulphidities, although none has been tried on a commercial scale. H. A. Simons Ltd. (P. P. H. Lownertz, World patent, WO92/20856, 26 Nov. 1992) proposed a process in which the sodium sulphide content of recovery boiler smelt is leached with water or sulphide-poor white liquor. The solid sodium carbonate content is separated from the sulphide-rich green liquor and dissolved prior to causticizing. The sodium carbonate solution is causticized to a sulphide-poor white liquor. This sulphide-poor liquor can be used for leaching the smelt, for oxygen delignification and for flue gas scrubbing. The sulphide-rich white liquor can be used in the initial phase as well as at the beginning of the bulk delignification phase of the pulping process. The system used is based on technology developed for neutral sulphite semichemical (NSSC) recovery (S. Mizuguichi and T. Naito, Pulp & Paper Canada, 79(8), T251-253, 1978), but is modified to avoid oxidation of sulphide, and to utilize the heat content of the smelt to evaporate water from the liquor.
Another system proposed by Ahlstrom Corporation is a combination of liquor heat treatment (R. Ryham and S. Nikkanen, Proceedings of the 4th SPCI International Conference: Book 1, pp.266-280, Bologna, Italy, May 19-22, 1992) and the DESULPHUR process (R. Ryham and H. Lindberg, 80th Annual Meeting, CPPA Technical Section, B179-B190, February 1994). The basic step in the DESULPHUR process is heat treatment of black liquor, in a process where up to 50% of the sulphur content in the black liquor is released as methyl mercaptan and dimethyl sulphide. The organic sulphides are then converted to hydrogen sulphide. Scrubbing the hydrogen sulphide gas with white liquor provides a white liquor with high sulphidity. In this way about 75% of the total sulphide charge is concentrated in a stream containing about 60% of the total charge of effective alkali. This composition approximates the chemical requirement in the impregnation stage of modified cooking processes.
White liquor with split sulphidity can also be prepared by crystallizing sodium carbonate from well-purified green liquor, Green Liquor Cooling Crystallization (GLCC), (R. Ryham and H. Lindberg, 80th Annual Meeting, CPPA Technical Section, B179-B190, February 1994). The crystallization is accomplished by simultaneous evaporation and cooling of green liquor to about 12° C. The alkali metal carbonate crystals are separated and dissolved prior to causticizing. In this way it is possible to produce a stream that contains about 60% of the EA charged to the digester. The remaining 40% of the EA will be in a sulphur-free caustic stream. Compared to a normal white liquor having 38% sulphidity, the sulphide-rich white liquor would have a sulphidity of about 62%.
Since white liquor is generated in a largely closed causticizing cycle, the ratio of Na 2 S to NaOH remains constant. In order to obtain two streams of white liquor with different concentrations of Na 2 S and NaOH, while maintaining the overall sulphidity in the recovery cycle, electrodialysis of white liquor prior to cooking is proposed.
Electrodialytic systems have been generally used for the separation and concentration of electrolytes (H. Hirai, S. Matsushita and I. Tsuyuki, U.S. Pat. No. 4,207,157, Jun. 10, 1980, D. J. Vaughan, U.S. Pat. No. 4,325,792, Apr. 20, 1982). More particularly, they have been used to separate monovalent anions and cations from multivalent anions and cations by incorporating into these systems monovalent anion- and cation-selective membranes. Examples of these applications include the separation of chloride and fluoride ions from a metal sulphate solution (D. L. Ball and D. A. D. Boateng, U.S. Pat. No. 4,715,939, Dec. 29, 1987), the separation of chloride ions from sulphate ions in seawater (G. Saracco and M. C. Zanetti, Ind. Eng. Chem. Res., 33, 96-101, 1994) and the separation of chloride ions from oxalate ions in an industrial waste water from electrolytic production of titanium (G. Saracco, M. C. Zanetti and M. Onofrio, Ind. Eng. Chem. Res., 32, 675-662, 1993). In a recent patent (M. W. Kennedy et al., U.S. Pat. No. 5,324,403, Jun. 28, 1994), electrodialysis is used to separate sulphate and thiosulphate from a hydrogen sulphide scrubber solution of the liquid redox type. There are, however, no published data on the selectivity of anion-selective membranes towards monovalent anions on the basis of their basicity, nor are there any published methods of separating hydrosulphide from kraft mill white liquor (a mixture of sodium sulphide and sodium hydroxide) and from kraft mill green liquor (a mixture of sodium sulphide, sodium carbonate and sodium hydroxide) by electrodialysis.
There are also, no published data on the separation of hydroxide from polysulphide in a Kraft mill polysulphide liquor.
SUMMARY OF INVENTION
It is an object of this invention to provide a process for separation of monovalent anions on the basis of their basicity.
It is also an object of this invention to provide a process for the separation of sulphide from hydroxide in white liquor used in kraft pulping.
It is a further object of this invention to provide a process for the separation of sulphide from carbonate and hydroxide in green liquor. Green liquor is the liquor which upon causticizing yields white liquor.
It is a further object of this invention to provide a process for the separation of chloride from hydroxide and sulphide in white liquor used in Kraft pulping.
It is still a further object of this invention to provide a process for the separation of hydroxide from polysulphide in polysulphide liquor. Polysulphide liquor is a liquor that can be used in the modified kraft pulping process to improve yield.
It is still a further object of this invention to provide such processes employing an electrodialysis system incorporating cation-selective membranes and anion-selective membranes, in particular, monovalent anion-selective membranes.
In accordance with the invention there is provided a process for separating an alkaline aqueous sulphide-containing solution into a sulphide-rich solution and a sulphide-poor solution comprising: i) feeding an aqueous sulphide-containing solution into a diluting compartment of an electrodialysis cell, said diluting compartment being separated from a concentrating compartment by an anion-selective membrane, ii) feeding a liquid comprising water into said concentrating compartment, iii) passing a direct current through the electrodialysis cell to effect transfer of hydrosulphide ions from said diluting compartment to said concentrating compartment, iv) recovering a sulphide-rich solution from said concentrating compartment, and v) recovering a sulphide-poor solution from said diluting compartment.
In accordance with the invention, there is also provided a process for separating an aqueous alkaline chloride-containing solution into a chloride-rich solution and a chloride-poor solution comprising: i) feeding an alkaline chloride-containing solution into a diluting compartment of an electrodialysis cell, said diluting compartment being separated from a concentrating compartment by an anion-selective membrane, ii) feeding a liquid comprising water into said concentrating compartment, iii) passing a direct current through the electrodialysis cell to effect the transfer of chloride ions from said diluting compartments to said concentrating compartments, iv) recovering a chloride-rich solution from said concentrating compartment, and v) recovering a chloride-poor solution from said diluting compartment.
In accordance with the invention, there is also provided a process for separating an aqueous alkaline polysulphide-containing solution into a polysulphide-rich solution and a polysulphide-poor solution comprising: i) feeding an alkaline polysulphide-containing solution into a diluting compartment of an electrodialysis cell, said diluting compartment being separated from a concentrating compartment by an anion-selective membrane, ii) feeding a liquid comprising water into said concentrating compartment, iii) passing a direct current through the electrodialysis cell to effect the transfer of hydroxide ions from said diluting compartments to said concentrating compartments, iv) recovering a hydroxide-rich solution from said concentrating compartment, and v) recovering a polysulphide-rich solution from said diluting compartment.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The sulphide content of white liquor hydrolyses according to the following reaction:
S.sup.2- +H.sub.2 O⃡HS.sup.- +OH.sup.- ( 1)
Because of the high pK a of HS - of 13-16, in the range of pH values encountered in kraft pulping liquors of 12-14, most of the sulphide is in the hydrosulphide (HS - ) form.
In accordance with the invention it has been found that alkali metal sulphides can be removed from kraft mill pulping liquors by using a two-compartment electrodialysis system employing alternate cation-selective and anion-selective membranes, particularly monovalent anion-selective membranes.
In accordance with a preferred embodiment of the invention there is provided a process which comprises the steps of: a) providing a cell comprising an anode, a cathode and at least two compartments therebetween defined by spaced apart, alternating cation-selective and anion-selective membranes, a first of said compartments defined between an anion-selective membrane and a first cation-selective membrane, being a diluting compartment, and a second of said compartments defined between said anion-selective membrane and a second cation selective membrane, being a concentrating compartment; said diluting compartment being disposed between said concentrating compartment and said cathode, and said concentrating compartment being disposed between said diluting compartment and said anode; b) feeding white liquor solution into the diluting compartment; c) feeding a liquid comprising water into the concentrating compartment; d) passing a direct current through said cell to effect migration of hydrosulphide ions through said anion-selective membrane from said diluting compartment to said concentrating compartment; e) bleeding from said diluting compartment a white liquor solution depleted in sulphide, and f) bleeding from said concentrating compartment a liquid enriched in sulphide.
In particular, the cell of the invention may comprise a plurality of concentrating compartments and a plurality of diluting compartments, in alternate relationship between the anode and the cathode. In this way the direct current in d) effects migration of cations, more especially alkali metal ions from the diluting compartments, towards the cathode, whereby they are collected and trapped in the concentrating compartments. In this way, the liquid bled from the concentrating compartments is rich in alkali metal sulphide, while the liquid bled from the diluting compartments in depleted in alkali metal sulphide.
Furthermore, in accordance with a preferred embodiment of the invention there is provided a process which comprises the steps of: (a) providing a cell comprising an anode, a cathode and at least two compartments employing alternate cation-selective and anion-selective membranes, particularly monovalent anion-selective membranes (b) feeding a pulping liquor, for example, a white liquor solution into a diluting compartment between a cation-selective membrane and a monovalent anion-selective membrane; (c) feeding a liquid comprising water (which may contain an electrolyte) into each concentrating compartment, between a cation-selective membrane and an anion-selective membrane (or a monovalent anion-selective membrane); (d) passing a direct current through the electrodialysis (ED) system thereby causing the transfer of, for example, alkali metal ions and hydrosulphide ions from the pulping liquor solution in the diluting compartments to the concentrating compartments; (e) bleeding from the diluting compartments in this example a pulping liquor solution that is depleted in alkali metal sulphide; (f) bleeding from the concentrating compartments a liquid that is enriched in alkali metal sulphide.
The present invention contemplates a process which includes the following steps:
(a) Filtering the industrial white liquor to remove suspended particles;
(b) feeding the purified solution of white liquor into an ED system composed of alternating cation-selective, and anion-selective membranes, the solution is introduced into each diluting compartment between a cation-selective membrane and an anion-selective membrane;
(c) feeding a liquid comprising water or dilute alkali metal hydroxide and/or sulphide into each concentrating compartment, between a cation-selective membrane and an anion-selective membrane;
(d) passing a direct current through the ED system thereby causing the transfer of alkali metal ions and hydrosulphide ions from the feed liquor in the diluting compartments to the concentrating compartments;
(e) bleeding from the diluting compartments a solution that is depleted in alkali metal sulphide;
(f) bleeding from the concentrating compartments a liquid enriched in aqueous alkali metal sulphide.
The two-compartment ED system referred to in the process of the invention may be any of the systems described in U.S. Pat. No. 4,715,939, Dec. 29, 1987 by D. L. Ball and D. A. D. Boateng. The two-compartment ED system is composed of a large number of cation-selective and anion-selective membranes alternately stacked between two electrodes.
The cation-selective membranes useful in the process of the present invention can be weakly acidic or strongly acidic cation-selective membranes. Examples of suitable cation-selective membranes are Selemion CMV cation-selective membranes (Trademark--Asahi Glass Co, Tokyo, Japan), but other commercially available cation-selective membranes can be used. In order to minimize the fouling of cation-selective membranes by multivalent cations, monovalent cation-selective membranes (e.g., Selemion CSV, Asahi Glass Co. or Neosepta CMS, Trademark--Tokuyama Soda Co., Tokyo, Japan) can be used; these are prepared by synthesizing a thin positively-charged layer on their surface (T. Yawataya, Dechema Monogr., 47, 501-514, 1962, T. Sata et al., J. Membr. Sci., 45, 197-208, 1989 and T. Sata and R. Izuo, J. Membr. Sci., 45, 209-224, 1989).
The anion-selective membranes useful in the process of the present invention are strongly basic anion-selective membranes such as Neosepta AM-1 (Trademark--Tokuyama Soda) and, in particular, monovalent anion-selective membranes such as the Selemion ASV membrane (Trademark--Asahi Glass Co.) and the Neosepta ACS membranes (Trademark--Tokuyama Soda Co.). The Selemion ASV membrane is composed of a polystyrene matrix with quaternary ammonium groups which provide it with its anion-selective properties. In addition, this membrane incorporates a thin highly cross-linked surface layer composed of both strongly (--NR 3 + ) and weakly (--NR 2 ) basic anion-exchange groups. The thickness of the highly cross-linked layer is optimized so as to reduce divalent-ion transport without unacceptably increasing the electrical resistance of the membranes. Under neutral or mild pH conditions, monovalent anions such as Cl - are preferentially passed through the membranes as compared to divalent anions such as SO 4 -2 , based on size exclusion and/or other mechanisms. The Neosepta ACS membrane (Tokuyama Soda Co.) is manufactured in a similar fashion and has similar characteristics to the Selemion ASV membrane.
It has now been found, that anion-selective membranes, particularly monovalent anion-selective membranes, can also separate anions on the basis of their basicity. In particular it has been found that the rate of transport of monovalent anions across these membranes is in decreasing order as follows: Cl - >HS - >OH - . It is this selectivity which allows the novel separations which are described herein.
In general, stacks that are suitable for electrodialysis can be used. Such stacks are available commercially from Asahi Glass Co., Tokyo, Japan, Tokuyama Soda Co., Tokyo, Japan; Ionics Inc., Watertown, Mass., USA, and other commercial sources.
The operating temperature of the two-compartment ED system may be any temperature compatible with the membranes and above the freezing and/or precipitation point of the solutions, preferably in the 20°-60° C. temperature range.
The feed into the diluting compartments could be any soluble salt mixture composed of monovalent cations (e.g., the Group Ia alkali metals such as sodium and potassium or the non-metal monovalent cations such as ammonium ions) and monovalent anions (e.g. hydroxide, hydrosulphide and chloride) which may contain polyvalent anions (e.g. sulphate, carbonate, polysulphide, etc.).
The operation of the ED system is further described below in an example where white liquor is considered.
The white liquor solution fed into the diluting compartments of the ED stack is suitably of a median composition of 1.2N sodium sulphide and 2.9N sodium hydroxide but may also be composed of different ratios. These concentrations, however, can be higher or lower without adversely affecting the normal operation of the system. Preferably, the feed solution should be free of large amounts of divalent and/or trivalent cations of elements such as calcium, magnesium, manganese, chromium, nickel and iron whose hydroxides could potentially foul the membranes. The problems arising from such cations, can be minimized by filtering the as-received white liquor solution to eliminate suspended particles. The feed solution is also, preferably, free of organic contaminants such as phenolic-type lignin fragments that could potentially foul the anion-selective membranes. In the case of membrane fouling by organics, periodic reversal of electrical polarity, together with simultaneous switching of flows to the diluting and the concentrating compartments, is recommended.
The liquid fed to the concentrating compartments may be water alone, or may be water containing any electrolyte which is compatible with the first stage of pulping. Preferably, this liquid is neutral or alkaline.
The current passed through the ED system in conventional fashion is direct current of a voltage dictated by the resistance of the membranes and the various solution streams between the two electrodes. Current densities between about 20 and about 70 milliamps per square centimeter are preferred. Higher or lower current densities are contemplated, however, for certain specific applications.
The result of the current flow is electrodialysis to produce a white liquor solution depleted in the sulphide of the alkali metal in the diluting compartments and a liquid mainly comprising alkali metal sulphide in the concentrating compartments. It is contemplated that by adjusting the water feed rates into the concentrating compartments and/or the current density, the product alkali metal sulphide solution can be of any desired concentration as limited by acceptable current efficiencies.
The residence time of the aqueous white liquor solution in the diluting compartments is suitably sufficient to cause sulphidity in this compartment to be reduced to less than about 16%. Suitably, the liquid comprising sodium sulphide and sodium hydroxide withdrawn from the concentrating compartment has a sulphidity as high as 78%.
Representative white liquor compositions in the feed solution are between 0.9N and 1.3N in sodium sulphide, while sodium hydroxide concentrations in these same solutions are 2.6 to 3.9N, although sodium hydroxide concentrations may be as low as 2N in some cases.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is illustrated in preferred embodiments by reference to the accompanying drawings in which:
FIG. 1 illustrates schematically a two-compartment ED cell stack of the invention.
FIG. 2 illustrates the initial changes in the concentration of hydroxide and sulphide with time in a laboratory prepared white liquor processed through the ED system shown in FIG. 1 (Example 1).
FIG. 3 illustrates the changes in the concentration of hydroxide, sulphide and chloride with time in a mill white liquor spiked with sodium chloride and processed through the ED system shown in FIG. 1 (Example 5).
FIG. 4 illustrates the changes in the concentration of hydroxide, sulphide and carbonate with time in a laboratory prepared green liquor processed through the ED system shown in FIG. 1 (Example 6).
FIG. 5 illustrates the changes in the concentration of hydroxide, sulphide and polysulphide with time in a laboratory prepared polysulphide liquor processed through the ED system shown in FIG. 1 (Example 7).
DESCRIPTION OF PREFERRED EMBODIMENTS WITH REFERENCE TO THE DRAWINGS
FIG. 1 illustrates the process of the invention employing a unit ED cell. An ED cell stack 1 is shown with cation-selective membranes 2a, 2b and monovalent anion-selective membrane 3a, alternately stacked together between an anode 4 and a cathode 5. In FIG. 1 two cation-selective membranes 2a, and 2b and one anion-selective membrane 3a, are shown, however, a much greater number of such units can be incorporated between the two electrodes as suggested by the three dots near each electrode. A minimum of two cation-selective and one anion-selective membranes are needed for a complete unit cell.
In this example a solution of white liquor is fed in stream 7 into the ED cell between the cation-selective membrane 2b and monovalent anion-selective membrane 3a (diluting compartment 10).
The divalent anion X 2- in FIG. 1 is, in particular, polysulphide, sulphate, sulphite, thiosulphate, carbonate or mixtures of two or more of these.
Simultaneously, a water stream 6, which may contain an electrolyte (preferably low concentrations of sodium sulphide and/or sodium hydroxide), is fed into the ED cell between the cation-selective membrane 2a and the anion-selective membrane 3a (concentrating compartment 12). An alkaline solution such as sodium hydroxide or a neutral solution such as sodium sulphate is fed to the compartments 14 and 16, adjacent to the anode 4 and cathode 5, respectively, from a reservoir, and returned from compartments 14, 16 to the reservoir, after degassing to remove hydrogen and oxygen.
Current is passed between anode 4 and cathode 5 through the ED cell, causing alkali metal cations to migrate toward the cathode across the cation-selective membranes 2a and 2b, and the monovalent anions such as HS - and OH - ions to migrate towards the anode across the monovalent anion-selective membrane 3a. It was found that HS - passes preferentially through the monovalent anion-selective membrane. Accordingly, mainly alkali metal sulphide is formed in the concentrating compartment 12 between the cation-selective membrane 2a and the anion-selective membrane 3a, and this alkali metal sulphide is bled from the ED cell through stream 8. The diluting compartment 10 between the cation-selective membrane 2b and the adjacent anion-selective membrane 3a will contain mainly sodium hydroxide which is bled through stream 9.
The solution bled from the concentrating compartment may be used in the initial stage of kraft pulping, or may be used to prepare polysulphide liquor of higher concentration than obtained by available methods in the literature, whereby polysulphide liquor is prepared from normal white liquor by using an activated carbon catalyst (M. Nakamura and T. Ono, Proceedings of the Tappi Pulping Conference, Atlanta, 407, 1988 and W. E. Lightfoot, Pulp and Paper, 64(1):88, 1990), or using a lime mud catalyst in the presence of MnO 2 (G. M. Dorris, U.S. Pat. No. 5,082,526, Jan. 21, 1992). The solution bled from the diluting compartment can be used in the final stage of pulping as well as, in place of sodium hydroxide, in an oxygen delignification stage, for pH adjustment or flue gas scrubbing.
The electrodialysis cell employed in this process can be operated in a batch or a feed and bleed mode. A batch mode refers to the case in which the same solution is being recirculated continuously through the system thereby allowing the accumulation of product in the concentrating compartments and the depletion of products in the diluting compartments. A feed and bleed mode of operation provides steady-state operation with constant concentration of the required product.
The current passed through the ED cell is a direct current of a voltage dictated by the resistance of the membranes and the various solution streams between the two electrodes. Current densities between 20 to 70 mA/cm 2 are preferred.
EXAMPLES
Example 1
This example illustrates the separation of sulphide ions from a laboratory prepared white liquor. An 8-unit cell electrodialysis stack using Asahi Glass Selemion CMV cation-selective membranes and Asahi Glass Selemion ASV anion-selective membranes (91 cm 2 effective membrane area) was set up. Nafion 417 (Trademark--E.I. DuPont de Nemours & Co.) cation-selective membranes were used for the rinse compartments. A unit cell is shown in FIG. 1. Throughout the experiment, the circulation tanks of the concentrating and diluting compartments were blanketed with nitrogen gas to minimize the oxidation of sulphide. White liquor of a median composition (e.g., 1.2N Na 2 S, 2.9N NaOH, sulphidity of 29.5%) was prepared (at 27.8° C.). Other constituents of the white liquor used are given in Table 1. The experiments were run in the batch mode with an initial concentration of 0.25N NaOH (at 28.3° C.) in the concentrating compartment, and simulated white liquor in the diluting compartment. The current densities applied were lower than the limiting current density as determined by polarization curves recorded during the experiment. The standard kraft pulping terms are defined as follows: Active Alkali (AA) is NaOH+Na 2 S, expressed as g/l Na 2 O; Total Titratable Alkali (TTA) is NaOH+Na 2 S+Na 2 CO 3 , expressed as g/l Na 2 O and Sulphidity is the ratio of Na 2 S to AA in % on Na 2 O basis. The concentration of NaOH, Na 2 S and Total Titratable Alkali (TTA) were determined through a potentiometric titration. The reported concentration of NaOH excludes the amount of NaOH produced from the hydrolysis of Na 2 S.
TABLE 1______________________________________Median composition of white liquor Concentration, Concentration, Concentration, Range, g/lComponent N g/l Na.sub.2 O Na.sub.2 O______________________________________NaOH 3.06 95 81-120Na.sub.2 S 1.22 38 30-40Na.sub.2 CO.sub.3 0.84 26 11-44Na.sub.2 SO.sub.3 0.15 4.8 2-6.9Na.sub.2 SO.sub.4 0.30 9.1 4.4-18Na.sub.2 S.sub.2 O.sub.3 0.19 6 4-8.9______________________________________
A 10% NaOH solution was fed to the compartments adjacent to the anode and the cathode from a reservoir and returned to the reservoir, after degassing to remove hydrogen and oxygen. Each cell compartment was connected to its appropriate reservoir tank and all compartments operated in the batch mode. Table 2 shows the conditions used for the operation of the cell stack.
TABLE 2______________________________________General experimental conditions Diluting Concentrating______________________________________Initial Concentration in Loop, N NaOH Na.sub.2 S NaOH Na.sub.2 S 2.92 1.22 0.25 0.0Initial Volume in Loop, L 7.8 5.7Circulation Rate, L/min 3.9 3Hydraulic Pressure, kPa (ga.) 65 65______________________________________
In the first 225 minutes (3.75 hours) of operation, the sulphide concentration in the concentrating compartment increased from zero to 0.93N, whereas the hydroxide concentration increased only slightly from 0.25N to 0.26N. In the same time period, the concentration of sulphide in the diluting compartment declined from 1.22N to 0.56N, whereas the hydroxide concentration declined only slightly from 2.92N to 2.88N (FIG. 2). These results show that under the conditions of this experiment, the ASV anion-selective membrane is more selective to hydrosulphide anions than hydroxide anions. The sulphidity was 78.3% in the concentrating compartment, versus 16.3% in the diluting compartment. In order to be consistent with the normal definition of sulphidity and TTA, sulphide ions are represented as Na 2 S, although it is hydrosulphide ions (HS - ) which are crossing through the membrane. The average current efficiencies over a period of 3.75 hours, were 41.7% for total hydroxide (total hydroxide includes the amount produced from the hydrolysis of Na 2 S) and 41.3% for hydrosulphide.
Potentiometric and conductimetric titrations showed that the concentrating compartment did not contain any carbonate. Chemical analyses for other sodium salts showed that the amount of carbonate, sulphate, sulphite and thiosulphate in the concentrating compartment was insignificant. It appears that these ions do not pass through the membrane because, as a result of the high pH of the solution, they are in their divalent form.
Two polarization curves were recorded during the experiment, and the operating current density was adjusted between 44 to 66 mA/cm 2 . After 3.75 hours, the cell voltage (excluding the electrode compartments) was 0.57 V per unit cell, at 6A and 29.3° C.
On the basis of the data obtained in this experiment, it is possible to operate the system under steady-state condition to produce a white liquor of high sulphidity (78%). Depending on the pulping requirement, white liquor of lower sulphidity can be obtained. The feed rate of water to the concentrating compartment can be adjusted in order to obtain the desired concentration of sulphide while maintaining the ratio of sulphide/hydroxide at the required level.
Example 2
In order to evaluate other membranes, the Selemion ASV membranes used in the ED cell stack were replaced by Tokuyama monovalent anion-selective membranes (Neosepta ACS). The initial concentration of white liquor in the diluting compartment was 1.08N Na 2 S and 2.8N NaOH, sulphidity of 28.1%. The initial concentration of NaOH in the concentrating compartment was 0.32N. Over a period of 4 hours, the diluting compartment had a concentration of 0.57N Na 2 S and 2.5N NaOH (sulphidity of 19%). The current density was adjusted to be 44 to 66 mA/cm 2 . The concentrating compartment had a concentration of 1N Na 2 S and 0.35N NaOH (sulphidity of 73.8%). The average current efficiencies were 26% for total hydroxide and 33.2% for hydrosulphide. The carbonate content of the white liquor remained mainly unchanged in the diluting compartment. Table 3 shows the molar ratios of hydrosulphide/hydroxide in the concentrating compartments in Examples 1 and 2. It appears that the Neosepta ACS is more selective towards hydrosulphide ions as compared to the Selemion ASV.
TABLE 3______________________________________The molar ratio of hydrosulphide to hydroxide in theconcentrating compartmentTime, Selemion ASV Neosepta ACShours NaHS/NaOH NaHS/NaOH______________________________________0 0 01 1.09 2.332 1.24 1.953 -- 1.603.75 0.99 --4 -- 1.28______________________________________
Example 3
To examine the selectivity of the general purpose anion-selective membranes, as compared to monovalent anion-selective membranes, the monovalent anion-selective membranes used in the ED cell stack were replaced by a strongly basic, anion-selective membrane (Neosepta AM-1, Tokuyama Soda Co.). A white liquor of similar composition (1.1N Na 2 S and 3.1N NaOH, sulphidity of 26.2%) was placed in the diluting compartment and a 0.3N NaOH solution was placed in the concentrating compartment. The current density was adjusted to be 44 to 66 mA/cm 2 . Over a period of 4 hours, the diluting compartment had a concentration of 0.66N Na 2 S and 2.9N NaOH (sulphidity of 18.5%). The concentrating compartment had a concentration of 0.74N Na 2 S and 0.53N NaOH (sulphidity of 58.3%). The average current efficiencies were 60% for total hydroxide and 37.2% for hydrosulphide. The carbonate content of the white liquor remained unchanged in the diluting compartment. Table 4 shows the molar ratio of hydrosulphide/hydroxide in the concentrating compartments in Examples 2 and 3. It appears that the monovalent anion-selective membrane (Neosepta ACS) is more selective to hydrosulphide ions than the general purpose anion-selective membrane (Neosepta AM-1).
TABLE 4______________________________________The molar ratio of hydrosulphide to hydroxide in theconcentrating compartmentTime, Neosepta ACS Neosepta AM-1hours NaHS/NaOH NaHS/NaOH______________________________________0 0 01 2.33 0.942 1.95 0.753 1.60 0.734 1.28 0.62______________________________________
Example 4
This example illustrates the separation of sulphide ions from a white liquor obtained from a mill. The mill white liquor containing 2.14N NaOH and 1.02N Na 2 S was filtered and then processed through the ED stack used for example 1. Because of some residual water in the system, the concentrations dropped to 1.83N NaOH and 0.95N Na 2 S (sulphidity of 34.2%). A solution of 0.24N Na 2 S was fed into the concentrating compartment. The experimental conditions are given in Table 5.
TABLE 5______________________________________Experimental Conditions Used for Example 4 Diluting Concentrating______________________________________Initial Concentration in Loop, N NaOH Na.sub.2 S NaOH Na.sub.2 S 1.83 0.95 0.0 0.24Initial Volume in Loop, L 8.3 6Circulation Rate, L/min 2.2 3.3Hydraulic Pressure, kPa (ga.) 65 65______________________________________
After 5.6 hours, the concentration of NaOH and Na 2 S in the concentrating compartment rose to 0.21N and 1.08N respectively (sulphidity of 83.7%). At the same time, the sulphidity of white liquor in the diluting compartment declined to 16.4% (1.79N NaOH and 0.35N Na 2 S). The current density was adjusted to be 22 to 66 mA/cm 2 . The average current efficiencies were 41.4% for total hydroxide and 27.4% for hydrosulphide. These results are in agreement with the data obtained in Example 1.
Example 5
This example illustrates the separation of chloride from a mill white liquor. A mill liquor of similar composition to Example 4 (1.76N NaOH, 0.9N Na 2 S) and 33.9% sulphidity) was chosen for this experiment. To examine the degree of separation of chloride from a chloride-rich white liquor, 67 g/L of NaCl was added to the test liquor. A solution of 0.27N Na 2 S was fed to the concentrating compartment. The experimental conditions are shown in Table 6.
TABLE 6______________________________________Experimental Conditions Used for Example 5 Diluting Concentrating______________________________________Initial Concentra- NaOH Na.sub.2 S NaCl NaOH Na.sub.2 S NaCltion in Loop, N 1.76 0.90 1.15 0.0 0.27 0.0Initial Volume in 7.4 5.5Loop, LCirculation Rate, 2.4 3.2L/minHydraulic Pres- 65 65sure, kPa (ga.)______________________________________
During a 6-hour run, the sulphidity of white liquor dropped to 23.2% and the chloride level decreased from 1.15N (67 g/L) to 0.48N (28.2 g/L, i.e., 58% removal). The liquor from the concentrating compartment had a sulphidity of 89% and a chloride content of 0.79N (46 g/L); the concentrations of NaOH and Na 2 S in this compartment were 0.09N and 0.74N, respectively. The current density was adjusted to be 22 to 66 mA/cm 2 . The average current efficiencies were 18.2% for total hydroxide, 12.9% for hydrosulphide and 44.7% for chloride. The changes in concentrations versus time are shown in FIG. 3. It appears that the transfer rate increases with decreasing basicity of the ion transferred, i.e., the rate of tranfer is in the order of Cl - >HS - >OH - .
This experiment demonstrated that this particular membrane configuration can be used to decrease the sulphidity and the chloride level of white liquor. This configuration can be particularly useful to coastal and/or closed cycle mills in which chloride accumulates in the liquor cycle. The starting solution in the concentrating compartment can be sodium chloride; in such a case, the solution discarded from the concentrating compartment would be mainly sodium chloride. Depending on the chloride and sulphidity requirements of the white liquor, varying ratios of Na 2 S to NaCl can be produced. The liquor obtained from the diluting compartment can either be used directly in conventional cooking, or can be further processed to produce two streams of high sulphidity and high alkalinity liquors.
Example 6
This experiment illustrates that sulphide ions can be separated from a laboratory prepared green liquor. Green liquor of a median composition (e.g., 0.40N NaOH, 1.07N Na 2 S and 2.8N Na 2 CO 3 ) was prepared. Other constituents of the green liquor used are given in Table 7. The cell stack used was identical to the one used in Example 1. The experiments were run in the batch mode with an initial concentration of 0.12N Na 2 S in the concentrating compartment, and simulated green liquor in the diluting compartment. The current density was adjusted to be 22 to 66 mA/cm 2 . The concentration of NaOH, Na 2 S and Total Titratable Alkali (TTA=NaOH+Na 2 S+Na 2 CO 3 ) were determined through a potentiometric titration. The difference between TTA and Active Alkali (AA=NaOH+Na 2 S), is assumed to be alkali-metal carbonate. The experimental conditions are given in Table 8.
TABLE 7______________________________________Median composition of green liquor Concentration, Concentration, Concentration, Range, g/lComponent N g/l Na.sub.2 O Na.sub.2 O______________________________________NaOH 0.48 15 10-18Na.sub.2 S 1.19 37 35-40Na.sub.2 CO.sub.3 3.44 107 78-135Na.sub.2 SO.sub.3 0.19 6.1 4.2-7.6Na.sub.2 SO.sub.4 0.35 11 7.4-24Na.sub.2 S.sub.2 O.sub.3 0.18 5.5 4.3-6.5______________________________________
TABLE 8______________________________________Experimental Conditions Used for Example 6 Diluting Concentrating______________________________________Initial NaOH Na.sub.2 S Na.sub.2 CO.sub.3 NaOH Na.sub.2 S Na.sub.2 CO.sub.3Concentra- 0.40 1.07 2.8 0.0 0.12 0.0tion in Loop,Initial 7.1 6.6Volume inLoop, LCirculation 2.4 3.2Rate, L/minHydraulic 63 63Pressure,kPa (ga.)______________________________________
After three hours, the concentrations of NaOH, Na 2 S and Na 2 CO 3 in the concentrating compartment were 0.027N, 0.70N and 0.02N respectively (sulphidity of 96.2%). At the same time, the concentrations of NaOH, Na 2 S and Na 2 CO 3 in the diluting compartment were 0.38N, 0.50N and 2.6N respectively (sulphidity of 56.8%). The current efficiencies were 9% for hydroxide and 54.2% for sulphide. The changes in concentrations versus time are shown in FIG. 4.
This experiment demonstrates that green liquor can be separated into a sulphide-rich liquor (concentrating compartment) and a sulphide-poor liquor (diluting compartment). The sulphide-rich liquor can be used in the initial stage of pulping, or it can be used to make polysulphide liquor. The sulphide-poor liquor can be causticized (at higher efficiency) to a caustic-rich white liquor, which can be used in the final stage of pulping.
Example 7
This experiment illustrates that polysulphide liquor can be separated into a polysulphide-rich and a caustic-rich component. A laboratory made polysulphide liquor was prepared by dissolving elemental sulphur in a mixture of sodium sulphide and sodium hydroxide. The chemical composition of the prepared liquor is given in Table 9. The cell stack used was identical to the one used in Example 1. The experiments were run in the batch mode with an initial concentration of 0.26N NaOH in the concentrating compartment, and simulated polysulphide liquor in the diluting compartment. The current density was adjusted to be 44 to 66 mA/cm 2 . The concentration of polysulphide (PS), expressed as sulphur (S) concentration was measured by a gravimetric method. A known volume of polysulphide liquor was acidified with hydrochloric acid (pH=5-5.5). The precipitated sulphur was then filtered, dried and weighed to determine the amount of polysulphide sulphur. The concentration of NaOH, Na 2 S and Total Titratable Alkali (TTA=NaOH+Na 2 S+Na 2 CO 3 ) were determined through a potentiometric titration. The difference between TTA and Active Alkali (AA=NaOH+Na 2 S), is assumed to be alkali-metal carbonate. The experimental conditions are given in Table 10.
TABLE 9______________________________________Composition of the laboratory made polysulphide liquor Concentration, Concentration,Component N g/l Na.sub.2 O______________________________________NaOH 2.53 78.4Na.sub.2 S 0.46 14.3Na.sub.2 CO.sub.3 0.13 4Na.sub.2 S.sub.2 O.sub.3 0.08 4.8PS as S, g/l 10.1 --______________________________________
TABLE 10__________________________________________________________________________Experimental Conditions Used for Example 7 Diluting Concentrating__________________________________________________________________________Initial Concentration in Loop, N NaOH Na.sub.2 S Na.sub.2 Co.sub.3 S, g/l NaOH Na.sub.2 S Na.sub.2 CO.sub.3 S, g/l 2.53 0.46 0.13 10.1 0.26 0.0 0.0 0.0Initial Volume in Loop, L 7.7 6.2Circulation Rate, L/min 2.3 3.4Hydraulic Pressure, kPa (ga.) 62 62__________________________________________________________________________
After 6.25 hours, the concentrations of NaOH, Na 2 S and PS sulphur in the concentrating compartment were 1.39N, 0.2N and 0.24 g/l respectively (sulphidity of 12.5%). At the same time, the concentrations of NaOH, Na 2 S and PS sulphur in the diluting compartment were 1.77N, 0.33N and 9.7 g/l respectively (sulphidity of 15.8%). The current efficiencies were 88.5% for hydroxide and 9.7% for sulphide. The changes in concentrations versus time are shown in FIG. 5.
This experiment demonstrates that polysulphide liquor can be separated into a polysulphide-rich liquor (diluting compartment) and a polysulphide-poor liquor (concentrating compartment). The polysulphide-rich liquor can be used in the initial stage of pulping, whereas the polysulphide-poor liquor (caustic-rich) can be used in the final stage of pulping.
The sulphur in polysulphide liquor is in the form of S n S -2 , where n=1 to 4. The relatively large and mainly divalent polysulphide ions would, therefore, stay in the diluting compartment. The competition is mainly between the OH - and HS - ions. Although the HS - ions preferentially cross the membrane initially, because of their low concentration in the polysulphide liquor (less than half the concentration in a typical white or green liquor), it is hydroxide ions that end up being concentrated in the concentrating equipment.
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A process using an electrodialysis system employing cation-selective membranes and anion-selective membranes, particularly monovalent anion-selective membranes is used to separate kraft pulping liquors into two streams; one that is rich in sulphides (to be used in the initial stage of pulping), and another that is poor in sulphides (to be used in the final stage of pulping). By separating pulping liquors in this way, the sulphur balance in the kraft process can be maintained while obtaining the benefits of modified pulping. The same electrodialytic system can be used to separate green and polysulphide liquors into sulphide-rich and sulphide-poor components.
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This is a division, of application Ser. No. 07/470,242, filed Jan. 25, 1990.
FIELD OF INVENTION
The present invention relates to the measuring of gas pressures and, in particular, to a gauge for measuring the pressure in certain high pressure gas cylinders.
BACKGROUND TO THE INVENTION
Gases, such as oxygen, nitrogen and argon, are delivered to a use point in a number of ways. When the use of such gases requires relatively small quantity of gas at one time, such as in metal cutting, welding, blanketing or metal fabrication operations, the gas typically is delivered to the use point and stored there in a gas storage cylinder.
A recent very significant advancement in the field of such gas storage vessels, such as gas cylinders, is the high strength cylinder described and claimed in U.S. Pat. Nos. 4,461,657 and 4,578,113, the disclosures of which are incorporated herein by reference. This new gas storage cylinder enables the storage and transport of significantly more gas than is possible in a conventional cylinder of comparable size and weight because the gas can be safely maintained within the new gas storage cylinder at a pressure much higher than that possible with such conventional cylinders. For example, whereas a conventional cylinder may safely hold gas at a pressure up to about 2700 psia, the new high pressure gas storage cylinder may safely hold gas at a pressure up to about 4500 psia.
Gas is used at a use point at a defined pressure or pressure range. Generally, this use pressure is less than the pressure of the gas source and typically is around 50 psig. In such cases, a pressure regulator is employed to cause a reduction in the gas pressure and to ensure that the pressure of the gas going to the use point does not exceed the allowable use point pressure limit. The new gas storage cylinder provides gas at a pressure significantly in excess of the conventional pressures and thus at a pressure greater than that which can be handled by conventional regulators.
Once the new high strength gas storage cylinder is empty of gas, it must be refilled. In order to retain the advantages of the high strength cylinder, it must be recharged at the high pressure. In U.S. Pat. No. 4,844,111, the disclosure of which is incorporated herein by reference, there is a described a regulator which is capable both of rendering a high pressure gas source compatible with a lower pressure use point and also enabling recharging of the high pressure gas source to a high pressure. For this purpose, the regulator is equipped with two outlet ports, one to be used by the user to withdraw gas and the other to be used for refill.
One of the problems associated with the new high strength gas cylinders equipped with this regulator is the lack of a contents gauge on the gas cylinder. This lack of a contents gauge is problematical to users of the cylinders, particularly with respect to mobile operations, where an operator desires to know how much gas is in the cylinder, so that he can ensure that sufficient gas is available for the expected activity.
SUMMARY OF INVENTION
In accordance with the present invention, there is provided a contents gauge for the high pressure cylinders which is designed to be located in the high pressure refill outlet port of the regulator described above.
Accordingly, in one aspect, the present invention provides a combination of elements, including a high pressure gas storage cylinder, which generally is enclosed at one end and exhibits leak-before-break behavior, and a valve-regulator assembly mounted on the storage cylinder. The valve-regulator assembly has a valve body with main conduit means in flow communication with high pressure gas in the storage cylinder and a high pressure gas outlet in direct flow communication with the main conduit means. The valve-regulator assembly also includes a regulator in direct flow communication with the main conduit means for preventing gas flow from the main conduit means to a lower pressure outlet downstream of the regulator at a pressure above a predetermined minimum.
The combination further includes a combination pressure gauge-plug mounted in the high pressure outlet to measure the gas pressure in the cylinder. The combination pressure gauge-plug comprises a cylindrical gauge mechanism and housing having bourdon tube means communicating with high pressure gas in the main conduit means and a retaining nut threadedly received in the high pressure outlet and mounting the housing in the high pressure outlet. When it is desired to refill the gas storage cylinder, the combination pressure gauge-plug is removed from the high pressure outlet and the cylinder is refilled through that outlet. The combination gaugeplug, therefore, replaces the conventional plug normally positioned in the high pressure outlet prior to shipping to the customer. When the gauge is removed from the high pressure outlet, a retaining spring may be mounted on the housing to maintain the housing and nut in an assembled condition.
The housing is rotatable with respect to the retaining nut, so that the gauge may be positioned in any desired orientation irrespective of the position of the nut in the high pressure outlet. The gauge may include any desired form of visual display which indicates the pressure of the gas in the cylinder.
As described in the aforementioned U.S. Pat. Nos. 4,461,657 and 4,578,113, the high strength cylinder may comprise a shell of a low alloy steel consisting essentially of:
(a) from 0.28 to 0.50 weight percent carbon;
(b) from 0.6 to 0.9 weight percent manganese;
(c) from 0.15 to 0.35 weight percent silicon;
(d) from 0.8 to 1.1 weight percent chromium;
(e) from 0.15 to 0.25 weight percent molybdenum
(f) from 0.005 to 0.05 weight percent aluminum;
(g) from 0.04 to 0.10 weight percent vanadium;
(h) not more than 0.040 weight percent phosphorus;
(i) not more than 0.015 weight percent sulfur;
(j) calcium in a concentration of from 0.8 to 3 times the concentration of sulfur, a rare earth element(s) in a concentration of from 2 to 4 times the concentration of sulfur; and
(k) the remainder iron.
Such gas cylinders are enclosed at one end and exhibit leak-before-break behavior. By using such alloy to construct the cylinder, increased cylinder efficiency, ultimate tensile strength, fracture toughness and fire resistance are achieved. The ultimate tensile strength generally is at least 150 thousands of pounds per square inch and the fracture toughness is at least 70 ksi square root inch.
As described in the aforementioned U.S. Pat. No. 4,844,111, the valve-regulator assembly renders a high pressure gas source compatible with a lower pressure use point. The regulator may comprise a spring-loaded piston, a sensing chamber at one end of the piston and sealing plug at the other end of the piston. The plug is capable of stopping gas flow from the main conduit when high pressure is present in the sensing chamber.
In another aspect of the invention, there is provided a gauge mechanism for determining the pressure of an enclosed gas atmosphere including a plurality of elements including a generally cylindrical body member having a first outer region of uniform diameter and a second outer region of increased. An axial elongate bore extends within the body member and communicates at one end with an enlarged cylindrical recess having a transparent cover, indicia means designating a pressure scale and pointer means and communicates at the other end with a narrow bore.
A copper or other suitable metal tube of diameter generally corresponding to that of the narrow bore has a portion thereof extending through the narrow bore and opening to exterior of the body member and usually communicating with the gas atmosphere, a coiled portion thereof located in said elongate bore and a portion thereof operatively connected to said pointer means for positioning the pointer means relative to the indicia means in response to contraction and expansion of the length of the coiled portion.
The copper tube functions in accordance with the bourdon tube principle and the lengthening or shortening of the length of the coiled portion occurs in accordance with the pressure of the gas atmosphere being measured.
An annular retaining nut has an internal diameter corresponding to the outer diameter of the first outer region of the body member to be slidably received thereon and to abut at one end thereof against the second outer region. The nut also has an outer screw-threaded surface for screw threaded mounting of the gauge mechanism in a threaded bore.
A releasably engageable retaining ring is provided in abutment with the other end of the annular retaining nut to maintain the nut assembled with the body member and preferably is received in a recess in the first outer surface. When it is desired to position the gauge mechanism in the high pressure outlet of a gas cylinder, the retaining ring is removed.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a simplified cross-sectional view of gas storage cylinder of typical design to which a pressure gauge is to be applied;
FIG. 2 is a plan cross-sectional view of a valve-regulator used in conjunction with the gas storage cylinder of FIG. 1 to provide high and low gas pressure outlets;
FIG. 3 is a front elevational view of a contents gauge of construction in accordance with one embodiment of the invention; and
FIG. 4 is a longitudinal sectional view of the contents gauge of FIG. 3.
DESCRIPTION OF PREFERRED EMBODIMENT
Referring to the drawings, a gas storage cylinder 10 is composed of a shell comprising a cylindrical midsection 11 having a relatively uniform sidewall thickness, a bottom wall portion 13 which is somewhat thicker than the sidewall, and a top portion 12 which forms a narrowed neck region to support a gas valve and regulator 20 (FIG. 2) to fill and discharge gas from the cylinder 10. The bottom portion 13 of the cylinder 10 is formed with a inward concave cross-section in order to be able to more suitably carry the internal pressure load of the cylinder 10. The cylinder 10 is intended to stand upright on the bottom portion.
The valve regulator assembly 20 mounted on the cylinder 10 comprises a valve body 21 having a main conduit 22 capable of flow communication with the high pressure contents of the cylinder 10.
A high pressure outlet 23 is in direct flow communication with the main conduit 22. In this way, gas at high pressure may flow through the outlet 23, through the main conduit 22 and into the cylinder 10, so as to recharge the cylinder at high pressure. In addition, high pressure from the cylinder 10 may flow through the main conduit 22 and through the high pressure outlet 23, so as to deliver gas at high pressure in the event that such high pressure delivery is required.
Also provided in direct flow communication with the main conduit 22 is a regulator 24. The regulator 24 comprises a piston 25 loaded by a spring 26. A sensing chamber 27 is provided at one end of the piston 25 and a sealing plug 28 is provided at the other end. A passage 29 communicates between the sensing chamber 27 and a low pressure outlet 30, which is in flow communication with the main conduit means 22 and is downstream of the regulator 24.
A lower pressure burst disk assembly 31 communicates between the lower pressure outlet 30 and the outside of the valve body 21. The burst disk assembly comprises a burst disk with gasket which are sealed in place by a threaded plug having an open center to complete a properly sized passage for relief flow, if and when the disk bursts due to overpressure.
The regulator 24 is set to lock at a predetermined desired pressure by adjusting the compression of spring 26. For example, in the case where the high pressure gas in the cylinder 10 is at 4500 psia and the use point equipment at the interface can handle gas at a maximum pressure of 3000 psia., the regulator 24 would be set to lock at a lower pressure, such as 2000 psia, thus ensuring that gas exceeding the use point maximum pressure is not delivered, in the following manner.
With the high pressure outlet 23 plugged off, such as by the contents gauge of the present invention, as described below, gas flows from the high pressure cylinder 10 through the main conduit 22 and lower pressure outlet 30, and then on to a lower pressure use point. A conventional step-down regulator may be positioned upstream of the lower pressure use point to further decrease the pressure. The pressure of the gas within the lower pressure outlet 30 depends on the rate at which the use point is using the gas. Should the pressure in the lower pressure outlet 30 rise to the 2000 psia level of this example, then gas flowing through the conduit 29 will deliver this pressure to the sensing chamber 27, causing the spring-loaded piston 25 to move sealing plug 28 into the position blocking off the passage from the main conduit 22 so as to stop gas flow. When the pressure in the lower pressure outlet 30 decreases below the setpoint, then the piston 25 moves back and gas flow is resumed.
In this way, the use point sees gas only at conventional pressure and not the high pressure in the cylinder 10. Because of the high pressures involved, two precautions are built into the assembly. The burst disk assembly 31 serves to ensure that should the regulator 24 fail, then high pressure gas will be released through the burst disk assembly and hence not cause harm downstream. In addition, the chamber for springs 26 is vented to the outside of the valve body 21 through a passage 32, thereby ensuring that, should high pressure gas pass by the O-ring seal on either side of springs 26, such gas will be vented out of the assembly and not cause spring malfunction leading to regulator malfunction.
In order for the user to determine the actual pressure of gas in the cylinder 10, a contents gauge 50 is screwed into the high pressure outlet 23, thereby fulfilling the dual function of a plug for the high pressure outlet 23 and a contents gauge.
The contents gauge 50 comprises three parts, namely a gauge mechanism and housing 52, a threaded retaining nut 54 and a retaining spring 56. This three-part design permits the gauge to be maintained in an upright position at all times, regardless of the seating of the retaining nut 54.
The gauge mechanism and housing 52 comprises a dial 58 bearing indicia 60 indicating the pressure and a lens 62 enclosing the dial 58. A coiled hollow copper tube 64 is located in an elongate axial bore 66 within the housing and has a first closed-end tail piece 68 which acts as a pointer associated with the dial 58 and a second open-end tail piece 70 projecting in sliding relation with a narrow bore 72 communicating between the axial bore 66 and the exterior of the gauge 50.
The retaining spring 56 is used solely to maintain the assembly 50 together when it is not mounted in the high pressure outlet 23. The retaining nut 54 is provided with slots 74 to permit the use of a tool to install and remove the gauge assembly 50. A sealing ring 76 may be mounted to the inner end of the gauge mechanism and housing 52.
When the assembly 50 is mounted in the high pressure outlet 23 of the regulator 20, the pressure of the gas in the cylinder 10 is continuously measured using the bourdon-tube principle. Different pressures in the cylinder 10 cause the copper tube 64 to deform elastically to varying degrees, resulting in a corresponding coiling and uncoiling of the copper tube 64, thereby affecting the specific orientation of the tail piece or finger 68. The coiling or uncoiling of the copper tube 64 in response to differences in pressure causes the tail piece 68 to change position relative to the indicia 60, thereby indicating the pressure in the cylinder 10.
In this way, the user is able to determine accurately the contents of the cylinder 10, even though a low pressure only is required to be delivered to the use site. When the cylinder 10 is required to be refilled, the assembly 50 is removed from the high pressure outlet 23 and the cylinder 10 is filled. Once the cylinder 10 is full, the assembly 50 is replaced in the high pressure outlet 23.
SUMMARY OF DISCLOSURE
In summary of this disclosure, the present invention provides a novel contents gauge for a high pressure gas cylinder which also acts as a plug for a high pressure outlet from the cylinder. Modifications are possible within the scope of this invention.
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A gauge is described for measuring the gas pressure in high pressure gas cylinders. The gauge is mounted in the high pressure port of the cylinder valve, while gas is delivered through a lower pressure portion. The gauge comprises a cylindrical housing and a retaining nut, with the housing rotatable relative to the retaining nut. The cylindrical housing encloses a coiled bourdon tube which communicates with the gas in the cylinder and coils up or uncoils in response to changes in pressure. A viewing glass encloses a pointer and scale arrangement seated in the housing to permit the gas cylinder pressure to be displayed.
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BACKGROUND OF THE INVENTION
This invention relates to the field of paint coatings, especially paint coating on architectural surfaces, and the application, preservation, and removal of such paint coatings.
The references cited in this description are not admitted to be prior art to the present invention, but are provided solely to assist the understanding of the reader.
Black in U.S. Pat. No. 5,387,434 described the application of an easily removable aqueous wax emulsion onto architectural surfaces to protect these surfaces against damage by graffiti paint and ink. The wax coating of Black is waterproof, and it is intended to function as a temporary protective coating, being conveniently removed together with any graffiti markings, using pressurized hot water.
Similarly, Hereth et al. in U.S. Pat. No. 4,315,957 describe the use of aqueous emulsions of hydrocarbon wax or other wax, mixed with an alkaline agent and an emulsifier to form a temporary protective wax coating on a metal or lacquered surface, in which the coating is easily removable with steam/hot water.
Similarly, Kawabata in U.S. Pat. Nos. 4,594,109 and 5,049,186 describes water-based wax emulsions which can be applied onto a painted or otherwise coated surface of a product to provide temporary protection for the coated surface until the product is sold.
Gustafson in U.S. Pat. No. 4,046,934 describes the use of a wax emulsion as a hydrophobic substance applied over a "crackled", i.e., cracked and discontinuous, paint surface on a fibrous building material to aid in shedding water from the surface of the building material. The wax emulsion produces a discontinuous, but water-resistant wax coating on the outer surface of a "crackled" water-base paint. The discontinuous wax coating results from the wax particles being negatively charged "so as to repel each other and to be oriented in mutual spaced relationship . . . and form therebetween interstices or cracks 5 through which vapour may pass", as shown in FIG. 2, items 4 and 5 of the patent. The wax emulsion is preferably applied while the water-based paint is still wet following paint application.
Sejournant in U.S. Pat. No. 4,349,586 describes application of a microcrystalline wax and a silicone oil dissolved in an organic solvent, after an initial application of a water-borne vegetable-based or microcrystalline wax, to protect walls and other surfaces against bill-posting, penetration by graffiti, and adherence of polluting agents.
In U.S. Pat. No. 5,773,091, Perlman and Black describe the addition of UV-protective agents and antioxidants to the wax component of aqueous wax emulsions to provide more durable and long-lasting protective wax coatings for resisting not only graffiti, but also environmental soiling in general.
The use of some outdoor preservative coatings and waterproofing liquid treatments which may contain wax for unpainted wood has been described. For example, Parker in U.S. Pat. No. 4,323,602 describes a water repellent wood preservative, in which a water-borne paraffin wax emulsion is combined with a fungicide. Another wood preservative known as Zar Clear Wood Sealer, is manufactured by the United Gilsonite Laboratories (Scranton, Pa.). It also incorporates a wax constituent, and is intended for use on exterior unpainted and unstained wooden surfaces.
The combining of wax coatings and paint coatings is usually considered undesirable. Directions for applying most exterior and interior paint products instruct the user to remove all traces of oil and wax from a surface before painting. Similarly, addition of a wax coating to an existing painted surface would be expected to interfere with subsequent painting or restoration of the architectural surface. In fact, the use of an aqueous wax emulsion as an anti-graffiti coating by Black in U.S. Pat. No. 5,387,434, and by Perlman and Black in U.S. Pat. No. 5,773,091, is intended to prevent unwanted graffiti paint from permanently adhering to a painted or unpainted surface.
SUMMARY OF THE INVENTION
This invention relates to the use of an aqueous wax emulsion (hereinafter abbreviated AWE), to produce upon drying, an aqueous wax emulsion coating (hereinafter abbreviated AWEC) which can be used as a primer coating under new paint coatings, and instilled into and under older cracked and partially lifting oil (alkyd) and water-based paint coatings to extend the lifetime of the paint coatings. With water-based paint, the AWE can even be combined within the paint as a water-repellent additive.
Accordingly, this invention relates to the use of AWEs to form paintable, waterproof AWECs, which are also water vapor hyper-permeable. By forming adherent (non-peeling), paintable, and compliant coatings on almost all kinds of architectural surfaces, the AWEC is ideal as an undercoating (paint primer). By also adhering to dried oil and water-borne paints, it is ideal as an overcoating to protect paint, to reattach any lifting and peeling paint to an underlying surface. A painted surface which has been overcoated by the wax emulsion coating can also be conveniently repainted. Therefore, the wax emulsion can be placed beneath, between and above coatings of paint.
Thus, in a first aspect, the invention includes a method of improving the adhesion and durability of both new paint coatings, and older paint coatings which may include areas of cracked or peeling paint on either a painted or unpainted architectural surface. The method involves utilizing an aqueous wax emulsion (AWE) liquid which upon drying, forms a solid aqueous wax emulsion coating (AWEC) which is adherent to the underlying architectural surface, and also adherent to both new and older paint coatings. Furthermore, the AWEC is waterproof and is hyper-permeable to water vapor, thereby preventing moisture-related bubbling and peeling of both new and older paint coatings. The method includes the steps of:
(i) providing an AWE which contains between approximately 2% and 50% by weight of at least one water-dispersible microparticulate wax whose melting point is between 50° C. and 100° C., at least one emulsifier, in which the emulsifier concentration is at least sufficient to stabilize the AWE against separation into a water phase and a wax phase, but is less than that concentration which would render the dried AWEC re-dispersible in water, and thus not waterproof, and approximately 40% to 98% by weight water;
(ii) applying the AWE to at least a portion of the painted or unpainted architectural surface, where the presence of an older cracked or peeling paint coating on the architectural surface benefits from penetration of the AWE through or under the cracked or peeling paint surface, and
(iii) allowing the AWE to fully dry before applying any paint overcoating.
Usually the total emulsifier concentration ranges between 1% and 20% by weight of the total microparticulate wax concentration.
Note that on either an unpainted surface or an intact painted surface (such as an alkyd paint surface being primed to receive a water-based paint (see Example 6 below), the AWE is applied directly to either the architectural surface or to the paint.
Preferably the dried AWEC forms a continuous coating on the surface, preferably at least 2 particle layers in thickness, more preferably at least 3, 4, or 5 layers, still more preferably at least 8, 10, 12, 15, or 20 layers in thickness.
For the purposes of this invention, an "AWE" is defined as a wax-containing water-based emulsion in which microscopic solid wax particles are suspended in an aqueous liquid which contains a concentration of at least one emulsifying agent which is sufficient to provide emulsion stability (i.e., the emulsion does not separate into its component parts upon standing), but is less than that concentration which would render the dried AWEC re-dispersible in water and therefore not waterproof. The dried AWEC preferably contains greater than 50% by weight wax, and typically contains greater than 80% by weight wax.
The term "wax" includes the plant waxes, e.g., carnuba wax; the animal waxes, e.g., beeswax; the mineral waxes, e.g., paraffin and microcrystalline waxes; and the synthetic waxes, e.g., Fischer-Tropsch waxes. Preferably, the wax has a melting point in excess of 50° C. or 60° C., and preferably in excess of 70° C. or 80° C., more preferably in excess of 85° C., and most preferably in excess of 90° C. or even 100° C.
In the context of the present invention, the term "water vapor hyper-permeable" refers to a cohesive coating comprising one or more waxes (defined above), in which the coating has a microscopically particulate structure, and transmits water vapor at least 30%, and preferably 50% more rapidly (at room temperature and 30% relative humidity) than a coating of identical composition having a microscopically smooth and uninterrupted physical structure, i.e., at 1000× magnification, appearing "continuous", as if deposited and solidified from a melted wax.
In the context of this invention, the term "emulsion" refers to a wax emulsion, which is a suspension of a wax in an aqueous carrier. Typically the wax component is emulsified in liquid form at elevated temperature, but solidifies at room temperature to form a suspension of wax solids in water.
The term "emulsifier" refers to a compound or mixture of compounds which are surface-active compounds which stabilize a suspension of immiscible liquids. Generally emulsifiers act either by coating internal phase droplets to prevent coalescing and/or alter the surface tension at the interface of the suspended droplets. A large variety of different emulsifiers are known to those skilled in the art, along with parameters for selecting emulsifiers for particular formulations. In the present invention, emulsifiers generally remain active to stabilize the suspension of solid wax particles in a wax emulsion.
The term "architectural surface" refers to a surface constructed of a material commonly used for the construction of man-made objects and structures, such as, for example, buildings, signs, walls, fences, walls, ships, and monuments. Thus, such materials include, but are not limited to, wood, stone, masonry, concrete, plaster, metal, gypsum wallboard, and stucco surfaces. As described herein, the surface may be painted or unpainted, or may be partially or completely coated with another coating so long as an AWEC is able to adhere to that coating.
The term "water-dispersible" means that a component can be stably distributed in an aqueous medium, for example, in an aqueous solution, suspension, or emulsion. With respect to the AWEs of the present invention, for example, the AWE can be incorporated in a stable emulsion using, as needed, at least one emulsifier which stabilizes the emulsion.
In connection with an AWEC, the term "re-dispersible" means that the wax particles in the AWEC will re-suspend or re-distribute in water in contact with the AWEC surface without mechanical abrasion. Thus, if an AWEC is not re-dispersible, it means that the wax particles will not spontaneously resuspend in such water. This does not imply that zero wax particles will resuspend in the water, but rather that the AWEC layer will remain intact after continuous water contact of at least one day, preferably of at least one week, more preferably at least one month, and most preferably at least one year.
In connection with the wax particles used in AWEs in this invention, the term "microparticulate" indicates that the wax is in particulate form, with the mean diameter of the particles being of generally microscopic size. Generally, the mean particle diameter is between 0.1 μm and 10 μm, preferably between 0.5 μm and 5 μm, more preferably between 0.8 μm and 3 μm, and most preferably between 1 μm and 3 μm.
By "comprising" is meant including, but not limited to, whatever follows the word "comprising". Thus, use of the term "comprising" indicates that the listed elements are required or mandatory, but that other elements are optional and may or may not be present. By "consisting of" is meant including, and limited to, whatever follows the phrase "consisting of". Thus, the phrase "consisting of" indicates that the listed elements are required or mandatory, and that no other elements may be present. By "consisting essentially of" is meant including any elements listed after the phrase, and limited to other elements that do not interfere with or contribute to the activity or action specified in the disclosure for the listed elements. Thus, the phrase "consisting essentially of" indicates that the listed elements are required or mandatory, but that other elements are optional and may or may not be present depending upon whether or not they affect the activity or action of the listed elements.
From the description in Perlman and Black, U.S. Pat. No. 5,773,091, hereby incorporated by reference in its entirety, the wax component is preferably selected from the group consisting of mineral waxes (e.g., hydrocarbon waxes such as microcrystalline and paraffin waxes) and synthetic waxes. The durability, resistance to soiling, and extended water-repellency is improved by including in the wax portion of the AWE (termed "coating material" in U.S. Pat. No. 5,773,091) an effective concentration of at least one wax-protective chemical agent selected from the group consisting of photostable wax-soluble/water insoluble solar UV light absorbers, wax-soluble/water-insoluble free-radical and peroxy-radical scavengers, and wax-soluble/water-insoluble antioxidants. Preferably, the wax portion of the AWE includes at least three wax-protective chemical agents including a photostable wax-soluble/water insoluble solar UV light absorber, a wax-soluble/water-insoluble free-radical and peroxy-radical scavenger, and a wax-soluble/water-insoluble antioxidant. Within these three categories of wax-protective chemical agents, various preferred classes of agents, and many preferred examples of these agents are provided in U.S. Pat. No. 5,773,091. For example, free radical scavengers include the hindered amines and aminoethers, and the UV light absorbers include derivatized benzotriazoles and derivatized benzophenones. The meanings of terms referring to the various wax protective compounds are provided in U.S. Pat. No. 5,773,091 as reference above.
Preferred embodiments of the present invention include useful AWE compositions described in Black, U.S. Pat. No. 5,387,434. Also preferred embodiments utilize improved AWECs (termed "barrier coats") which contain UV protectants and antioxidants as described in U.S. Pat. No. 5,773,091. A typical AWE useful in embodiments of the present invention is manufactured by Hercules, Inc. (Industrial Specialties, Wilmington, Del. and is known as "Microlube C". This AWE contains 48% by weight solids, and is based upon microcrystalline mineral wax having a melting point of approximately 180° F. which has been emulsified to an average particle size of approximately one micron, and stabilized using a proprietary synthetic non-ionic emulsifier system containing, for example, polyoxyethylene ethers known to those skilled in the art. As described in U.S. Pat. No. 5,773,091, prior to emulsification, UV-protectants and an antioxidant (e.g., Tinuvin 328®, Tinuvin 292® and Irganox 1076® from the Ciba-Geigy Corp, Hawthorne, N.Y.) are added to the molten microcrystalline wax in selected amounts.
In preferred embodiments of this invention, the AWEC serves as a paint primer for new paint coatings. Preferably the applying step is accomplished by direct application of the AWE to the architectural surface, which may be either painted or unpainted, using a process selected from the group consisting of brushing, spraying and roller application. The AWE is allowed to fully dry before applying the paint coating.
In preferred embodiments, the AWEC serves as a repair adhesive agent, repair sealer agent, and restoration coating for older cracked and peeling paint coatings. Preferably the appying step is accomplished by application of the AWE to the surface of older paint coatings using a process selected from the group consisting of brushing, spraying and roller application. With older cracked and peeling paint, the AWE penetrates inward through cracks in an older paint coating, or under the peeling or lifting layer of paint to adhere the paint to the architectural surface.
In preferred embodiments, the new and older paint coatings which can be adhered to the architectural surface with the AWE are selected from the group consisting of oil-based and water-based paint coatings. Preferably the oil or water-based paint coatings include at least one resin selected from the group consisting of acrylic, latex, urethane and alkyd resins. The terms "oil-based", "water-based", "acrylic", "latex", "urethane" and "alkyd" resins have the meanings as understood in the paint coatings industry.
In preferred embodiments, the microparticulate wax used to manufacture the AWE includes at least one wax selected from the group consisting of mineral waxes and synthetic waxes. Preferably, the mineral wax is selected from the group consisting of microcrystalline, semimicrocrystalline, and paraffin-type hydrocarbon waxes. Most preferably, the microparticulate wax includes at least one microcrystalline hydrocarbon wax. The synthetic wax is selected from the group consisting of polyethylene, Fischer-Tropsch, and chemically modified hydrocarbon waxes. Preferably, the chemically modified hydrocarbon wax is selected from the group consisting of oxidized microcrystalline and oxidized paraffin waxes.
The meanings of these terms concerning the types of waxes are known to those skilled in the art, and are provided, for example, in standard textbooks and references. For example, brief desriptions are provided in KIRK-OTHMER: CONCISE ENCYCLOPEDIA OF CHEMICAL TECHNOLOGY, John Wiley and Sons, 1985, pp. 1259-1260. Longer descriptions are provided in KIRK-OTHMER: ENCYCLOPEDIA OF CHEMICAL TECHNOLOGY, 3 rd ed., Vol. 24, John Wiley & Sons, pp. 466-481.
Preferably, the AWE contains between 2% and 50% by weight microparticulate, preferably between 5% and 50%, still more preferably between 10% and 40%, and most preferably between 10% and 25% by weight microparticulate wax. Also preferably, the melting point of the wax in the AWEC is between 65° C. and 90° C., or is at least a temperature as indicated above.
In preferred embodiments, the emulsifier is selected from the group consisting of non-ionic, cationic and anionic emulsifiers. Preferably, the non-ionic emulsifier is selected from the group consisting of polyoxyethylene alkyl ethers, polyoxyethylene alkylphenyl ethers, polyoxyethylene fatty acid esters, and polyoxyethylenesorbitan fatty acid esters.
In preferred embodiments, the total emulsifier concentration is between 5% and 15% by weight of the total microparticulate wax concentration in the AWE, more preferably, the total emulsifier concentration is between 8% and 12% by weight of the total microparticulate wax concentration in the AWE.
In preferred embodiments of the invention, the durability and extended water-repellency of the AWEC is improved by including in the wax portion of the AWE an effective concentration of at least one wax-protective chemical agent selected from the group consisting of photostable wax-soluble/water insoluble solar UV light absorbers, wax-soluble/water-insoluble free-radical and peroxy-radical scavengers, and wax-soluble/water-insoluble antioxidants. Preferably, the wax portion of the AWE includes at least three wax-protective chemical agents including a photostable wax-soluble/water insoluble solar UV light absorber, a wax-soluble/water-insoluble free-radical and peroxy-radical scavenger, and a wax-soluble/water-insoluble antioxidant. Within these three categories of wax-protective chemical agents, various preferred classes of agents, and many preferred examples of these agents are provided in U.S. Pat. No. 5,773,091. Preferably, the free radical and peroxy-radical scavengers include the hindered amines and aminoethers. Preferably, the solar UV light absorbers include the derivatized benzotriazoles and derivatized benzophenones. Reference to "solar UV light absorbers" indicates that the absorbing compound appreciably absorbs light in the wavelengths of UV light which reach the surface of the Earth from the sun, generally light wavelengths in the range of 300 to 400 nanometers, especially around 325-350 nm.
The methods described above not only improve the adhesion and durability of paint coatings, but also permit the subsequent convenient removal of the paint. For applications where an AWEC, as described above, has been used as a primer coating, one can strip away an old paint coating or an undesirable color of paint (which can subsequently be replaced with a new paint coat) using pressurized hot water. Thus, if an AWEC is used as a primer, then the coating of paint above the primer can be easily removed using pressurized hot water to melt the primer coating of wax, carrying away the old paint. Compared with the current method of removing regular paint from the outside of a house by paint scraping, paint sanding and chemical paint stripping, the present invention, i.e., using a heated pressurized water spray to strip paint from a house is revolutionary. This new water-based method of paint removal is labor saving, cost-saving, protects the worker against potential inhalation of paint dust, and protects the environment against pollution by paint dust and pollution by caustic and toxic solvents used as paint strippers. Applicants have demonstrated that, in practice, paint stripping with the presently described pressurized hot water system (e.g., using water at a temperature of approximately 165-195° F. and a pressure of at least 250 psi) can remove paint from a microcrystalline wax-based AWEC primer coating applied on a wooden clapboard house at least 10-fold more rapidly than the conventional paint removing methods described above.
Accordingly, in another aspect of this invention, a method is provided for removing a protective coating of paint from a man-made object or structure. The surface of the structure includes a paint coating which was applied over an AWEC. The AWEC was formed by applying an AWE as a primer coating to the surface of the structure (as described above) before the paint was applied. The coating of paint is removed from the man-made structure using pressurized hot water to soften or melt the AWEC primer, thereby removing the paint. Preferably the AWEC is also removed prior to application of a new paint coat, preferably also by using pressurized hot water, preferably at the same time as the paint overcoating is removed. Before recoating with paint, a new AWEC primer coat or other suitable primer will be applied and allowed to dry.
In preferred embodiments, the coat of paint which can be removed is selected from the group consisting of oil-based and water-based paints and stains, waterproof varnishes, preservative coatings and other clearcoat finishes, and anti-fouling paints applied to boat bottoms and to other water-submerged surfaces susceptible to bio-fouling.
Also in preferred embodiments, the AWEC is as described for aspects and embodiments above.
Other features and advantages of the present invention will be apparent from the following description of the preferred embodiments and from the claims.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
As described in the Summary above, the present invention concerns the use of AWECs in paint coating methods, specifically use as a primer coat under a new paint coating, and use as a paint coating restorative when applied over old paint coatings.
The invention relates to several new and interrelated observations, namely:
(i) the discovery of unexpectedly rapid transport of water vapor through an AWEC, essentially independent of its coating thickness. As is shown below, the rate of water vapor transport through the AWEC is almost two-fold greater than through the same wax coating which has been melted into a smooth, transparent non-emulsive, or non-particulate, coating. This so-called "hyper-permeability" property of the dried AWEC allows moisture to escape from an architectural material (such as the outside structural material of a building). Otherwise, moisture which is trapped under the surface, can cause bubbling in a water-impermeable coating, e.g., a water sealant-type paint coating applied to the architectural material.
(ii) the surprising ability of oil and water-based paints to permanently adhere to these beaded wax coatings used as "paint primers". Such adhesion is surprising because it contrasts with the failure of most if not all paints, such as acrylic latexes to adhere to smooth wax finishes applied in organic solvents.
(iii) the ability of AWEs to infiltrate cracked and peeling paint coatings, and re-adhere the paint to the underlying architectural surface.
In this invention, the water vapor hyper-permeability property of AWECs is useful in allowing moisture to escape through the wax-repaired cracks in the coating. By using AWEs containing suitable UV protectants as described by Perlman and Black in U.S. Pat. No. 5,773,091, the rejuvenated and repaired painted surface can effectively resist sunlight and rain over an extended period of time, e.g., several years. If, in addition to the repair treatment, a newly painted top surface is desired, the new paint can be applied directly over the AWEC-repaired old paint.
To better understand the properties of AWECs as used in the present invention, the commercially prepared AWE described in the Summary above was diluted with water to a final concentration of 15% by weight solids, applied to a microscope slide, and examined using high power (approximately 1000× magnification) phase contrast light microscopy. Photomicrographs printed at a final magnification of 5,000× were analyzed. At this magnification, a very rough surface was apparent consisting of closely packed, somewhat irregular spheres whose diameters measured between approximately 5 mm and 9 mm. This measurement divided by 5,000 is consistent with the 1.5 micron diameter average particle size reported to Applicant by Hercules, Inc. The visual examination of photomicrographs definitively confirmed that AWE microparticles remain morphologically discrete in the dried AWEC, yet are sufficiently self-adherent to form a substantially tough and scuff-resistant waterproof coating. Subsequently, the above microscope slide, carrying the dried AWEC, was briefly heated (3-5 seconds) to a temperature of approximately 210° F. (a temperature above the melting point of the microcrystalline wax). The slide was cooled to room temperature and the coating was re-examined and again photomicrographed. Not surprisingly, the discrete wax spheres were absent, replaced by an optically clear, somewhat puckered surface indicative of wax which had melted and re-solidified.
The surprising characteristics of the AWEC (now understood to consist of closely packed wax microspheres) is the extent to which these coatings tenaciously hold paints, are physically resilient, and are surprisingly permeable to water vapor (while still remaining waterproof). Without water vapor permeability, a coating will hold humidity in the architectural substrate material and cause undesirable paint bubbling and structural damage. For example, in chronically moist wood, dry rot usually occurs, and in brick and other masonry, spalling and ice-associated damage can occur under the paint. The waterproof, vapor-hyper-permeable properties of the presently described AWEC suggest its use as both a paint primer and an overcoating for protecting newly painted surfaces, and repairing and protecting old painted surfaces. In overcoatings applied to old paint, the AWECs show surprising adhesive and cohesive properties after drying. These properties allow the wax (which infiltrates a cracked and peeling painted surface) to glue old and peeling paint to the underlying architectural surface, e.g., wooden trim, clapboard and shingles on a house. Improvements to the stability of wax compositions described in U.S. Pat. No. 5,773,091, based upon the use of wax-soluble, water-insoluble UV protectants and antioxidants are especially important for assuring the longevity of overcoatings applied to both new or old painted surfaces.
This invention is especially useful when applied to dimensionally unstable surfaces (flexible or expanding and contracting surfaces), as the AWEC resists cracking and peeling. Applied to old and cracked paint, the AWEC provides adhesive, waterproof repair of the paint. Yet the AWE which infiltrates through cracks, and dries beneath the cracked and/or peeling paint, produces an AWEC which becomes water vapor hyper-permeable.
The examples below demonstrate certain of the advantageous properties and characteristics of the described AWECs and their use in the methods of this invention.
EXAMPLE 1
Non-Linear Water Vapor Transmission Through AWECs
In the course of conducting research for U.S. Pat. No. 5,773,091, the AWE described above (Microlube C, Hercules Inc.) which had been modified with UV protectants, and previously sold commercially as an anti-graffiti coating known as G PRO® (BAT Inc., New Rochelle, N.Y.) was applied to a variety of architectural materials including wood and concret masonry blocks. Even when such blocks were moist, and heavily coated on all surfaces with the AWE described above (approximately 200-300 square feet per gallon coverage using an AWE containing 15% by weight microcrystalline wax), the resulting dried coatings allowed these blocks to lose moisture rapidly upon exposure to wind and sun.
To better understand the properties of AWECs, a moisture transmission measurement system for coatings was developed by Applicants. This system consists of a set of small, identical polystyrene plastic Petri dishes (52 mm inside diameter; 21.2 cm surface area, Nalge Nunc International, Naperville, Ill.) covered with 0.0010 inch thick (1.0 mil) regenerated cellulose dialysis membrane (manufactured by the Union Carbide Corp., Chicago, Ill.). The dialysis membrane was pre-moistened with water and cut to form 6.5 cm discs. Each membrane disc, while slightly moist, was pulled tightly and formed over the lip of the petri dish, and sealed in place by wrapping an adhesive polyethylene tape around the outside wall of the dish, capturing the outer edge of the membrane. Then, precisely weighed amounts of G PRO® AWE were applied to duplicate membrane surfaces and dried, producing duplicate dry wax coatings ranging from 7 microns to 40 microns in thickness (between approximately 4 and 25 wax bead diameters thick, with 1.5 micron beads). For the commercial G PRO® liquid (containing 15% by weight microcrystalline wax), these dry coating thicknesses are obtained using liquid coverages ranging from 900 ft 2 /gal to 150 ft 2 /gal. For purposes of reference, a typically recommended and effective anti-graffiti coating is obtained with a 300 ft 2 /gal coverage rate, i.e., the dried coating is approximately 20 microns thick.
Once the wax coatings had dried, 8 milliliters of distilled water was injected through a melted hole (made by hot syringe needle) in the sidewall of each Petri dish. After the holes were sealed the Petri dish samples were all weighed, including two dishes sealed with dialysis membranes lacking wax coatings as controls. Over a period of six hours, the samples, incubated at room temperature (20° C.), were weighed each hour. The amounts of water loss (termed "water evap", in grams per 21.2 cm 2 of membrane area) for the duplicate coatings were averaged and tabulated, and were compared to the control samples without any wax. The decreased rate of water evaporation (water blocking) for each coating was calculated by subtracting each relative % evaporation rate from 100% (the rate for the uncoated control, see Table 1). After these measurements were made, a number of the covered Petri dish samples were briefly exposed to an elevated temperature in a warming oven (110° C. for one minute) to melt and fuse the wax microparticles in the coatings. These samples were again followed for rates of water evaporation over a six hour period, and the numbers are provided in parentheses () in Table 1.
TABLE 1______________________________________ B. Coating C. D. E. F.A. Cover- Coating Water Water WaterCoating age Thickness Evap. Evap. Blocking(micorliter/cm.sup.2) (ft.sup.2 /gal) (microns) (grams) (Relative Rate %)______________________________________1. zero (control) -- -- 0.597 100 (100) --2. 4.5 900 7 0.312 52 483. 6.8 600 10 0.282 47 534. 9.1 450 15 0.281 47 (27) 535. 13.6 300 20 0.260 44 (26) 566. 20.4 200 30 0.220 37 (24) 637. 27.2 150 40 0.209 35 (17) 65______________________________________
Results and Discussion
All of the AWECs applied to the membrane show relatively high rates of water vapor transmission (35%-52%) compared to the uncoated membrane (control). Once these microparticulate coatings are melted and fused, their rates of water vapor transmission decrease to about 50%-60% of their original rates (cf. 27% vs. 47% in line 1, and 17% vs. 35% in line 7). These tests conclusively prove that a microparticulate wax coating is more water vapor-permeable than a continuous wax coating of identical composition (formed by melting the original microparticulate coating). Continuous wax coatings (which may be applied as a hot-melt or from an organic solvent vehicle which evaporates to leave the wax coating) are smoother, more optically transparent, and can sometimes be made more scuff-resistant. Such continuous coatings are often preferred for use in polishes.
However, in the present invention, the water vapor permeability of an AWEC is advantageous. In addition, the non-linearity in the rate of water vapor transmission as a function of the thickness of the AWEC is important, surprising, and technically valuable. As a result of this non-linearity (see Table 1, column E.), the water vapor transmission rate is maintained almost constant (only a 33% decrease rather than a 600% decrease as the wax coating thickness is increased almost 6-fold (from approximately 7 microns to 40 microns). That is, in column E, the rate of water vapor transmission decreases from 52% to 35% of the control rate, and 52%-35%/52% equals a 33% decrease. This 7-40 micron range of wax coating thickness spans most if not all of the useful range for the present invention. Given that the average wax bead diameter in this G PRO® AWE preparation was 1.5 microns, the number of beads required to span these coatings ranged from approximately five to twenty-five.
EXAMPLE 2
Water Vapor Transmission Through Wax Paper
As a control experiment for Example 1, a water vapor transmission experiment was carried out using the same protocol described in Example 1, except that instead of using AWE-coated dialysis membranes, commercial food grade wax paper was substituted on the Petri dishes (see Table 2). The purpose of this comparison was to determine how the moisture transmission rates through the AWEC compositions of Example 1 compared with the well known conventional wax coating found in wax paper. The wax paper (Cut-Rite® brand, manufactured by Reynolds Metals Company, Richmond, Va.) consisted of a paraffin wax-continuously melt-coated paper which varied in thickness between 0.0011 and 0.0012 inches (1.1 and 1.2 mils). Duplicate Petri dishes were covered and sealed with either one layer or two layers of the wax paper (samples designated "wax 1L and wax 2L " respectively in Table 2). The rates of water vapor transmission through these wax papers (measured by water weight loss) were compared with three different "control" membranes over Petri dishes. The first control was the uncoated cellulose dialysis membrane (designated "dialysis"), and was identical to the "zero (control)" in Example 1. The second and third controls were extruded linear polyethylene membrane (designated "Polyethylene"), 0.0007 inches thick, i.e., 0.7 mils, and vinylidene polymer membrane (designated "saran") 0.0004 inches thick, i.e., 0.4 mils. Water rate loss data represents the average of duplicate Petri dish samples incubated for 23 hours at 23° C. (see Table 2).
TABLE 2______________________________________ C.A. B. Water D.Petri Covering Membr. Thickness Evaporation Water EvaporationMaterial (mils) (microns) (grams) (Relative Rate %)______________________________________1. dialysis 1.0 25 2.42 100.02. wax 1L 1.15 29 0.653 27.03. wax 2L 2.3 58 0.309 12.84. Polyethylene 0.7 18 0.012 0.505. Saran 0.4 10 0.007 0.29______________________________________
Results and Discussion
In Example 1, melting and fusion of the AWEC coatings caused a substantial decrease in the water vapor transmission rate. For example, in the case of the 30 micron thick wax coating in Table 1, water transmission decreased from 37% of the control rate (before fusion) to 24% of the control rate (after fusion), while the 40 micron wax coating showed a rate decrease from 35% (before fusion) to 17% (after fusion). Wax paper can be considered a continuous (or fused) wax coating. Thus, the data in Table 2 for the wax paper can be compared to the "after fusion" results (in parentheses) in Table 1. Comparing the 29 micron single layer wax paper (Table 2, line 2.) to the 30 micron fused AWEC (Table 1, column E line 6.), the relative rates of water vapor transmission are very similar (27% and 24% respectively). Not surprisingly, the addition of a second layer of wax paper caused a proportional, i.e., 2-fold, decrease in the water vapor transmission rate, from 27% to approximately 13% of the control. Interestingly, the relatively high rates of water vapor loss through wax paper show how relatively permeable mineral waxes are to water vapor, compared to conventional thermoplastics such as polyethylene and saran. The anticipated and confirmed linear decrease in water vapor transmission, with increasing wax paper thickness, underscores the surprising nature of the results in Example 1, Table 1. That is, with the intact unmelted AWECs which consist of packed microparticles of mineral wax, a disproportionately high and almost constant rate of water vapor transmission is maintained, even as the thickness of these coatings is increased from 10 microns to 40 microns or more.
EXAMPLE 3
AWEC as a Paint Primer Coating
Paints Adhere to an AWEC But Not to a Solvent-Applied Wax Coating
While conducting background research for U.S. Pat. No. 5,773,091, it was found that alkyd-based graffiti paint which, by chance, had not been removed from an AWE-treated surface, could persist on the AWEC for several years without peeling or fading. For example, graffiti paint markings which are at least four years old have been found and are in excellent condition, having survived outdoors and in the sun and rain (graffiti spray-paint on an anti-graffiti AWEC based upon Microlube C, Hercules Inc.). Realizing that the AWEC was itself waterproof, tenacious to most surfaces, resistant to both peeling and embrittlement, and highly permeable to water vapor, Applicants investigated whether the AWEC might be suitable for use as a paint primer. Subsequently, experimental testing showed that both oil- and water-based paints could be permanently adhered to these AWECs. Paint adhesion persisted in cold and hot environments, during extended solar UV exposure, during continuous, as well as alternating exposure to soaking and drying conditions, and during salt water exposure.
The observation of long term adhesion of paint to the AWEC was surprising because it contrasted with the expectation that paints would not adhere to wax coatings. In fact, this expectation was confirmed by dissolving paraffin and microcrystalline petroleum waxes in chloroform, then applying these separate solutions by brush to a wooden surface. Following solvent evaporation, the two wax coatings were painted with alkyd and acrylic latex paints. It was difficult to obtain a uniform paint coating on either wax because the wet paints beaded up on the wax surfaces rather than wetting them. After drying, both paint coatings could be easily wiped away from the solvent-applied wax coatings. By comparison, it is believed that the microscopically porous beaded surface of an AWEC allows a paint to firmly anchor itself to the wax. Such anchoring is not possible on a smooth, solvent-applied wax surface.
Besides the obvious chemical difference, there are interesting physical differences between an AWEC primer and a traditional alkyd or latex-type paint primer. Traditional primers tend to be strongly adherent to architectural substrates, and somewhat elastic so that the primer can expand and contract along with the architectural surface. Still, at least two problems can arise. As the primer ages, it tends to become less elastic and more prone to cracking and separating from an expanding and contracting architectural surface. If the primer coat fails, the finish coat of paint will also fail. Insofar as the AWEC primer is strongly adherent to substrates and receptive to paint top-coatings, it is somewhat like the traditional primer. However, the AWEC primer is unlike the traditional primer because it contains a myriad of void spaces (between the myriad of wax microparticles). The void spaces, i.e., nooks and crannies, not only allow anchoring of a top coat of paint, but also facilitate microscopic expansion and contraction of the wax coating to occur (with wax particles moving over one another within the coating). It is hypothesized that this wax particle movement within the coating serves to relieve stress. This movement, in turn, reduces the shearing force at the interface between the primer and the expanding and contracting architectural material. This is particularly important if cracking and peeling of the primer is to be avoided.
To determine if and how the concentration of wax in the AWE (and the resulting AWEC thickness) would affect the quality of subsequently applied oil and water-based paint coatings, two successive aqueous dilutions of the AWE used in Example 1 (15% by weight microcrystalline wax) were made, in which the wax concentration was decreased by one-half in each successive dilution (15%, 7.5% and 3.8% by weight wax). One coat of these three different AWE dilutions was then applied by urethane foam brush to three different substrate materials: porous wall plaster, red cedar clapboard wood, and a sheet-metal surface. After the AWECs were thoroughly dry, three different paint coatings: red latex gloss enamel, red alkyd gloss enamel (both Krylon® brand, Sherwin-Williams Company, Solon, Ohio), and a brown linseed oil-based outdoor stain finish (Olympic Solid Color Stain, PPG Architectural Finishes, Inc. Pittsburgh, Pa.) were applied to the nine different surfaces (3 wax coating densities on each of 3 different substrates).
After the paints were thoroughly dried and aged for one week at room temperature, the water-repellency and the resistance of the paints to mechanical removal (by fingernail abrasion) were examined. Results were as follows. The three finishes (two paints and one stain) adhered to all of the wax coatings on all of the substrates. All of the finishes were water-repellent and all of the finishes were resistant to peeling when submerged in water for at least one week. However, on the porous surfaces (wood and plaster) the best water-repellency was observed with the highest concentration of wax. Water repellency diminished continuously as the wax concentration in the AWE decreased. The most pronounced effect was evident in the abrasion test. Given the softness of the microcrystalline wax, the highest concentration of wax (15%) produced the most abrasion-susceptible paint coatings, and the lowest concentration of wax (3.8%) produced the most abrasion-resistant paint coatings. On an absorbent wood or plaster surface, the 15% wax content AWE appeared to be workable, although the paint top coat was somewhat abrasion-susceptible. On the other hand, the 7.5% wax content primer coating yielded a more scratch-resistant paint top coat (for all three paint types tested). However, on a non-porous surface (sheet metal), a paint top coating on top of even the 7.5% microcrystalline wax content primer, was very susceptible to scratching and abrasion. Therefore, the ideal wax concentration in the AWE must be determined, based upon the physical properties of the substrate being coated (e.g., its porosity and absorbency), and the required hardness and scratch resistance/abrasion resistance of the top coat of paint.
An additional parameter which can be varied is the hardness of the wax itself which is used in the manufacture of the AWE. A harder AWEC produces a more abrasion-resistant paint top coat. Intermediate hardnesses can be created by blending hard and softer waxes. Thus, for example, a hard synthetic wax having a suitable melting point (less than 200° F.), can be blended with a softer microcrystalline wax to produce a wax of intermediate hardness. If the wax composition is altered, the new wax emulsion is tested for maintaining stability, and upon drying, the coalesced AWEC is tested for retaining its waterproof property. The amount of emulsifier and its composition (often a balanced blended composition) can be adjusted to sustain these essential properties.
EXAMPLE 4
AWEC for Repair of Old Paint Coatings
Cracked and Peeling Paints are Re-adhered to Architectural Surfaces
It was recognized that an AWEC was waterproof, resistant to both peeling and embrittlement, highly permeable to water vapor, and adherent to essentially all dried paints (both water- and alkyd-based paints), and to architectural surfaces. Despite the dogma in painting protocols that wax and paint coatings should not be be intermingled, Applicants believed that if an AWEC could function as a paint primer, then it might also be useful for re-adhering and repairing cracked and peeling paint. Tests have now shown that cracked and peeling oil and water-based paints can be re-adhered to the underlying architectural surface. The old paint is overcoated with an AWE, preferably containing a high concentration of wax (e.g., 15-50% by weight microcrystalline wax), so that paint cracks can be substantially filled with AWE solids. The AWE infiltrates paint cracks and reaches the underside of lifting and partially detached paint areas. The AWE is brushed into the paint cracks, and/or applied in a heavy "soak-coating" so that the AWE can penetrate by capillary action, and fill cracks and any spaces under the lifting paint. As the AWE dries, it cements down and embeds these areas of weakened paint.
In one test, an extensively cracked and partially lifting, eight year old linseed oil-based outdoor stain (Olympic Solid Color Stain, PPG Architectural Finishes, Inc. Pittsburgh, Pa.) present on dry and porous fir window frames (approximately 100 year old wood) was treated with the AWE used in Example 1 (15% by weight microcrystalline wax). Following drying, some of the AWE-treated areas were left "as is", while some areas were over-painted with the same linseed oil-based Olympic stain. After two full years on a southeast-facing wall in New England, including summer heat, winter cold, and rains, the AWE-treated, and the over-painted-AWE-treated surfaces both appear essentially newly repaired. That is, paint cracks remain filled with wax, and the over-paint (stain) remains firmly attached to the underlying microporous wax repair coating (the AWEC).
EXAMPLE 5
AWEC as Primer for Boat Bottoms Having Copper Oxide-Based Bottom Paint and for Repair of Such Paint
It was recognized that an AWEC is waterproof, resistant to both peeling and embrittlement, and adheres to essentially all dried paints (both alkyd and waterborne) on essentially any architectural surface. The underwater surfaces of boats, docks, and other structures which are maintained in fresh or salt water are painted with specialized bottom paints that contain copper oxide. The function of the copper oxide is to prevent or discourage residence by animal and vegetable species, e.g., barnacles, snails, seaweed, algae, and the like. The highly toxic copper oxide deteriorates after one season in an aqueous environment. When a boat is hauled, it is power-washed to remove plant growth and loose barnacles. The copper oxide coating is sanded to remove loose paint material, and the boat is repainted before returning to the water. The highly toxic copper oxide dust from sanding becomes airborne, and is a hazard to the environment as well as to workers who remove the deteriorated bottom paint and may breathe the dust.
The G PRO® AWE described above (containing approximately 15% by weight microcrystalline wax) was applied to the bottom of a power boat at a spread rate of 300 ft 2 per gallon. The resulting AWEC was allowed to dry for 24 hours. Alkyd-based Pettit brand "Trinadad Bottom Paint" was applied to the AWEC surface of the boat bottom according to the manufacturer's recommended application rate. The bottom paint was allowed to dry for 24 hours before the boat was launched into salt water. The boat was used regularly for two months, and operated at normal running speeds. After two months, the boat was hauled and inspected for paint failure and any other abnormalities. None were found. The boat bottom was then subjected to high temperature power washing (1,000 psi water pressure, 195° F.). The bottom paint was removed with some difficulty.
The above experiment was repeated using two coats of the G PRO® AWE so that the wax coating density on the boat bottom was effectively doubled (150 ft 2 coverage per gallon). This time when the boat was hauled after two months, the high temperature power washing removed all of the bottom paint quickly and easily. The bottom paint came off in large sheets, and these sheets of bottom paint could be swept up or vacuumed easily. No hazardous toxic bottom paint dust was produced in this process which produced only sheet waste material. As an additional benefit, applying the AWEC to the boat bottom served to adhere any loose flakes of pre-existing bottom paint to the boat hull before the new coating of bottom paint was applied.
EXAMPLE 6
AWEC as a Primer for Water-Based Paint Over Oil-Based Paint
Once an architectural surface has been painted with an oil-based paint, i.e., alkyd paint, a waterborne paint may adhere poorly to the alkyd surface. As a result of this incompatibility, it is recommended that an oil-based paint be removed before applying a new coat of water-based paint such as acrylic latex-type paint.
Two samples of gypsum wallboard were coated with a Glidden brand alkyd-based paint. These samples were allowed to dry for two days. A second coat of the same alkyd paint was applied to the samples and also allowed to dry for two days. One sample was painted over (without priming), using a Glidden brand water-based acrylic latex paint. The second sample was primed with one coat of G PRO® AWE at a spread rate of 300 ft 2 per gallon, allowed to dry for 24 hours, and then painted over with the same Glidden brand water-based acrylic latex paint. After the acrylic latex waterborne paint coating on each sample had dried at least two days, the two samples were compared. The acrylic latex paint adhered well to the surface of the AWE-primed sample but not to the unprimed surface. In fact, upon close inspection of the unprimed sample, the acrylic latex paint coating contained discontinuities in the coverage of the alkyd surface and was judged unsatisfactory.
All patents and publications mentioned in the specification are indicative of the levels of skill of those skilled in the art to which the invention pertains. All references cited in this disclosure are incorporated by reference to the same extent as if each reference had been incorporated by reference in its entirety individually. One skilled in the art would readily appreciate that the present invention is well adapted to carry out the objects and obtain the ends and advantages mentioned, as well as those inherent therein. The specific compounds and methods described herein as presently representative of preferred embodiments are exemplary and are not intended as limitations on the scope of the invention. Changes therein and other uses will occur to those skilled in the art which are encompassed within the spirit of the invention are defined by the scope of the claims.
It will be readily apparent to one skilled in the art that varying substitutions and modifications may be made to the invention disclosed herein without departing from the scope and spirit of the invention. For example, those skilled in the art will recognize that the invention may suitably be practiced using a variety of different wax or emulsifier compounds within the general descriptions provided.
The invention illustratively described herein suitably may be practiced in the absence of any element or elements, limitation or limitations which is not specifically disclosed herein. Thus, for example, in each instance herein any of the terms "comprising," "consisting essentially of" and "consisting of" may be replaced with either of the other two terms. The terms and expressions which have been employed are used as terms of description and not of limitation, and there is not intention that in the use of such terms and expressions of excluding any equivalents of the features shown and described or portions thereof, but it is recognized that various modifications are possible within the scope of the invention claimed. Thus, it should be understood that although the present invention has been specifically disclosed by preferred embodiments and optional features, modification and variation of the concepts herein disclosed may be resorted to by those skilled in the art, and that such modifications and variations are considered to be within the scope of this invention as defined by the appended claims.
In addition, where features or aspects of the invention are described in terms of Markush groups or other grouping of alternatives, those skilled in the art will recognize that the invention is also thereby described in terms of any individual member or subgroup of members of the Markush group or other group.
Thus, additional embodiments are within the scope of the invention and within the following claims.
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A method of improving the adhesion and durability of both new paint coatings, and older cracked or peeling paint coatings on an architectural surface is described. An aqueous wax emulsion (AWE) which, upon drying, forms an aqueous wax emulsion coating (AWEC), is adherent to an architectural surface as well as to new and older paint coatings. The AWEC is furthermore waterproof, and is hyper-permeable to water vapor, thereby preventing moisture-related bubbling and peeling of the new and older paint coatings.
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CROSS-REFERENCE TO RELATED PATENT APPLICATION
The present patent, application claims priority from U.S. Provisional patent application No. 60/261,042 filed Jan. 11, 2001 entitled COMPUTER BACKPLANE EMPLOYING FREE SPACE OPTICAL INTERCONNECT and listing Robert Mays, Jr. as inventor, which is incorporated herein in its entirety.
BACKGROUND OF THE INVENTION
The present invention relates to an optical free space interconnect of circuitry. Particularly, the present invention concerns optical interconnection employed in computers.
Expansion slots greatly increase operational characteristics of personal computers (PCs). The expansion slots are connected to various PC circuitry, such as a microprocessor, through a bus and allow the PC to communicate with peripheral devices, such as modems, digital cameras, tape drives and the like. To that end, electrical interface circuitry, referred to as adapters or expansion cards, are inserted in the expansion slots to facilitate communication between the PC circuitry and the peripheral devices. The combination of expansion slots, expansion cards and bus system is commonly referred to as a backplane interconnect system. The bus system associated with the backplane interconnect system connects power, data and control lines to the expansion cards and facilitates communication between the expansion cards and other PC circuitry. The bus system cooperates with a protocol to, among other things, prevent two or more expansions cards from concurrently communicating on a common bus line.
Referring to FIG. 1, an example of a prior art backplane interconnect system 10 includes expansion slots 12 mounted on a motherboard 14 . The expansion slots 12 are wired together with one or more busses 16 disposed on the motherboard 14 . Each bus 16 normally has multiple lines with terminations 18 at opposing ends of each line. The expansion card 22 has a mating connector 20 that is adapted to be received into the expansion slot 12 . Each expansion card 22 may contain numerous circuits and components 24 to perform desired functions. The circuits and components 24 are in electrical communication with conductive traces 26 on the mating connector 20 through bus transceivers 28 . Bus transceivers 28 facilitate communication between components 24 of the various expansion cards 22 in backplane interconnect system 10 by driving and detecting signals on the bus lines 16 .
As the operational speed of PCs increases, the need to increase the data transfer rate over the backplane interconnect system becomes manifest. Conventionally, increases in data transfer rate have been achieved by either increasing the operational frequency of the individual expansion boards or by increasing the number of lines associated with a bus. Increases in data transfer rates of backplane interconnect systems have been inhibited by crosstalk, noise, degradation in signal integrity and the operational limitations of connectors. One attempt to increase the data transfer rates of a backplane interconnect system has been directed to controlling the impedance associated with the bus lines, as discussed in U.S. Pat. No. 6,081,430 to La Rue. However, it has been recognized that optical backplanes have been successful in increasing the data transfer rates of backplane interconnect systems.
U.S. Pat. No. 6,055,099 to Webb discloses an optical backplane having an array of lasers in optical communication with a lens relay system. The lens relay includes a series of coaxially aligned lenses. The lenses are spaced apart along a planar substrate and form repeated images of an optical array at the input to an interconnect. Output ports are located at different points along the interconnect. Each pair of lenses encloses one of the repeated images and is formed as a single physically integral member. The integral member may take the form of a transparent rod having spherical end surfaces. Each of the spherical end surfaces then provided one of the pair of lenses.
U.S. Pat. No. 5,832,147 to Yeh et al. discloses an optical backplane interconnect system employing holographic optical elements (HOEs). The backplane interconnect system facilitates communication with a plurality of circuit boards (CBs) and a plurality of integrated circuit chips. Each CB has at least an optically transparent substrate (OTS) mate parallel to the CB and extending outside a CB holder. On another OTS mate, two HOEs are utilized to receive and direct, at least part of, a light beam received to a detector on a corresponding CB via free space within the circuit board holder or reflection within the OTS mate. A drawback with the prior art optical backplane interconnect system is that the number of optical channels that may be provided is limited due to the difficulty in achieving discrimination between optical free space signals.
What is needed, therefore, is an optical backplane interconnect system that increases the number of optical channels while avoiding crosstalk in optical signals propagating along the optical channels.
SUMMARY OF THE INVENTION
Provided is an optical backplane interconnect system, one embodiment of which features transceiver subsystems employing holographic optical elements (HOEs) that define, and discriminate between, differing optical channels of communication. The HOEs employ a holograph transform to concurrently refract and filter optical energy having unwanted characteristics. To that end, the transceiver subsystem is mounted to an expansion card and includes a source of optical energy and an optical detector. The HOE need not be mounted to the expansion card. In one embodiment, however, the HOE is mounted to the expansion card and in optical communication with either the source of optical energy, the optical detector or both.
The expansion card is in optical communication with an additional expansion card associated with the interconnect system that also includes the transceiver subsystem and HOE discussed above. The source of optical energy is positioned so that the optical detector associated with the additional expansion card senses the optical energy produced by the source, defining a first source/detector pair. A first HOE is disposed between the source and the detector of the first source/detector pair. A second HOE is disposed between a second source/detector pair that includes the optical detector of the expansion card positioned to sense optical energy produced by the optical source of the additional expansion card. The first and second HOEs are formed to limit the optical energy passing therethrough, attenuating all optical energy that impinges thereupon and having unwanted characteristics. In this example, optical energy of the type that is attenuated by the first HOE may propagate through the second HOE, and optical energy of the type attenuated by the second HOE may propagate through the first HOE. In this manner, the first and second HOEs may define differing optical channels by selectively allowing optical energy to pass therethrough. To that end, the first HOE is placed in close proximity with the optical detector of the additional expansion card, and the second HOE is placed in close proximity to the optical detector of the expansion card. Each of the two aforementioned optical detectors would sense only optical energy having desired characteristics. Hence, two discrete optical channels are defined, each of which may be in communication with one or both of the two sources of optical energy.
In another exemplary embodiment, each of the aforementioned optical channels may be uniquely associated with one of the optical detectors and one of the sources of optical energy. To that end, two or more pairs of HOEs are employed. Each HOE of one of the two pairs is associated with a source/detector pair and has holographic transforms that is substantially similar, if not identical, to the holographic transform associated with the remaining HOE of the pair. However, the holographic transform associated with one of the pairs of HOEs differs from the holographic transform associated with the remaining pair of HOEs. In this manner, two optical channels may be defined with crosstalk between the channels being substantially reduced, if not eliminated. With this configuration, the number of optical channels may be increased so that hundreds of optical channels may facilitate communication between two expansion cards, with some of the optical channels being redundant to increase the operational life of the optical backplane interconnect system. These and other embodiments are described more fully below.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a backplane interconnect system in accordance with the prior art;
FIG. 2 is a simplified plan view of a computer system employing an optical backplane interconnect system in accordance with the present invention;
FIG. 3 is a simplified plan view of a source of optical energy mounted to a first expansion card and optical detector mounted to a second expansion card spaced apart from the first expansion card;
FIG. 4 is a cross-sectional view of a lens employed in the backplane interconnect system shown above in FIG. 2, in accordance with the present invention;
FIG. 5 is a cross-sectional view of the lens shown above in FIG. 4 in accordance with an alternate emb the present invention;
FIG. 6 is a cross-sectional view of the lens shown above in FIG. 4 in accordance with a second alternate embodiment of the present invention;
FIGS. 7A-7B are perspective views of an optical communication system employed in the backplane interconnect system shown above in FIG. 2, in accordance with an alternate embodiment;
FIG. 8 is perspective view of an array of the lenses fabricated on a photo-sheet shown above in FIGS. 7A-7B,
FIG. 9 is a cross-sectional plan view of the optical communication system shown above in FIGS. 7A-7B, in accordance with the present invention;
FIG. 10 is a cross-sectional plan view of the optical communication system shown above in FIG. 9, in accordance with an alternate embodiment of the present invention;
FIG. 11 is a simplified plan view showing an apparatus for fabricating the lenses shown above in FIGS. 4-6 and 8 , in accordance with the present invention;
FIG. 12 is a cross-sectional view of a substrate on which the lenses discussed above with respect to FIGS. 4-6 and 8 are fabricated;
FIG. 13 is a cross-sectional view of the substrate, shown above in FIG. 12, under going processing showing a photoresist layer disposed thereon;
FIG. 14 is a cross-sectional view of the substrate, shown above in FIG. 13, under going processing showing a photoresist layer being patterned;
FIG. 15 is cross-sectional view of the substrate, shown above in FIG. 14, under going processing after a first etch step; and
FIG. 16 is a cross-sectional view of the substrate, shown above in FIG. 15, under going processing after a second etch step.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 2, shown is an exemplary computer system 30 , such as a personal computer that includes a power supply 32 , a processor 34 , input/output device controller and associated memory (I/O controller) 36 , main memory 38 , expansion slots 40 and expansion cards 40 a, 40 b, 40 c and 40 d. The expansion slots 40 are in electrical communication with the power supply 32 over a power bus 42 . The power bus 42 includes multiple lines, each of which is dedicated to carrying a single voltage level. A main system data bus 44 is in data communication with processor 34 , expansion slots 40 and main memory 38 . Main data bus 44 includes eight to sixty-four different lines, depending upon the data transfer protocol supported by the system 30 , e.g., ISA, EISA, or MCA protocols and the like. Main data bus 44 carries data transferred between processor 34 , main memory 38 and expansion slots 40 . An address bus 46 comprising, for example, twenty lines is in data communication with main memory 38 , processor 34 and expansion slots 40 . Address bus 46 carries information that specifies the address from, or to, data that is to be moved. To facilitate data transfers, a control bus 48 is included that has a plurality of lines placing main memory 38 and expansion slots 40 in data communication with I/O controller 36 .
Referring to both FIGS. 2 and 3, as mentioned above, each of the expansion slots 40 is adapted to receive an expansion card 40 a, 40 b, 40 c and 40 d. One or more optical channels facilitate communication between two or more of the expansion cards 40 a, 40 b, 40 c and 40 d. One optical channel includes one or more sources of optical energy 48 a mounted to expansion card 40 a, and one or more optical detectors 50 a mounted to expansion card 40 b and in data communication with the source of optical energy 48 a. A HOE 52 a is disposed between the source of optical energy 48 a and the detector 50 a. A second optical channel includes one or more sources of optical energy 48 b mounted to expansion card 40 b, and one or more optical detectors 50 b mounted to expansion card 40 a and in data communication with the source of optical energy 48 b. A HOE 52 b is disposed between the source of optical energy 48 b and the detector 50 b.
Source of optical energy 48 a directs optical energy 54 a along a path 56 a in which the detector 50 a lies. The HOE 52 a is disposed in the optical path 56 a. Source of optical energy 48 b directs optical energy 54 b along a path 56 b in which the detector 50 b lies. The HOE 52 b is disposed in the optical path 56 b. Each of the HOEs 52 a and 52 b has both a refractory function and a holographic transform function enabling the HOEs 52 a and 52 b to concurrently filter and refract the optical energy propagating therethrough. In this manner, the HOEs 52 a and 52 b filter the optical energy 54 a and 54 b, respectively so that the optical energy passing therethrough to impinge upon the optical detectors 50 a and 50 b, respectively, have desired characteristics.
HOE 52 a and 52 b are identical in construction and, therefore, only HOE 52 a will be discussed, but it should be borne in mind that the discussion with respect to HOE 52 a applies with equal weight to HOE 52 b. HOE 52 a is a refractory lens having a bulk hologram recorded therein that defines a holographic transform function. The bulk hologram facilitates characterizing the optical energy 54 a to have desired characteristics that may improve detection, by the optical detector 50 a, of information contained in the optical energy 54 a. For example, the transform function may allow a specific wavelength to pass through the lens, diffracting all other wavelengths to deflect away from the optical detector 50 a. Alternatively, the transform function may allow only a certain polarization of the optical energy 54 a to propagate therethrough, diffracting all other polarizations away from the optical detector 50 a.
The refractory function of the HOE 52 a facilitates impingement of the optical energy 54 a onto the optical detector 50 a. In this manner, the precise alignment of the optical detector 50 a with respect to the source 48 a and, therefore, the path 56 a may be relaxed. This is beneficial when facilitating communication between expansion cards, such as 40 a and 40 b, because the mechanical coupling of the expansion cards 40 a and 40 b to the respective slots 40 would typically make difficult precisely aligning source 48 a with the detector 50 a.
Referring to FIG. 4, the HOE 52 a is a lens 58 having an arcuate surface 60 , e.g., cylindrical, spherical and the like with a bulk holographic transform function formed therein. The bulk holographic transform function is shown graphically as periodic lines 62 for simplicity. The bulk holographic transform function 62 is recorded in substantially the entire volume of the lens 58 through which optical energy will propagate. The transform function 62 is a periodic arrangement of the space-charge field of the material from which the lens 58 is fabricated. To that end, the lens 58 may be formed from any suitable photo-responsive material, such as silver halide or other photopolymers. In this manner, the lens 58 and the bulk holographic transform function 62 are integrally formed in a manner described more fully below. Although the surface 64 of the lens 58 disposed opposite to the spherical arcuate surface 60 is shown as being planar, the surface 64 may also be arcuate as shown in surface 164 of lens 158 in FIG. 5 .
Referring to both FIGS. 4 and 5, were it desired to further control the shape of optical energy propagating through lens 58 , a Fresnel lens 258 may be formed opposite to the spherical surface 260 . To that end, the Fresnel lens 258 includes a plurality of concentric grooves, shown as recesses 258 a, 258 b and 258 c that are radially symmetrically disposed about a common axis 256 . Thus, the lens 258 may have three optical functions integrally formed in a common element, when providing the bulk holographic transform function 262 therein, which facilitates creation of well defined optical channels between expansion cards 40 a and 40 b shown in FIG. 3 .
In FIG. 2, facilitating communication between expansion cards 40 a and 40 b over optical channels increase the bandwidth of the computer system 30 's bus systems. Specifically, the transfer of power and data between the expansion cards 40 a and 40 b and the computer system 30 is bifurcated. The power to the expansion cards 40 a and 40 b is transferred over power bus 42 and the data transfer between two or more expansion cards may be achieved over one or more optical channels. To that end, the expansion cards 40 a and 40 b are made backwards compatible with existing technology. This is shown by the implementation of standard expansion cards 40 c and 40 d along with expansion cards 40 a and 40 b, as well as the compatibility of expansion cards 40 a and 40 b with standard expansion slots 40 . The presence of the optical channels, however, reduces the need to transfer information between the expansion cards 40 a and 40 b over the main data bus 44 , as well as the need to transfer information over the address bus 46 or the control bus 48 , were appropriate control circuitry included on the expansion cards 40 a and 40 b. Thus, employing the optical channels as described above, the computer system 30 bus bandwidth may be increased.
Referring to FIGS. 2 and 7 A- 7 B, as mentioned above the expansion cards 40 a and 40 b may each include multiple sources of optical energy 48 a and multiple detectors 50 a. To that end provided are an array of sources of optical energy 348 , shown generally as optical emitters 348 a - 348 p, and an array of optical detectors 350 , shown generally as optical receivers 350 a - 350 p. The optical emitters 348 a - 348 p generate optical energy to propagate along a plurality of axes, and the optical receivers 350 a - 350 p are positioned to sense optical energy propagating along one of the plurality of optical axes. Specifically, the array 348 is an (X×Y) array of semiconductor lasers that produce a beam that may be modulated to contain information. The array 350 may comprise of virtually any optical receiver known, such a charged coupled devices (CCD) or charge injection detectors (CID). In the present example, the array 350 comprises of CIDs arranged in an (M×N) array of discrete elements. The optical beam from the each of the individual emitters 348 a - 348 p may expand to impinge upon each of the receivers 350 a - 350 p of the array 350 if desired. Alternatively, the optical beam from each of the individual emitters 348 a - 348 p may be focused to impinge upon any subportion of the receivers 350 a - 350 p of the array 350 . In this fashion, a beam sensed by one of the receivers 350 a - 350 p of the array 350 may differ from the beam sensed upon the remaining receivers 350 a - 350 p of the array 350 . To control the wavefront of the optical energy produced by the emitters 348 a - 348 p, the HOE 52 a - 52 b, discussed above with respect to FIGS. 3-6 may be employed as an array of the lenses, shown more clearly in FIG. 8 as array 400 .
Specifically, referring to FIGS. 7A-7B and 9 , the individual lenses 458 of the array are arranged to be at the same pitch and sizing of the array 348 . The numerical aperture of each of the lenses 458 of the array 400 is of sufficient size to collect substantially all of the optical energy produced by the emitters 348 a - 348 p corresponding thereto. In one example, the array 400 is attached to the array 348 with each lens resting adjacent to one of the emitters 348 a - 348 p. To provide the necessary functions, each of the lenses of the array 400 may be fabricated to include the features mentioned above in FIGS. 4-6. As a result, each of the lenses 458 of the array 400 may be formed to have functional characteristics that differ from the remaining lenses 458 of the array 400 . In this manner, each beam produced by the array 348 may be provided with a unique wavelength, polarization or both. This facilitates reducing cross-talk and improving signal-to-noise ratio in the optical communication system.
Specifically, an additional array of lenses 400 b that match the pitch of the individual receivers 350 a - 350 p of the array 350 , is shown more clearly in FIG. 10 . The lenses may be fabricated to provide the same features as discussed above with respect to array 400 , shown in FIG. 8 .
Referring to FIGS. 7A-7B, 8 and 10 each of the emitters 348 a - 348 p of the array 348 would then be uniquely associated to communicate with only one of the receivers 350 a - 350 p of the array 350 . In this manner, the emitter 348 a - 348 p of the array 348 that is in data communication with one of the receivers 350 a - 350 p of the array 350 would differ from the emitters 348 a - 348 p in data communication with remaining receivers 350 a - 350 p of the array 350 . This emitter/receiver pair that were in optical communication is achieved by having the properties of the lens 458 a in array 400 a match the properties of the lens 458 b in array 400 b . It should be understood, however that one of the emitters 348 a - 348 p may be in data communication with any number of the receivers 350 a - 350 p by multiple lenses 458 b matching the properties of one of the lenses 458 a . Similarly, one of the multiple emitters 348 a - 348 p may be in optical communication with one or more of the receivers 350 a - 350 p by appropriately matching the lenses 458 a to the lenses 458 b.
In one example, superior performance was found by having the array 350 sectioned into (m×n) bins, with each bin corresponding to a particular polarization and/or wavelength that matched a particular polarization and/or wavelength corresponding to a emitter 348 a - 348 p . Thus, were a beam from one or more of the emitters 348 a - 348 p to flood the entire (M×N) array 350 or multiple (m×n) bins, only the appropriate receivers 350 a - 350 p sense information with a very high signal-to-noise ratio and discrimination capability. It will be noted that the (m×n) bins can also be effectively comprised of a single sensing pixel (element) to exactly match the (X×Y) array.
Additional beam-sensor discrimination may be achieved by employing emitters 348 a - 348 p having different wavelengths or by incorporating up-conversion processes that include optical coatings applied to the individual emitters 348 a - 348 p or made integral therewith. One such up-conversion process is described by F. E. Auzel in “Materials and Devices Using Double-Pumped Phosphors With Energy Transfer”, Proc. of IEEE, vol. 61. no. 6, June 1973.
Referring to FIGS. 3, 10 and 11 , the system 500 employed to fabricate the lens 58 and the lens arrays 400 a and 400 b includes a beam source 502 that directs a beam 504 a into wave manipulation optics 506 such as a ¼ waveplate 508 so that the beam 504 b is circularly polarized. The beam 504 b impinges upon polarizer 510 so that the beam 504 c propagating therethrough is linearly polarized. The beam 504 c impinges upon a Faraday rotator 512 that changes birefringence properties to selectively filter unwanted polarizations from the beam 504 c . In this manner, the beam 504 degressing from the rotator 512 is linearly polarized. The beam 504 d impinges upon a beam splitter 514 that directs a first subportion 504 e of beam 504 d onto a planar mirror 516 . A second subportion 504 f of the beam 504 d pass through the splitter 514 . The first and second subportions 504 e and 504 f intersect at region 520 forming an optical interference pattern that is unique in both time and space. A photosensitive sheet 558 is disposed in the region 520 so as to be exposed to the optical interference pattern. The interference pattern permeates the photosensitive sheet 558 and modulates the refractive index and charge distribution throughout the volume thereof. The modulation that is induced throughout the volume of the photosensitive sheet 558 is in strict accordance with the modulation properties of the first and second subportions 504 e and 504 f . Depending upon the photosensitive material employed, the holographic transform function may be set via thermal baking.
Referring to FIGS. 11 and 12, an arcuate surface is formed in the photosensitive sheet 558 by adhering a photosensitive layer 600 to a sacrificial support 602 , such as glass, plastic and the like to form a photosensitive substrate 604 . Typically, the photosensitive layer 600 is tens of microns thick. As shown in FIG. 13, a photo resist layer 606 is deposited onto the photosensitive layer 600 and then is patterned to leave predetermined areas exposed, shown as 608 in FIG. 14, defining a patterned substrate 610 . Located between the exposed areas 608 are photo resist islands 612 . The patterned substrate 610 is exposed to a light source, such as ultraviolet light. This ultraviolet light darkens the volume of the photosensitive layer 600 that is coextensive with the exposed areas 608 being darkened, i.e., become opaque to optical energy. The volume of the photosensitive layer 600 that are coextensive with the photo resist islands 612 are not darkened by the ultraviolet light, i.e., remaining transparent to optical energy. Thereafter, the photo resist islands 612 are removed using standard etch techniques, leaving etched substrate 614 , shown in FIG. 15 .
The etched substrate 614 has two arcuate regions 616 that are located in areas of the photosensitive layer 600 disposed adjacent to the islands 612 , shown in FIG. 14 . The arcuate regions 616 of FIG. 15 result from the difference in exposure time to the etch process of the differing regions of the photosensitive layer 600 .
Referring to FIGS. 10 and 16, a subsequent etch process is performed to form array 400 . During this etch process the support is removed as well as nearly 50% of the photosensitive layer 600 to form a very thin array. The array 400 is then placed in the system 500 , shown in FIG. 11, and the bulk holographic transform functions are recorded in the arcuate regions 616 that define the lenses 458 , as discussed above. A Fresnel lens may also be formed on the lenses 458 a and 458 b of the array 400 using conventional semiconductor techniques. Thereafter, the lenses may be segmented from the photo resistive sheet or M×N subarrays of lenses may be segmented therefrom.
Lenses with differing transform functions are formed on differing photosensitive sheets 558 . Specifically, the transform function is defined by the interference pattern formed by the first and second subportions 504 e and 504 f intersecting at region 520 . This interference pattern is unique in both time and space. As a result, each of the lenses formed on the sheet 558 would have substantially identical holographic transform functions. To create lenses with differing transform functions, an additional photosensitive sheet 558 would be employed and, for example, the Faraday rotator 512 may be rotated to provide the lenses formed on the photosensitive sheet 558 with a holographic transform flnction that differs from the holographic transform function associated with the lenses formed on a previous photosensitive sheet 558 . Therefore, lenses 458 a associated with the first array 458 would come from differing sheets 558 if the lenses were to have differing holographic transform functions.
Although the invention has been described in terms of specific embodiments, one skilled in the art will recognize that various changes to the invention may be performed, and are meant to be included herein. For example, instead of forming the arcuate regions 616 , shown in FIG, 15 , using standard etch techniques, the same may be formed by exposing the substrate 610 , shown in FIG. 14, to thermal energy. In one example, the substrate 610 is convectionally heated, and the photo resist layer 606 is patterned to control the regions of the photosensitive layer 600 that may expand. In another example, the photosensitive layer is heated by conduction employing laser ablation/shaping. Specifically, a laser beam impinges upon areas of the photosensitive layer 600 where lenses are to be formed. The thermal energy from the laser beam causes the photosensitive layer 600 to bubble, forming arcuate regions 616 thereon shown in FIG. 15 . Therefore, the scope of the invention should not be based upon the foregoing description. Rather, the scope of the invention should be determined based upon the claims recited herein, including the full scope of equivalents thereof.
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Provided is an optical backplane interconnect system, one embodiment of which features transceiver subsystems employing holographic optical elements (HOEs) that define, and discriminate between, differing optical channels of communication. The HOEs employ a holograph transform to concurrently refract and filter optical energy to remove optical energy having unwanted characteristics. To that end, the transceiver subsystem is mounted to an expansion card and includes a source of optical energy and an optical detector. The HOE need not be mounted to the expansion card. In one embodiment, however, the HOE is mounted to the expansion card and in optical communication with either the source of optical energy, the optical detector or both.
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PRIORITY CLAIM
[0001] In accordance with 37 C.F.R. 1.76, a claim of priority is included in an Application Data Sheet filed concurrently herewith. This application is a continuation-in-part of U.S. patent application Ser. No. 14/021,482, entitled “INTERVERTEBRAL SPACER, filed Sep. 9, 2013, which is a divisional of U.S. patent application Ser. No. 12/496,824, entitled “INTERVERTEBRAL SPACER,” filed Jul. 2, 2009, now U.S. Pat. No. 8,529,627, issued Sep. 10, 2013. The contents of the above referenced applications are incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
[0002] The invention relates to spinal implants for intervertebral body fusion devices and an instrument for properly inserting the implant between the vertebral bodies.
BACKGROUND OF THE INVENTION
[0003] The spine is a complex structure capable of performing a broad range of kinematic functions. The spinal vertebrae and elastic disk permit the spine to move in three axes of motion. These axes include rotation, such as twisting of the upper back and shoulders relative to the pelvis, horizontal movement, such as forward (anterior) or backward (posterior), and lateral bending movement to either the right or left side.
[0004] The spacing between adjacent vertebrae is maintained by a disc having both elastic and compressible characteristics. The appropriate spacing in a healthy spine is maintained between adjacent vertebrae during the rotational, horizontal and lateral movement of the spine, thereby allowing for maximum freedom of motion of the spine. The spacing between adjacent vertebrae is also critical to allow the nerves radiating from the spine to extend outwards without being pinched or compressed by the surrounding vertebrae.
[0005] Spinal discs can be damaged by physical injury, disease, genetic disposition, and aging, and become less than fully functional. When this happens, the disc is incapable of maintaining the proper intervertebral spacing and, as a result the nerves radiating from the spine can be compressed. Nerve damage could also be caused by root compression in neural foramen, compression of the passing nerve, and an enervated annulus which occurs when the nerves flow into a cracked annulus that results in pain each time the disc is compressed. Obviously other organic abnormalities can occur in the presence of a dysfunctional disc.
[0006] Many solutions have been developed to eliminate or at least minimize nerve compression and the attendant pain that commonly results from spinal nerve pressure. These solutions approach the problem by surgically removing the defective disc and thereafter replacing it with an insert that is subsequently fused to the adjacent discs, thereby maintaining an appropriate distance between adjacent vertebrae. While prior insert solutions have been successful in improving the patient's condition, it is somewhat problematic for the surgeon to gain the necessary access to the space between the vertebrae without doing harm to adjacent body structures such as the spinal cord, other nerves, and other adjacent body organs.
[0007] A surgical solution that utilizes a less invasive technique will result in less trauma and unintended damage to surrounding bone, organ, muscle and nerve tissue while achieving the desired results. The present invention relates to an insert that can be advanced into a prepared space between vertebral bodies by a novel instrument, and, upon reaching the appropriate insertion point, a pivotal motion is imparted to the insert to provide proper placement of the insert. The pivotable insert provides the surgeon with the capability to implant the insert using a nonlinear path. The insertion and placement is achieved in a minimally invasive manner.
DESCRIPTION OF THE PRIOR ART
[0008] What is needed, therefore, is an intervertebral insert and delivery instrument that will be minimally invasive.
[0009] U.S. Published Patent Application No. 2008/0009880 discloses a pivotable interbody spacer system includes an insertion instrument configured to manipulate a pivotable interbody spacer during surgical insertion; wherein the insertion instrument includes means for coupling the interbody spacer and a means for fixing the angular position of the interbody spacer. According to one exemplary method for inserting the interbody spacer in a spinal disc space, the interbody spacer is grasped by the insertion instrument and fixed at a first angular position; the interbody spacer is inserted into the surgical site; the interbody spacer is released from the first angular position; the insertion instrument is pivoted about the coupling such that the interbody spacer is in a second angular position; the angular position of the interbody spacer is fixed in the second angular position; and the insertion process continues until the interbody spacer is positioned in the desired location.
[0010] U.S. Published Patent Application No. 2008/0221694 discloses a spinal spacer system which includes a handle member and an extension member including a first and a second end, wherein the first end of the extension member is coupled to the handle member. Additionally, a coupling device configured to selectively couple a spacer to the second end of the extension member is disposed on the extension member and includes an angular fixation member configured to fix the spacer in an angular position relative to the handle member. The spinal spacer system also includes an actuator configured to selectively actuate the coupling device and the angular fixation member.
[0011] U.S. Published Patent Application No. 2008/0140085 discloses a method to insert a spinal implant into a vertebral space, the method including the steps of: grasping the implant with a distal end of an implant insertion tool; holding a proximal end of the implant insertion tool and inserting the implant toward the vertebral space; and manipulating the proximal end to apply a yaw movement to the implant while the implant is attached to the tool and in the vertebral space. Two slideable rods inside sheath 1514 activate rotation of the spacer implant.
[0012] U.S. Published Patent Application No. 2008/0109005 discloses a system for replacing a natural nuclear disc in an intervertebral space which has a spinal device configured for placement in the intervertebral space. An insertion tool is configured for holding the spinal device while the spinal device is inserted into the intervertebral space. A gripping member of the insertion tool has an end for adjustably holding the spinal device within the intervertebral space. A steering actuator of the insertion tool is operatively connected to the spinal device and configured for pivoting the adjustably held spinal device within the intervertebral space while the steering actuator is controlled remotely from the intervertebral space.
[0013] U.S. Published Patent Application No. 2003/0208203 discloses instruments and methods for inserting one or more implants to a surgical site in a patient in a surgical procedure, including minimally invasive surgical procedures. The implant is mountable to the instrument in a reduced profile orientation and after insertion is manipulated with the insertion instrument to the desired orientation.
[0014] U.S. Published Patent Application No. 2008/0065082 discloses instruments and methods for inserting a rasp into an intervertebral space of a spine and using the rasp to decorticate the adjacent vertebra. More particularly, one embodiment provides an instrument that actively changes the angle of the rasp relative to the instrument. The delivery instrument may use a gear portion to articulate the rasp. A second gear on the rasp may mate with a corresponding gear on the instrument. As the instrument gear rotates relative to the instrument, the instrument gear drives the rasp gear, thereby rotating the rasp to decorticate the vertebra. Trial inserts and methods are also provided to determine an appropriate size of a rasp for decortications.
[0015] U.S. Published Patent Application No. 2007/0225726 discloses a method, apparatus, and system provided to place an insert in a space between boney structures. The insert may be rotatably coupled to the delivery instrument. The delivery instrument may comprise a body and an articulating member. The articulating member may slidably interact with the insert to rotate the insert about a pivot point. A first actuator is operatively coupled to the articulating member, such that actuating the first actuator translates the articulating member relative to the body. An engagement member may be coupled to the body and adapted to releasably and rotatably secure the insert to the delivery instrument. The articulating member and the engagement member may be offset from each other in such a manner that when the articulating member engages the insert, the insert rotates relative to the delivery instrument. Alternatively, the insert may be coupled to the delivery instrument via rotatable attachment members.
[0016] U.S. Published Patent Application No. 2005/0192671 discloses an artificial disc device for replacing a damaged nucleus. In one form, the device may be inserted in components such that the device may be assembled within and retained by the natural annulus therein. In another form, the device may be inserted into the natural annulus in a collapsed or compressed state or arrangement and then be expanded within and retained by the annulus therein. In a further form, the device may be provided with a releasable connection so that the device may be connected in an insertion configuration, and may be released in an operable configuration.
[0017] U.S. Pat. No. 7,976,549 discloses a method and apparatus to place an insert in a space between boney structures. An articulating member slidably interacts with the insert to rotate the insert about a pivot point.
[0018] U.S. Pat. No. 8,043,293 discloses a pivotable implant having an inner cavity and a plurality of teeth formed on one end of the implant. An insertion instrument includes a retractable latching mechanism and an internal gear configured to mate with the teeth formed on the implant.
[0019] What is lacking in the art is a pivotable expandable implant and associated surgical implant tool.
SUMMARY OF THE INVENTION
[0020] The instant invention is comprised of a pivotable expandable insert that is positioned in a prepared space between adjacent vertebrae. The insert has an approximately centrally located pivot post and a curved end portion, each configured to cooperatively engage an instrument to advance the insert into an appropriate position. Various components of the instrument are manipulated to achieve the final placement of the insert. The instrument is then disengaged from the insert and removed from the patient. An adjustment screw is then used to engage the expandable insert to splay opposing side surfaces to a distance as required by the installation.
[0021] Accordingly, it is an objective of the instant invention to provide a spinal insert that is easily and accurately placed within a prepared space between two vertebrae using a minimally invasive technique.
[0022] Still another objective of the invention is to provide an implant that is compact in size for installation and expandable upon insertion, minimizing the stress placed on the body during installation.
[0023] It is a further objective of the instant invention to provide a surgical instrument configured to be operatively connected to the implantable insert that can be used by the surgeon to accurately place the insert within the intervertebral space using a minimally invasive technique, and expand the insert upon placement.
[0024] It is yet another objective of the instant invention to provide simple and reliable mechanical relationships between the insert and the surgical instrument to provide a minimally invasive approach to implanting a spinal insert.
[0025] It is a still further objective of the invention to provide an insert that will stabilize the spine and promote bone growth between adjacent vertebrae such that adjacent vertebrae are fused together.
[0026] Yet still another objective of the invention is to provide an insert that reduces the need for maintaining an inventory of different sized implants by providing an implant that is adjustable in size.
[0027] Other objectives and advantages of this invention will become apparent from the following description taken in conjunction with any accompanying drawings wherein are set forth, by way of illustration and example, certain embodiments of this invention. Any drawings contained herein constitute a part of this specification and include exemplary embodiments of the present invention and illustrate various objects and features thereof.
BRIEF DESCRIPTION OF THE FIGURES
[0028] FIG. 1 is a top view of the implantable insert.
[0029] FIG. 2 is a side view of the implantable insert.
[0030] FIG. 3 is a bottom view the implantable insert.
[0031] FIG. 4 is a side view of the implantable insert opposite to that shown in FIG. 2 .
[0032] FIG. 5 is a perspective view of the surgical instrument utilized to implant the insert.
[0033] FIG. 6 is a side view of the surgical instrument and implantable insert.
[0034] FIG. 7 is a top view of the surgical instrument and implantable insert.
[0035] FIG. 8 is a side view of the surgical instrument and implantable insert opposite to that shown in FIG. 6 .
[0036] FIGS. 9A , 9 B, 9 C, 9 D, and 9 E show the placement of the insert and the operative relationship of the surgical instrument at various stages of the insertion procedure.
[0037] FIG. 9F shows an alternative embodiment that utilizes a threaded implant interface.
[0038] FIG. 10 is a top view of an expandable implantable insert.
[0039] FIG. 11 is a side view of the expandable implantable insert.
[0040] FIG. 12 is a perspective view of the expandable implantable insert.
[0041] FIG. 13 is a top view of the expandable implantable insert in an expanded configuration.
[0042] FIG. 14 is a side view of the expandable implantable insert in an expanded configuration.
[0043] FIG. 15 is a perspective view of the expandable implantable insert in an expanded configuration.
[0044] FIG. 16 is an exploded view of the expandable implantable insert.
[0045] FIG. 17 is a frontal exploded view of the expandable implantable insert without the frame.
[0046] FIG. 18 is a rearward exploded view of FIG. 17 .
[0047] FIG. 19 is a cross sectional view of the expandable implantable insert.
[0048] FIG. 20 is a cross sectional view of the expandable implantable insert in an expanded configuration.
[0049] FIG. 21 is a side view of the expandable implantable insert mounted to a surgical implant tool.
[0050] FIG. 22 is a side view of the expandable implantable insert mounted to a surgical implant tool in a rotated position.
DETAILED DESCRIPTION OF THE INVENTION
[0051] Referring to FIGS. 1-9 in general, FIG. 1 is a top view of implantable insert 1 . Insert 1 is generally arcuate in shape and has a top surface 2 and a bottom surface 4 . Connecting top surface 2 and bottom surface 4 is a convex edge 6 on one side and a pair of concave edges 8 A and 8 B on the second, opposite side. The edges have first end portions 10 A and 10 B and second end portions 12 A and 12 B. A first curved portion 14 connects first end portions 10 A and 10 B and a second curved portion 16 connects second end portions 12 A and 12 B. Located on the top surface 2 is a plurality of apertures 18 A. Likewise, bottom surface 4 has a plurality of apertures 18 B. Apertures 18 A and 18 B form a substantially hollow center within the insert 1 . The hollow cavity within the insert is used to deliver a bone growth material to fuse the adjacent vertebrae together. The insert 1 is relatively small in overall size while providing both a large surface for support and a large cavity to provide bone growth material. A slotted passageway 20 is formed on the second side surfaces including the entire length of concave surface 8 B and a portion of concave surface 8 A. The slot 20 is also continued through first curved portion 14 . Insert 1 also includes a first cylindrical post 22 extending between, and attached to, the top surface 2 and bottom surface 4 at a first end portion of the insert 1 . Likewise, a second cylindrical post 24 extends between, and is attached to, the top surface 2 and bottom surface 4 at a second end portion of the insert 1 . A third cylindrical post 26 is located approximately midway between the first and second post in a location adjacent to the area where concave surfaces 8 A and 8 B approach one another.
[0052] FIG. 2 is a side view of insert 1 showing the pair of concave surfaces 8 A and 8 B, first curved portion 14 and second curved portion 16 . Also shown in FIG. 2 is slotted passageway 20 which extends from concave surface 8 A, through concave surface 8 B and continues into first curved portion 14 . Also illustrated in FIG. 2 is a first post 22 and third post 26 .
[0053] FIG. 3 is a bottom view of insert 1 showing bottom surface 4 , convex surface 6 on the first side and the pair of concave edges 8 A and 8 B on the second side, as well as first curved portion 14 and second curved portion 16 . Also illustrated in FIG. 3 are apertures 18 B.
[0054] FIG. 4 is a side view of insert 1 that showing the alternative side to that shown in FIG. 2 showing the convex surface 6 on the first side as well top surface 2 , bottom surface 4 , first curved portion 14 and second curved portion 16 . Also shown in FIG. 4 is a portion of slotted passageway 20 . As can best be seen in FIG. 4 the top surface 2 and bottom surface 4 are generally domed shaped with the high points 4 A and 2 A of each dome being located in the area surrounding the areas where the third cylindrical post 26 connects to the top and bottom surfaces respectively. These high points will form contact points with adjacent vertebrae, thereby facilitating pivotal motion of the insert about the third post 26 .
[0055] FIG. 5 is a perspective view of insert 1 mounted on surgical instrument 30 prior to implantation. The instrument 30 includes a sleeve 32 and an arm 34 . The arm 34 is mounted for relative reciprocal longitudinal movement with respect to sleeve 32 . The sleeve 32 includes a guide rail 36 . The guide rail 36 presents two tracks formed, with one formed on each side of a slot 38 designed to receive arm 34 . The arm 34 includes profiled surfaces formed on opposite sides of the arm 34 that are configured to operatively engage the tracks formed on the guide rail 36 . The sleeve 32 also includes a pair of curved surfaces 42 formed on opposite side of sleeve 32 that are shaped to mate with the first curved portion 14 of insert 1 .
[0056] FIG. 6 is a side view of insert 1 attached to surgical instrument 30 . In this view, concave surfaces 8 A and 8 B of the first side are shown. Also shown in this view is sleeve 32 , arm 34 , guide rail 36 and a gripping mechanism 40 .
[0057] FIG. 7 is a top view of the insert 1 attached to the surgical instrument 30 . In this view top surface 2 of the insert 1 is shown. As shown in this figure, surgical instrument 30 includes the sleeve 32 with mating surface 42 , arm 34 and gripping mechanism 40 .
[0058] FIG. 8 is a side view of insert 1 and surgical instrument 30 showing the side opposite to that shown in FIG. 6 . Convex surface 6 on insert 1 can be seen in this view. Also shown in this view is the sleeve 32 and gripping device 40 of surgical instrument 30 .
[0059] FIGS. 9A through 9E show the placement of the insert within the prepared space between the vertebrae, and the operative relationship of the surgical instrument and the insert at various stages of the procedure. As shown in FIG. 9E , arm 34 has a recess 46 that includes an aperture that is cylindrical in cross section. The recess can receive the third post 26 and is capable of retaining or releasing the post dependent upon on direction of the forces applied thereto. As shown in FIG. 9A , post 26 on insert 1 has been position within recess 46 on arm 34 . Likewise, the first end portion 10 on insert 1 is positioned to be in mating relationship with curved mating surfaces 42 located on sleeve 32 . The insert 1 as shown in FIG. 9A , is then inserted into the prepared site between adjacent vertebrae. Thereafter, instrument 30 is manipulated by gripping device 40 to advance the insert 1 toward a point that would be appropriate for rotation of the insert 1 . Upon reaching the pivot point, the sleeve 32 is retracted as shown in FIG. 9B and the instrument 30 is moved medially to impart the initial rotation. At this point, the instrument 30 is tamped slightly to impart a small amount of rotation to the insert 1 . Having been positioned as shown in FIG. 9C the sleeve 32 is advanced such that a corner portion 44 on the sleeve 32 makes contact with the first end portion of the insert 1 . The further advancement of sleeve 32 will result in the rotation of insert 1 about the post 26 which is retained in position by arm 34 . Additional tamping of the instrument 30 may be necessary. The sleeve 32 is advanced until the insert is rotated into its final position as shown in FIG. 9D . At this point, the sleeve 32 is retracted and the mating surfaces 42 are withdrawn from engagement with the first end portion 10 . As shown in FIG. 9E the instrument 30 is then manipulated such that the post 26 is removed from recess 46 and the instrument 30 is then released from the insert 1 . At this point the instrument 30 is removed from the prepared site. Bone growth material is provided in the hollow cavity formed within the insert 1 . Apertures 18 A and 18 b permit bone in growth with the insert 1 and adjacent vertebrae. As an alternative to the recess shown in FIG. 9E the arm 34 is provided with a threaded implant interface in the form of an externally threaded pin 48 that will threadably engage and disengage from a threaded bore that extends transversally to the longitudinal axis of the post 26 , as shown in FIG. 9F .
[0060] Referring in general to FIGS. 10-22 , the expandable implant 100 is generally arcuate in shape having a top surface 102 and a bottom surface 104 . A frame 106 has a convex edge 107 on one side and a convex edge 108 on the opposite side forming an inner side wall 111 . The edges have first end portions 112 and second end portions 114 . A first curved portion 110 connects first convex edge 107 to the second convex edge 108 on one end, and a second curved portion 116 connects said second convex edge 108 to said first convex edge 107 on the opposite end. A first insert 120 is constructed and arranged to fit within the inner side wall 111 of said frame 106 . The first insert 120 is defined by the top surface 102 having a first edge sleeve 122 cooperates with first frame alignment post 124 . A second edge sleeve 126 cooperates with a second frame alignment post 128 . A third edge sleeve 130 cooperates with a third frame alignment post 132 . A fourth edge sleeve 138 cooperates with a fourth alignment post 140 . Aperture 142 accepts an upper end 144 of adjustment post 150 . The upper end 144 is sized to allow rotation of the adjustment post 150 used during installation and displacement of the first insert 120 . The adjustment post 150 includes a threaded aperture 152 for receipt of a surgical insert tool 300 for installation. The threaded aperture 152 further receives an adjustment screw 154 which is used for displacement of the inserts. The frame 106 includes a slotted passageway 133 for ease of access to the adjustment screw 150 , and for placement of bone growth material.
[0061] A second insert 170 is constructed and arranged to fit within the inner side wall 111 of said frame 106 . The second insert 170 is defined by the bottom surface 104 having a first edge sleeve 172 that cooperates with first frame alignment post 124 . A second edge sleeve 174 cooperates with a second frame alignment post 128 . A third edge sleeve 176 cooperates with a third frame alignment post 132 . A fourth edge sleeve 178 cooperates with a fourth alignment post 140 . Aperture 180 accepts a lower end 182 of adjustment post 150 . The lower end 182 is sized to allow rotation of the adjustment post 150 used during installation and displacement of the lower insert 170 . Additionally, post 141 of first insert 120 can be used to engage a reciprocal post 143 of the lower insert 170 .
[0062] A wedge member 200 is positioned between the first insert 120 and the second insert 170 . The wedge member 200 includes a lower ramp surface 202 which cooperates with a lower angled surface 204 on the lower insert 170 . Similarly, an upper ramp surface 206 cooperates with an upper angled surface 208 on the upper insert 120 . As illustrated in FIGS. 19 and 20 , the rotation of screw 154 within the adjustment post 150 pushes the wedge member 200 away from the post, wherein the lower ramp surface 202 slides up the lower angled surface 204 , as does the upper ramp surface 206 which slides up the upper angled surface 208 . The ramps share a common proximal end with angled ramp surfaces that separated distal ends that position the upper and lower inserts in an expanded configuration. Movement of the wedge member 200 causes displacement of the upper surface 102 and lower surface 104 at equal rates. The wedge member 200 further includes lower guide posts 220 and 222 which engage lower slots 224 and 226 on the lower insert 170 . Similarly, upper guide posts 228 and 230 engage upper slots, not shown, forming a mirror image of the lower slots 224 , 226 .
[0063] Frame 106 further includes a pivot post 240 mounted along end 112 , wherein frame 106 has a first and second tang 117 and 119 extending between the edges 106 and 108 . A mounting aperture 121 is placed within the first tang 117 and mounting aperture 123 is placed within the second tang 119 .
[0064] For placement of the implant 100 between the vertebra, the receive arm 34 is threaded as shown in FIG. 9F and used to engage the adjustment post 150 . The pivot post 240 is engaged and, as illustrated in FIGS. 9A-9D , the implant rotated from a storage position as depicted in FIG. 21 , to a mounting position as depicted in FIG. 22 . The operative relationship of the surgical instrument 300 allows the threading of the adjustment post 150 by rotation of the knob 302 . Thereafter, the instrument 300 is manipulated by gripping device 304 to advance the implant toward a point that would be appropriate for rotation. Upon reaching a pivot point, the instrument 300 is moved medially to impart an initial rotation. At this point the instrument 300 can be tamped slightly on the knob 302 to impart a small amount of rotation to the implant. The grip 304 is drawn to the handle 306 to cause rotation, and once the implant is in position, the tool is removed from the insert by unthreading rotating of the knob 302 until the threaded end is released from the implant. The surfaces 102 and 104 can then be expanded by the use of the screw 154 to engage the adjustment post 150 . The screw is rotated to engage the wedge member 200 , wherein the wedge member is used to expand the surface 102 and 104 . With the surfaces expanded, bone growth material can be placed into the hollow cavity formed within the implant.
[0065] All patents and publications mentioned in this specification are indicative of the levels of those skilled in the art to which the invention pertains. All patents and publications are herein incorporated by reference to the same extent as if each individual publication was specifically and individually indicated to be incorporated by reference.
[0066] It is to be understood that while a certain form of the invention is illustrated, it is not to be limited to the specific form or arrangement herein described and shown. It will be apparent to those skilled in the art that various changes may be made without departing from the scope of the invention and the invention is not to be considered limited to what is shown and described in the specification and any drawings/figures included herein.
[0067] One skilled in the art will readily appreciate that the present invention is well adapted to carry out the objectives and obtain the ends and advantages mentioned, as well as those inherent therein. The embodiments, methods, procedures and techniques described herein are presently representative of the preferred embodiments, are intended to be exemplary and are not intended as limitations on the scope. Changes therein and other uses will occur to those skilled in the art which are encompassed within the spirit of the invention and are defined by the scope of the appended claims. Although the invention has been described in connection with specific preferred embodiments, it should be understood that the invention as claimed should not be unduly limited to such specific embodiments. Indeed, various modifications of the described modes for carrying out the invention which are obvious to those skilled in the art are intended to be within the scope of the following claims.
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An intervertebral insert member and an instrument for positioning the insert in a space between vertebral bodies in vivo. The insert member is advanced by the instrument into a prepared site located between adjacent vertebral bodies. Upon reaching the appropriate insertion point, the sleeve is retracted and a pivotal motion is imparted to the insert. The insert member is pivotally attached to the distal end of the delivery instrument such that it can be articulated about a pivot point that is located on the insert member until it is properly positioned. The positioning instrument is then released from the insert member and removed from the space between the vertebral bodies. An adjustment screw is available to expand the surfaces of the insert member by displacement of a wedge member within the insert.
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[0001] This patent application claims the benefit of Provisional Patent Application No. 60/232,223, filed Sep. 13, 2000.
FIELD OF THE INVENTION
[0002] This invention relates generally to the field of door security systems. More specifically, this invention relates to an improved electrically energizable, solenoid operated, door-strike mechanism that is easily switchable, to either of two different selected modes of operation. In one mode of operation the mechanism is in a fail-safe mode, wherein, if power to the solenoid fails, a keeper moves to allow a door to be safely opened. The other mode is called fail-secure, wherein, if power to the solenoid fails, the keeper secures the door against opening.
BACKGROUND OF THE INVENTION
[0003] Electric strikes for securing hinged or swinging doors are well-known in the field of door security systems. The electric strikes are employed with doors having projectable deadbolts or latch bolts that engage the electric strike. The electric strike can be configured to secure the door alone, or in combination with other conventional security systems. The electric strike typically is mounted to the door frame and defines an opening in the jam face of the door frame for receiving the latch bolt and/or deadbolt from the lockset mounted to the door. The electric strike further defines an opening in the frame face contiguous with the opening in the jam face of the door frame. A pivotal keeper on the electric strike selectively closes the opening in the frame face. A bolt, projecting from the edge of the door, engages the electric strike through the opening in the jam face. Actuation of the electric strike locks or unlocks the keeper. The keeper is pivotable to uncover or open the frame face opening to allow the bolt to swing there through, and thereby allow opening of the door. The keeper is pivoted by the door being pushed, whereby the bolt engages the keeper of the strike.
[0004] The lock assembly of a conventional electric strike is commonly operated by a solenoid. The solenoid is typically configured to be spring-biased so that energization of the solenoid overcomes the biasing force of the spring to either lock or unlock the electric strike. In a first configuration the power must be continuously supplied to the solenoid in order to maintain the electric strike in a locked condition. This configuration requires a relatively high and continuous input of energy and therefore, typically requires electrical wiring to the doorway from an electric line source.
[0005] Similarly, electric strikes that are configured to unlock upon energization can also require a continuous supply of energy in order to maintain the lock in unlocked condition.
[0006] There is a need for electrically-controlled strike mechanisms of simple, compact, construction for securing doors against opening (fail-secure mode), and also for allowing door opening (fail-safe mode), in the case of power failure. Most mechanisms permitting these two functions require two different strike devices, each device permitting only one of these functions. Current mechanisms which embody the two functions in a single mechanism require complicated disassembly and reassembly in order to accommodate both modes of operation. This invention permits alternating between fail-safe and fail-secure operation by simply turning a single part, an actuator, 180°.
SUMMARY OF THE INVENTION
[0007] Briefly stated, the electric strike in the preferred form employs a solenoid to transform the electric strike between the locked and unlocked states. The solenoid allows for the use of an on-board power source, such as batteries, or an exterior power source to energize the electric strike. In the event that the power source is terminated, for example, because of power failure, it may be desired that the electric strike automatically engages in a fail-safe or alternatively a fail-secure mode. The electric strike includes a means operatively connected between the solenoid and the keeper for causing the keeper to assume a fail-safe condition allowing the keeper to pivot when the solenoid is in either position, or alternatively a fail-secure condition preventing the keeper from pivoting when the solenoid is in either position. In the present invention, the means connecting the solenoid to the keeper can be configured in either mode by simply opening the strike, removing a solenoid assembly and actuators, turning the actuator over and reinserting the removed parts. This permits easy selection of either mode by an unskilled human operator, in the field, in a short period of time, without complicated disassembly and reassembly of the strike mechanism.
[0008] The actuator is a simple, unique, mechanical connection between a solenoid assembly and a lock link that permits or prevents the keeper from unlocking. The actuator is designed to operate in either of two positions. With one side up, the actuator is spring-biased to push the lock link into a fail-safe mode if the solenoid is unpowered. The actuator can be removed and reinserted with the other side or opposite side up. In this second position, the actuator is spring-biased to push the lock link into a fail-secure mode if the solenoid is unpowered.
[0009] It is an object of the invention to provide an improved and relatively compact electric door strike for controlling access through a doorway with a mechanism that permits alternatively selecting a fail-safe condition or alternatively fail-secure condition with a simple easy mechanical reconfiguration that can be accomplished quickly in the field.
[0010] It is another object of the invention to provide an electric strike mechanism that can be selectively configured in a fail-safe or fail-secure mode without a special operator, special tools or the addition of external devices.
[0011] These and other objects of the invention will become apparent from a review of the specification and the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] [0012]FIG. 1 is a partially exploded perspective view, of an electric strike in accordance with the invention;
[0013] [0013]FIG. 2 is an exploded perspective view, of a backbox assembly of the electric strike of FIG. 1;
[0014] [0014]FIG. 3 is a front perspective view, with a backplate, solenoid assembly, and actuator removed, of the backbox assembly of FIG. 1;
[0015] [0015]FIG. 4 is a partial front view of certain components inside the backbox assembly of FIG. 1, shown in an unlocked position of the electric strike;
[0016] [0016]FIG. 5 is a partial back view of certain components of the backbox assembly of FIG. 1, shown in an unlocked position of the electric strike;
[0017] [0017]FIG. 6 is a front view of the actuator, solenoid attachment plunger and lock link of FIG. 4 assembled with the electric strike in fail-safe mode;
[0018] [0018]FIG. 7 is a front view of the solenoid assembly, actuator, and lock link of FIG. 6 assembled in a fail-secure mode; and
[0019] [0019]FIG. 8 is a perspective view of the actuator shown in FIG. 2.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0020] With reference to the drawings wherein like numerals represent like parts, an electric strike is generally designated by numeral 10 . The electric strike 10 comprises one main assembly and two mounting parts. Referring to FIG. 1, the main assembly is called a backbox assembly 20 . The mounted parts comprise a face plate 14 and a lip attachment 16 . The face plate 14 is attached by flat-head screws 17 to the lip attachment 16 . The backbox assembly 20 is attached to the lip attachment 16 by button-head screws 18 , and the face plate is attached to a door frame (not shown) by additional flat-head screws 19 .
[0021] The backbox assembly 20 includes a keeper 12 and wires 25 for connection to a power source to power the electric strike 10 .
[0022] The electric strike 10 is mounted to a vertical edge of a door frame (not shown). The electric strike 10 can preferably, without modification, be readily mounted to a door frame with either left or right opening doors. The door (not shown) will have conventional lock hardware including a latch set with a latch bolt or deadbolt that extends from the door edge for engagement with the electric strike 10 . The electric strike 10 is positioned in a cut out through a door frame face and jam face of the doorframe.
[0023] Referring now to FIG. 2, the backbox assembly 20 is shown in an exploded form. The backbox assembly 20 has a strike or backbox frame 21 that constitutes principal support structure of the strike. The backbox frame 21 defines a jam face opening 27 that, after assembly, is oriented within a door frame toward a door and generally coplanar with a jam face of the door frame. The jam face opening 27 forms a locking cavity whereby the bolt of a lock on the door can be captured to lock the door, or swing there through to allow opening of the door.
[0024] Locking and Unlocking
[0025] Referring again to FIG. 2 the backbox assembly 20 contains three main locking components. These components are a keeper 12 , lock arm 22 and lock link 24 . These components interact to provide the strike with locking and unlocking capabilities. The locking and unlocking of these three components is controlled by a fail-safe/fail-secure mechanism comprising an actuator 30 , and a solenoid assembly shown generally at 41 , solenoid attachment 44 , solenoid 40 with a plunger 42 .
[0026] In operation of the components shown in FIG. 2, electrical power is supplied to or cut off from the strike 10 to lock or unlock the keeper 12 depending on the user's preferred mode of operation. This either retains a latch on the door lock in the locking cavity or allows the latch to rotate the keeper and open the door. The user specifies which mode the strike is to be in by setting the mechanism appropriately to take constant supply of power or no power at all to lock or unlock the door.
[0027] Locking is accomplished by the respective orientation of the three main locking components contained in the backbox assembly 20 . Referring to FIGS. 2 and 3 these components are shown and, in FIG. 3, the components are shown in a locked position. The keeper 12 rotates or swivels about a keeper pin 15 oriented along the X axis (as shown in FIG. 2) of the assembly. The keeper pin 15 is not visible in FIG. 2 but is shown in FIGS. 3, 4 and 5 . Referring again to FIGS. 2 and 3 the lock arm 22 rotates about the lock pin 28 oriented along the Y axis (as shown in FIG. 2) of the assembly. The lock link 24 pivots about its own pin 29 , also oriented to swivel or rotate along the Y axis. The lock arm 22 blocks the keeper's rotation and a lock link 24 blocks the lock arm's rotation when the strike is in its locked position. The unlocked position occurs when the keeper 12 and the lock arm 22 are allowed to rotate about their respective axes.
[0028] Referring now to FIGS. 4 and 5, a portion of the backbox assembly 20 is shown in an unlocked position. In FIG. 5, the lock arm 22 is shown rotated away from the keeper 12 which permits the keeper 12 to rotate about its keeper pin 15 . This unlocked position is accomplished by rotating the lock link 24 with the fail-safe/fail-secure mechanism thus unblocking the lock arm 22 .
[0029] Fail-safe and Fail-secure Modes
[0030] The fail-safe/fail-secure mechanism controls the locking and unlocking of the lock link 24 and thereby the locking and unlocking of the strike 10 . Actuation of the lock link is directly controlled through an actuator 30 . The actuator 30 also controls the fail-safe (FS) and fail-secure (FSE) interchangeability of the strike 10 . The actuator 30 is shaped as a pivoting arm and has two bosses 31 and 32 (best shown in FIG. 8). The two bosses are provided on opposite sides of the actuator 30 . The actuator 30 also has a slot 33 located at one end of the actuator 30 opposite the end upon which boss 31 is located. Referring now to FIGS. 4, 6, 7 , and 8 it can be seen how the slot 33 interacts with a lock link actuator pin 35 on the lock link 24 . When the actuator 30 is pivoted or rotated, the lock link is pivoted or rotated to block or unblock the lock arm 22 when voltage is supplied to the solenoid 40 . When the strike 10 is in the FSE or FS mode, one boss on the actuator pivots about a respective FSE hole 49 or FS hole 48 on the separator plate 26 , and the other boss on the actuator 30 interfaces with the solenoid attachment 44 . The solenoid plunger 42 is attached to a solenoid attachment 44 providing the necessary physical motion from the solenoid 40 . Therefore, when the solenoid plunger 42 is pushed in or out this operates the solenoid attachment 44 which ultimately causes rotation of the lock link 24 . Correspondingly rotation of the lock link 24 blocks or unblocks movement of the lock arm 22 .
[0031] It is been stated previously that an object of this invention is to facilitate simple and easy changeover from fail-secure to fail-safe mode or vice versa. Referring now to FIG. 2 the strike 10 can be changed from fail-secure to fail-safe mode by removing backplate screws 47 from the back plate 50 on the backbox assembly 20 . The solenoid 40 along with the plunger 42 , plunger spring 43 , and solenoid attachment 44 is removed by lifting it along the Y axis. The actuator 30 is then rotated 180°, or turned over, and replaced so that the boss that was in a solenoid attachment hole 45 is now inserted into the fail-safe hole 48 in the separator plate 26 . The lock link pin 29 is again located in the actuator slot 33 . The solenoid assembly is replaced in the backbox assembly 20 , oriented as before except that the solenoid attachment hole 45 is now oriented over the available boss 32 on the newly available side of the actuator 30 . This boss 32 was previously located in the fail-secure bole 49 in the separator plate 26 . The back plate 50 and screws 47 are then replaced to complete the backbox assembly.
[0032] Changing from fail-safe to fail-secure mode is done in the same manner. However, an actuator boss 31 is inserted in the fail-secure hole 49 on the separator plate 20 , and the solenoid attachment hole 45 is oriented over the remaining actuator boss 32 . The actuator 30 can be configured in different embodiments and still perform the functions described.
[0033] This unique design of the actuator 30 and its ability to interact with the solenoid attachment 44 , separator plate 26 and lock link 24 ultimately provides a very simple and efficient mechanism that permits easy changeover between fail-secure and fail-safe mode while the strike is in the field. This changeover is done in a manner that is repeatable without destruction of the mechanism. The ability to change from fail-safe to fail-secure modes and vice versa quickly is a main feature of this invention. This change can be made quickly because of the accessibility to the fail-safe fail-secure mechanism. It requires minimal part removal, and the simplicity in which the mechanism can be interchanged involves only one part reorientation. The user can reduce installation time and complexity as a result. This strike 10 allows the user to inventory only one strike that handles fail-safe and fail-secure job requirements instead of two different strikes or mechanisms.
[0034] Many existing products in this market require multiple parts to be removed for interchanging between fail-safe and fail-secure modes. Other products have only one mode of operation, and it must be specified when ordering the strike from the factory. The present invention provides a complete package of field-selectability to the end user without the common disadvantages.
[0035] Preferred embodiments of the present invention have been illustrated and described. It is to be recognized that modifications will be well within the ability of those skilled in the art. Therefore, the appended claims are intended to cover any and all modifications which fall within the scope of the invention.
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An electrically controlled strike including a strike frame; a keeper carried by said strike frame for movement when released allowing door opening and adapted to receive and resist door opening prior to keeper movement; an electrically powered solenoid carried by said frame; means operatively connected between the solenoid and the keeper for causing the keeper to assume a fail-safe condition allowing keeper movement when said solenoid is unpowered or alternatively a fail-secure condition preventing keeper movement when said solenoid is unpowered; the two conditions being selected by repositioning an actuator.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to portable decks and porches, and more specifically to collapsible porches and decks which, while they include the means for holding them sturdy and stable when set up as a porch or deck, also include means for collapsing them so as to create a very neat and compact package which requires a relatively small area for storage.
2. Description of the Prior Art
Past inventions have included collapsible stages, collapsible camping units and collapsible tables, each designed for different purposes and each designed to provide a compact, collapsible unit. While inventors in the past have directed their efforts toward creating collapsible units which might be easily stored, none of the prior art of which applicant is aware has taught a collapsible porch or deck having the unique features as taught by the present invention
SUMMARY OF THE INVENTION
The present invention consists of a collapsible porch having a platform which includes a surface which is easily removed and a frame structure which collapses into a small area for compact storage. The collapsible porch further includes legs, rails and a stair system, each collapsible but extremely sturdy when fully assembled. The collapsible porch includes adjustability to allow adjustment to different heights and individually adjustable feet and legs so that the collapsible porch can be adjusted to the terrain when used on uneven ground.
One of the objects of the present invention is to provide a collapsible porch which is easily assembled without the use of an excessive number of tools and which, when properly assembled, provides an extremely stable porch for use with campers, camping trailers and the like.
Anotner object of the present invention is to provide a collapsible porch which can be folded into an extremely compact unit so that it can be stored in a small area and transported in a camper, camping trailer or the like without undue restriction of the movement of the individuals utilizing the camper or camping trailer.
A further object of the present invention is to provide a collapsible porch which includes means for adjusting its legs to match different terrains.
Another object of the present invention is to provide a collapsible porch which, because of its unique rail arrangement, facilitates the stable positioning of the stairs and rails to provide ingress and egress parallel or perpendicular to the camper or camping trailer with which it is being used.
The foregoing objects, as well as other objects and benefits of the present invention, are made more apparent by the descriptions and claims which follow.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the collapsible porch showing its structure and how it is utilized with a camper, camping trailer or the like.
FIG. 1A is an expanded, exploded view of the encircled area designated lA in FIG. 1 showing the method of connecting and adjusting the feet to adjust the length of the legs.
FIG. 1B shows the foldable floor unit for use with the collapsible porch.
FIG. 2 is a perspective view showing the collapsible porch oriented differently with respect to the door of a camper or camping trailer.
FIG. 3 is a perspective view showing the frame structure of the platform and leg sections of the collapsible porch and showing the movements involved in folding the and leg structure.
FIG. 4 is an expanded perspective view of the encircled area 4 of FIG. 2 showing the structure of the stairway portion of the collapsible porch.
FIG. 5 is a cross-sectional view taken from the perspective of lines 5--5 of FIG. 4 showing the structure employed in attaching the stairway portion of the collapsible porch to the platform and leg structure of the collapsible porch.
FIG. 6 is a top view of the platform and leg structure of the collapsible porch taken along lines 6--6 of FIG. 3 and showing the platform structure in fully folded position.
FIG. 7 is an expanded view of the encircled area 7 of FIG. 2 showing how the rail structure attaches to the platform and leg structure of the collapsible porch.
FIG. 8 is an expanded assembly view of the encircled area 8 of FIG. 2 showing how the rail structure is assembled and positioned with respect to the platform and leg structure of the collapsible porch.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 of the drawings is a perspective view of the collapsible porch 10 showing it positioned against door 86 for use with living quarters 11 consisting generally of a camper or camping trailer or the like. Specifically, collapsible porch 10 includes a platform and leg structure which includes rods 59 and 60, rods 44 and 45, which are hinged together by hinge 37, and rods 46 and 47, which are hinged together by hinge 38. Legs 20, 21, 22 and another leg 52, not shown in FIG. 1, are attached to the platform and leg structure 85 to support it in an upright position as shown in FIG. 1. A floor section consisting of floor pieces 39 and 4 and a floor section consisting of floor pieces 41 and 42, each constructed of metal or wood sheeting or comparable materials, are positioned atop the platform and leg structure 85 to create a solid floor. Rails 27 and 28 are provided to ensure safety of individuals using the collapsible porch 10 and are attached to the platform and leg structure 85 by rods 25 and 26 and rods 23 and 24 respectively. A stairway section 12 consisting of tread units 13 and 14 attached to rods 33 and 34 and legs 35 and 36, together with stair rails 29 and 30, is attached to the platform and leg structure 85 as shown. Feet 15 are provided at the base of each of legs 20, 21, 22, 35, 36 and 52 to provide a stable base of support for the collapsible porch 10. FIG. lA, which is an expanded view of the encircled area lA of FIG. 1, shows the attachment of foot 15 to leg 20. Foot 15 includes an upright extension 16 which fits inside leg 20, which is generally structured of hollow rod and is attached to leg 20 by pin 19, which extends through one of holes 18 in leg 20 and hole 17 in extension 16 to attach foot 15 to leg 20. Construction of the leg and foot arrangement of FIG. lA is typical of each of legs 20, 21, 22, 35, 36 and 52 with feet 15. The units used to create the floor of collapsible porch 10 are shown in FIG. lB. Two floor units are utilized: a floor unit consisting of floor pieces 39 and 40, hinged together by hinges 80, and a second floor unit consisting of floor pieces 41 and 42, hinged together by hinges 80, are positioned on rods 44, 45, 46, 47, 59 and 60 to form the floor of collapsible porch 10.
FIG. 2 of the drawings shows collapsible porch 10 of FIG. 1 in a different configuration, positioned so that it provides ingress and egress parallel to door 86 of living quarters 11. Collapsible porch 10 is here turned 90 degrees, but rail 28 has been removed so that collapsible porch 10 interfaces properly with door 86, and rail 43 has been positioned between rods 23 and 26 to ensure safety. The positioning of leg 52 is also shown in FIG. 2, and the stairway construction is further illustrated.
FIG. 3 is a perspective view of the platform and leg structure 85 of collapsible porch 10. Rods 59 and 60 are substantially rigid, but are attached together by the combination of rods 46 and 47 and rods 44 and 45 to form a collapsible unit. Rod 45 is attached to rod 59 by hinge 48, and to rod 44 by hinge 37. Rod 44 is attached to rod 60 by hinge 49. Rod 47 is attached to rod 59 by hinge 50, and to rod 46 by hinge 38. Rod 46 is attached to rod 60 by hinge 51. Thus, as hinges 38 and 37 are pushed toward each other as shown in FIG. 3, rods 59 and 60 are pulled together, ultimately folding into a compact unit as shown in FIG. 6 of the drawings. In order to further increase the ease of storage of collapsible porch 10, legs 21 and 22 are attached to rod 60 by hinges 73 and 72 respectively so that they fold along arrows A and B to the position shown as 21' and 22', and ultimately up against the bottom surface of rod 60. Legs 52 and 20 are similarly attached to rod 59 so that they fold up against the bottom surface of rod 59 to make a compact, foldable unit.
FIG. 4 is an expanded perspective view of the encircled area 4 of FIG. 2. The tread units 13 and 14 of the stairway section 12 of collapsible porch 10 are positioned atop stair tread frames 53 and 54. Stair tread frame 53 is attached to leg 36 by pin 56, which extends through holes 58 of leg 36 into stair tread frame 53, and to rod 33 by pin 55, which extends through a hole in rod 33 and into stair tread frame 53. Stair tread frame 54 is held in position by pin 55, which extends through hole 57 of rod 33 into stair tread frame 54, and pin 56, which extends through a hole in leg 22 and into stair tread frame 54 to hold it rigid during use. Feet 15, which are attached to legs 22 and 36 by pins 19, are adjustable by the positioning of pin 19 in the desired holes 18, which allows vertical positioning of feet 15 with respect to the bottom of legs 22 and 36. With the stair tread frames 53 and 54 and the rest of the stairway section 12 installed together as a unit, the stairway section 12 is attached to the platform and leg structure 85 and the rail structure of collapsible porch 10. The attachment of the stairway section 12 to the rest of the structure of collapsible porch 10 is shown more clearly in FIG. 5 of the drawings.
FIG. 5 is a cross-sectional view of a portion of the stairway section of collapsible porch 10 taken along lines 5--5 of FIG. 4, but with part of rod 33 cut out. The attachment of rod 33 to leg 36 and leg 22 is typical of the installation of stair rails 29 and 30 to rods 24 and 25 and legs 35 and 36, and the attachment of rod 34 to leg 21 and leg 35. Specifically, rod 33, which extends between leg 22 and leg 36, includes extensions 63 and 64 on its ends. Leg 22 has a receptacle 61 with a hole 68 therein, and leg 36 has a receptacle 62 with a hole 69 therein. With rod 33 positioned as shown in FIG. 5 above receptacles 61 and 62, extensions 63 and 64 of rod 33 can be slid into holes 68 and 69 of receptacles 61 and 62 respectively. Once in position, legs 22 and 36 are held substantially rigidly with respect to each other.
FIG. 6 of the drawings is a top view of platform and leg structure 85 taken along lines 6--6 of FIG. 3, but in a fully folded position. Rods 44 and 45 fold on hinge 37 to be substantially flush against each other, and fold on hinges 48 and 49 to be substantially flush against rods 59 and 60. Rods 46 and 47 fold on hinge 38 to be substantially flush against each other, and on hinges 50 and 51 to be substantially flush against rods 59 and 60. When folded as here shown, and with legs 20, 21, 22 and 52 folded against the bottom surfaces of rods 59 and 60, platform and leg structure 85 forms a substantially rectangular compact unit ready for storage. Rods 59 and 60 include holes 74, 75, 76 and 77 positioned therein and extending therethrough so that, when legs 20, 21, 22 and 52 are constructed of hollow rod as is shown in FIG. 7 of the drawings, the rods 23, 24, 25 and 26, which are utilized to support rails 27, 28 and/or 43, slide through holes 74, 75, 76 and 77 into the interior of the legs 20, 21, 22 and 52, increasing the structural integrity of collapsible porch 10.
FIG. 7 is an expanded view of the encircled area 7 of FIG. 2 more clearly showing how rod 26 attaches to leg 52. Specifically, rod 26 slides through hole 76 in rod 59 and into the hollow interior of leg 52 to substantially rigidly position rod 26 and leg 52 with respect to rod 59. The extension of rod 26 through hole 76 in rod 59 and into leg 52 minimizes the likelihood that leg 52 will fold on hinge 82 against rod 59 at an inopportune time. Rod 26 is held in vertical position by the extension of pin 79 through one of holes 78. Thus, rod 26 butts against pin 79. Multiple holes 78 are provided to facilitate vertical adjustment of rod 26 and the entire hand rail system used with collapsible porch 10. The structure of rod 26 and leg 52 is typical for each of the rods 23, 24, 25 and 26 and each of the legs 20, 21, 22 and 52. While the attachment of rod 47 to rod 59 is not shown, the positioning of hinge 50 to allow attachment of rod 47 is shown.
FIG. 8 of the drawings is an expanded assembly view of encircled area 8 of FIG. 2. Rail 27 includes a hollow receptacle 70 designed to mate with rod 26 to hold rail 27 securely in position with respect to rod 26, but rail 27 further includes a receptacle 66 with a hole 67 therein attached to the side of rail 27. While such is not specifically shown in this view, rail 27, as well as rail 28, has a second hollow receptacle 70 positioned at the end opposite that shown here so that, when rail 27 is positioned, receptacle 70 and a substantially identical receptacle at the opposite end mate with rods 25 and 26 to position rail 27 as shown in FIG. 1 of the drawings. The structure of rail 28 is substantially identical to that of rail 27 except for receptacle 66, which is not included on rail 28. A special rail 43 is provided for use when collapsible porch 10 is oriented as shown in FIG. 2 of the drawings. In this circumstance, because rail 28 is not usable in the position in which rail 43 is utilized in FIG. 2, rail 43, which includes an extension 65 designed to fit into hole 67 of receptacle 66, is provided. A receptacle 71, substantially identical to receptacle 70, is provided and mates with upright rod 23 in substantially the same manner as that in which receptacle 70 mates with rod 26.
While the rods and rails here utilized are constructed generally of hollow metal rod, and while specific means of attaching parts to one another are here disclosed, any acceptable material and/or means of attachment can be used to accomplish construction of the collapsible porch 10.
Although the foregoing description of the invention has shown a preferred embodiment using specific terms, such description is presented for illustrative purposes only. It is applicant's intention that changes and variations may be made without departure from the spirit or scope of the following claims, and this disclosure is not intended to limit applicant's protection in any way.
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A portable collapsible porch is provided for use with campers, camping trailers and the like which includes a foldable platform structure and collapsible legs, stairway and protective rail structure, thereby requiring minimal space for storage and transportation, and further includes adjustable legs to facilitate use in uneven terrain.
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FIELD OF THE INVENTION
The invention relates to a process and an apparatus for producing high-pressure and superheated steam by means of hot reaction gases from a gas generator in which coal or carbon containing materials are gasified.
BACKGROUND OF THE INVENTION
Description of the Prior Art
According to processes known until now, the reaction gases, which accumulate in a gas generator lined with brick after termination of the gasification reaction of coal or carbon containing materials, are fed to a waste heat system connected at the outlet side of a pressure vessel, saturated steam preferably being produced in the waste heat system. The pressure stage of this known waste heat system in the form of a water-tube or fire-tube boiler is generally between 40 and 120 bar. The gas produced in this way is utilized within a larger process or within several process cycles in which the gas generator and the waste heat system are frequently connected in series with a chemical plant in which the generated synthesis gas is further processed.
When using gasification reactors and waste heat systems in connection with steam generators, the live steam conditions produced by the waste heat system, however, are essentially greater than in the above mentioned known waste heat system. In this process it concerns a connection between a known steam turbine process and a gas turbine process, in which there is a special advantage in an essential increase of efficiency. If a gas generator with a waste heat system is integrated in such a combination process, there is, regarding the utilization of waste heat to generate steam, a requirement to produce high-pressure, superheated steam which can be supplied to the or several steam turbine(s) together with the steam generated in a steam generator block of conventional design. This may be effected in the intermediary or end stage. In the course of further development, the pressures and temperatures of the operating media are very considerably increased during generation of high-pressure and superheated steam in power plant processes. In order to obtain a high efficiency, the power plants are in most cases operated with live steam conditions of more than 530° C. and pressures of more than 200 bar. The live steam generated in a waste heat system of a coal gasification plant therefore must have the same steam parameters in this combination process.
BRIEF SUMMARY OF THE INVENTION
It is therefore an object of the invention to provide a process and to suggest an apparatus, by means of which high-pressure, superheated live steam can be generated in a very simple and economical manner by means of hot, dust laden reaction gases of a gas generator having a temperature up to 550° C. and a below or super critical pressure.
According to the invention there is provided a process for producing high-pressure and superheated steam by means of hot reaction gases of a gas generator in which coal or carbon containing materials are gasified, characterized in that the production of the high-pressure, superheated steam is effected in the gas generator and in a waste heat system.
According to a preferred embodiment of the invention, the high-pressure, superheated steam is generated in the gas generator with waste heat system in at least two successive stages, whereby the steam is generated in the first stage in a radiation vaporizer and in a vaporizer located behind the reactor brick lining, and subsequently in a second stage flows through a radiation superheater. In certain loading conditions the steam is already slightly superheated in the vaporizer behind the reactor brick lining.
In another preferred embodiment of the invention the radiation vaporization is effected in several stages, preferably in two stages.
Furthermore, it is advantageous if a further superheating stage, preferably a convection superheating stage, is connected as an end stage at the outlet side of the radiation superheater in the gas generator.
In order to separate from the steam the liquid or the water carried along with the steam, in a further embodiment of the invention the high-pressure steam leaving the first stage is passed over a water separator before it is passed to the radiation superheater in the second stage. This manner of operation applies to the partial loading region. In the loading region 50-130%, the steam generator can be operated once-through in the waste heat system, and in the loading region <50%, in forced rotation.
In yet a further preferred embodiment of the invention a pressure resistant valve is provided on the side of steam-water between the vaporizer and the separating vessel. This valve enables the vaporizer to be operated supercritically. Any steam pressure can be adhered to in the superheating stages.
In order to keep reaction gases of the gas generator free from gasification residues, in a further preferred embodiment of the invention the reaction gases of the gas generator are substantially freed from solid before traversing the end stage in the form of a convection superheater.
In still a further preferred embodiment of the invention the heating surfaces are subjected to a mechanical cleaning of dust. The cleaning of the heating surfaces may be effected in a simple manner by means of a conventional mechanically or pneumatically operated beating device.
BRIEF DESCRIPTION OF THE DRAWINGS
Further details, features and advantages of the invention are apparent from the following description of the process variants with reference to the drawings.
FIG. 1 is an arrangement according to the invention of a gas generator with waste heat system and one-stage radiation vaporizer, and
FIG. 2 is an arrangement according to the invention of a gas generator with waste heat system and two-stage radiation vaporizer and pressure resistant valve.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
As can be seen in FIG. 1, feed water is preheated through a pressure line 1 to generate steam in a heat-exchanger F in the form of a convection preheater located in a pressure vessel 2, and is supplied to a radiation vaporizer A disposed in a gas generator 4 through a pressure line 3, where it vaporizes by means of hot reaction gases which are produced by gasification of coal or carbon containing materials. The feed water which is vaporized in the radiation vaporizer 4 at high pressure and high temperature leaves in the form of superheated steam after traversing vaporizer B located behind the brick lining of the gas generator 4. This superheated steam is fed to a separating vessel C through a pressure line 5, in which vessel separation of water carried alongwith the steam takes place for low-power operation. After traversing the separating vessel C which acts as a separator, the high-pressure, superheated steam arrives through a further pressure line 6 in a radiation superheater D disposed below the radiation vaporizer A. The radiation superheater D is connected on the side of the process gas at the outlet side of the radiation vaporizer A. The radiation superheater D is provided with mechanical cleaning devices. A further pressure line 7 passes the high pressure, superheated steam to a second superheating stage E. The end stage E is provided in the vessel 2 in the form of a convection heating surface and is connected in series with the feed water preheater F on the side of the process gas. The convection superheater E is provided with pneumatic beating devices (not shown in the drawing) which enable cleaning.
The high-pressure superheated steam generated in the convection superheater E is discharged for further utilization through a connected pressure line 8 at a temperature of about 550° C. and a pressure of about 185 bar, for example to drive steam turbines.
In the process of the invention, reaction gases having a temperature of about 1500° C. are produced in the gas generator 4 by means of coal or carbon containing residues. After traversing the radiation vaporizer A and the radiation superheater D they still show a temperature of about 800° C. To control the high heat flow densities at the outlet of the radiation chamber 9, it is necessary that the reaction gases in this region are cooled by means of a further heating surface. The reaction gas leaving the gas generator 4 through the processing gas line 10 is subjected in the pressure vessel 2 to a gas cleaning 11 before it traverses the convection superheater E. It is then substantially freed from solids, for example by means of a cyclone separator.
As shown in FIG. 2, according to the present invention it is also possible, in the gas generator 4 after the reaction chamber, to provide the first portion of the radiation cooler in the form of a vaporizer G, and the second portion in the form of a superheater D above which the radiation vaporizer A is then disposed. Moreover, the radiation vaporizer may have any number of stages. Also, according to FIG. 2 a pressure resistant valve 12 is incorporated in the pressure line 5 in order to be able to operate the vaporizer supercritically and the superheater with any pressure.
In order to achieve uniform heating, the heating surfaces are preferably coiled. From a certain inclination of the vaporizer tubes, it is required to operate the vaporizer with supercritical pressure. In the vaporizer region, the separation process, and the different heat transers to the inside of the tube associated therewith, are counteracted in this manner.
Heating surfaces are subjected to mechanical dust cleaning. A radiation vaporizer and radiation super heater comprise extruded Cr/Ni fin tubes. The gas generator 4 is in a pressure vessel; a fire-resistant packing mass is disposed between the cylindrical heating surfaces and pressure vessel.
The gas generator 4 includes a gasifier and, near the latter, a brick lining support comprising cooling elements that on the side of steam and water are integrated in a once-through circulation.
The gas generator 4 includes a reactor having a brick lining behind which is disposed a gastight vaporizer heating surface that, even when the brick lining fails, enabls safe operation of the reactor, thus increasing operating time.
The present invention is, of course, in no way restricted to the specific disclosure of the specification and drawings, but also encompasses any modifications within the scope of the appended claims.
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With a process for producing high-pressure superheated steam via hot reaction gases of a gas generator, in which coal or carbon containing materials are gasified, the production of the high-pressure superheated steam is effected in the gas generator and in a waste heat system. The gas generator preferably is provided with at least two integrated vaporizers, especially a radiation vaporizer and a radiation vaporizer and a radiation superheater.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional Application No. 60/368,491, filed Mar. 28, 2002.
TECHNICAL FIELD
[0002] The present invention relates to emulsion compositions which can uniformly deposit insoluble solid particles upon a substrate. Particularly, the present invention relates to pigmented emulsion cosmetic compositions which provide a natural appearance to the skin upon application. More particularly, these cosmetic compositions are formulated such that agglomeration of the pigment in the product and upon application to the skin is minimized.
BACKGROUND OF THE INVENTION
[0003] Foundation products are typically applied to the entire face to mask perceived imperfections in skin texture (e.g., fine lines and wrinkles), pigmentation or vascularization. It is desirable for foundations to mask these imperfections and yet still allow for a natural appearance of the skin. In other words, consumers want good coverage from a foundation product, but do not want the appearance of too much make-up, e.g., a cakey appearance.
[0004] Pigmented oil-in-water and water-in-oil emulsion foundations are a popular type of foundation product available on the market today. These products are relatively inexpensive and are easy to apply to the skin. Moreover, the pigmented oil-in-water or water-in-oil emulsion foundations lend themselves to variation in pigment type and level to give different degrees of color coverage and albedo of the face.
[0005] It is believed, however, that, in order to minimize the appearance of fine lines and wrinkles and to avoid a cakey appearance when utilizing a foundation product, it is important to deposit the pigment from the foundation product uniformly on the skin. Unfortunately, the tendency of the pigment is to agglomerate (i.e., flocculate) in the foundation product and, upon application of the foundation product to the skin, to either collect in the fine lines and wrinkles or agglomerate on the skin, thereby accentuating, rather than minimizing, the appearance of the fine lines or wrinkles, and further delivering a cakey, unnatural appearance to the skin.
[0006] Preventing agglomeration or flocculation of the pigment both in a foundation product and upon its application to the skin can be very difficult. One way to improve the stability of the pigments in foundation products is to “coat” the pigment, e.g., by adsorbing certain materials onto the surface of the pigment, wet ball milling or plasma treatment. See, e.g., Driscoll, P., “Treated Pigments in Decorative Cosmetics”, Cosmetics and Toiletries , Vol. 104 (July 1989), pp 43-45. For example, foundation and other personal care products containing hydrophobically- or hydrophilically-coated pigments are known in the art. (See, for example, Lee, J. et al., “Preparation of Ultra Fine Fe 3 O 4 Particles by Precipitation in the Presence of PVA at High pH”, J. Colloid Interface Sci., 177, p. 490 (1996) and European Patent Application 504,066, published Mar. 13, 1992). There is, however, an ongoing need for cosmetic foundations that exhibit lesser agglomeration of pigments in the product itself and when applied to skin. More importantly, there is a need to provide products that meet consumer needs with respect to the natural appearance of the skin when the product is applied.
[0007] It has now surprisingly been found that foundation products, wherein agglomeration of the pigment contained therein is minimized, can be formulated using the technology hereinafter described. Moreover, when the foundation products of the present invention are applied to the skin, the pigment remains essentially unagglomerated and is therefore capable of being uniformly deposited on the skin. Accordingly, good coverage of the skin and a natural appearance of the skin is provided. This is a surprising development, given that the use of oppositely charged particles in cosmetic formulations is typically avoided due to interactions which create negative effects.
[0008] It has also now been surprisingly found that products useful in fabric care products, home care products, diapers, incontinence articles, feminine care products, pharmaceuticals, oral care products, antiperspirants, deodorants, personal cleansing products, skin care products and hair care products, wherein agglomeration of the composition contained therein is minimized, can be formulated using the technology hereinafter described. Moreover, since the claimed composition remains essentially unagglomerated, it can also be utilized in the above disclosed consumer fields deposited on a substrate. Accordingly, good coverage of the substrate with the uniformly dispersed composition allows for enhanced improvements in the care of fabrics, skin, hair, and teeth.
SUMMARY OF THE INVENTION
[0009] The present invention relates to a particle stabilizing composition comprising:
[0010] a) an emulsion, comprising from about 1% to about 99%, by weight of the emulsion, of an internal phase and from about 1% to about 99%, by weight of the emulsion, of an external phase;
[0011] b) a charged species that is present in the emulsion; and
[0012] c) charged insoluble solid particles which are dispersed in said emulsion;
[0013] wherein the charged species possesses a charge which is opposed to that of the charged insoluble solid particles and wherein essentially all of the charged species and charged insoluble solid particles accumulate at the interface of the emulsion and wherein Brownian motion is not exhibited by the charged insoluble solid particles.
[0014] In addition to the charged species and particles within the present invention, the composition may also comprise additional charged or even uncharged particulate material dispersed in the emulsion.
DETAILED DESCRIPTION OF THE INVENTION
[0015] The present invention relates to compositions, particularly cosmetic compositions which provide a natural appearance to the substrate to which it is applied (e.g., hair, skin, and/or nails), and especially foundation compositions. In particular, the cosmetic compositions of the present invention are formulated such that agglomeration of an insoluble solid particle in the product and on the skin is minimized. In cosmetic compositions, the insoluble solid particle of the present invention may be a pigment. Using the present invention in foundations, the pigment has a significantly reduced tendency to collect in the fine lines or wrinkles (or otherwise agglomerate on the skin), a cakey appearance is avoided and the skin has a natural appearance. Without being bound or limited by theory, it is believed that as a result of minimizing agglomeration of the pigment, the pigment is uniformly distributed throughout the product and that, upon application to the skin, the pigment in the composition is uniformly deposited on the skin as perceived by the eye. In any event, the distribution of the pigment and/or its appearance on the skin becomes substantially independent of skin topography.
[0016] As used herein, the term “cosmetic compositions” refers to compositions for application to the hair, nails and/or skin, especially the face, which contain at least about 0.01% and up to about 50% of pigment as hereinafter defined. Cosmetic compositions include, but are not limited to, foundations, blush, mascara, eyeshadow, eyeliner, lipstick, nail polish and tinted moisturizers. The invention described herein is particularly suited for foundation compositions. As used herein, the term “foundation” refers to a liquid, solid or semi-solid facial skin cosmetic composition which includes, but is not limited to, lotions, creams, gels, serums, compacts, sticks and pastes all of which may or may not be applied using an applicator, substrate, sponge, a combination thereof or a similar means or some type of mechanical delivery such as air brush, electrostatic spray, a combination thereof or a similar means.
[0017] The benefits of the present invention are most apparent for liquid foundations and solid compact emulsion foundations. As used herein, “liquid foundations” refers to liquid or cream type foundation products which may range from thin liquids which are pourable (i.e., from a bottle) to viscous gels or creams which are often packaged in jars, tubes or pump-type dispensers. Liquid foundations typically have viscosities in the ranges of from about 10 to about 10,000 centipoise measured at a shear rate of 100 l/s. Viscosity can be measured using a typical rotational viscometer such as a Haake RS 100 with 35/1 degree cone and plate geometry or the equivalent thereof. The viscosity is determined on the composition after the composition has been allowed to stabilize following its preparation, generally at least 24 hours under the conditions of 25° C.±1° C. and an ambient pressure and is measured with the composition at a temperature of 25° C.±1° C., after 30 seconds rotation. Liquid foundations are typically applied to the skin by finger.
[0018] As used herein, “solid compact emulsion foundations” means foundations compositions which are made from an emulsion which is gelled to a solid or semi-solid state, for example, by a solid wax-like network, liquid crystals, polymers, surfactant/polymer/protein mixtures, etc.. Due to their solid or semi-solid consistency, solid emulsions are typically characterized by their hardness, which can be measured by their resistance to penetration by a probe or needle which is dropped or pushed into the solidfied composition. Hardness can be measured using typically penetrometers such as a Voland-Stevens LFRA Texture Analyzer available from Texture Technologies Corp. with Stevens probe #TA-PG (5 mm diameter Cylinder) or equivalent thereof. Solid emulsion foundations typically have a hardness in the range of 30-500 grams force as measured as the minimum force required to push a cylinder of 5 mm diameter to a depth of 3 mm into the composition at a speed of 0.2 mm/second. Hardness is determined after the composition has been allowed to stabilize following its preparation, generally at least 24 hours under the conditions of 25° C.±1° C. and ambient pressure and is measured with the composition at a temperature of 25° C.±1° C. Solid emulsion foundations include for example compacts and sticks, and are typically packaged in a compact or plastic cylinder and are typically applied to the skin by finger or sponge applicator. Typically, the foundations are used over a large area of skin, such as the face and neck.
[0019] As used herein, an “emulsion composition” means a composition comprising at least two distinct phases known as the internal phase and the external phase.
[0020] As used herein, the term “internal phase” of the emulsion composition is the phase wherein the material or materials of said phase are dispersed as small particles within another distinct phase of the emulsion composition.
[0021] As used herein, the term “external phase” of the emulsion composition is the phase wherein the internal phase is dispersed within.
[0022] Preferred compositions of the present invention are formulated such that the aqueous phase of the composition (whether as the internal phase or as the external phase) has a pH ranging from about 5 to about 10, more preferably from about 6 to about 8, most preferably from about 6.5 to about 7.5, although the benefits of the invention (natural appearance cosmetics) can be achieved at pHs as low as 2. The cosmetic compositions herein can be applied by any conventional means including, for example, with the fingers, with an applicator such as a brush or a sponge, or via aerolization, including, for example, airbrush or electrostatic spray devices.
[0023] The compositions of the present invention, including the materials contained therein and processes for making them, are described in detail as follows.
[0024] I. Materials
[0025] The compositions of the present invention are comprise the following materials:
[0026] A. The Emulsion
[0027] The compositions of the present invention comprise an emulsion, wherein the internal phase can be a liquid, gas, solid, liquid crystal, gel, or combinations thereof. In preferred embodiments, the emulsion is selected from the group consisting of water-in-oil emulsions, oil-in-water emulsions, water-in-silicone, silicone-in-water, water-in-silicone elastomer emulsions, silicone elastomer-in-water emulsions and combinations thereof. Preferably an oil-in-water or water-in-oil emulsion is used. More preferably, compositions of the present invention comprise water-in-oil emulsions. When the compositions of the present invention are used as cosmetic products, the compositions typically comprise from about 50% to about 99.9%, preferably from about 70% to about 95%, more preferably from about 80% to about 90%, of an emulsion. Solid emulsion compact foundation compositions of the present invention typically comprise from about 50% to about 99.9%, preferably from about 60% to about 99.9%, more preferably from about 70% to about 99.9%, by weight of the composition, of an emulsion. Liquid foundation compositions typically comprise from about 80% to about 99.9%, by weight of the composition, of an emulsion.
[0028] The emulsion may also contain an anti-foaming agent to minimize foaming upon application to a substrate. Anti-foaming agents include high molecular weight silicones and other materials well known in the art for such use.
[0029] Suitable emulsions may have a wide range of viscosities, depending on the desired product form. Exemplary low viscosity emulsions, which are preferred, have a viscosity of about 50 centistokes or less, more preferably about 10 centistokes or less, and most perferably from about 5 centistokes or less.
[0030] The emulsion comprises an internal (i.e., dispersed) phase and an external phase. When water is the internal phase (i.e., the aqueous phase of water-in-oil or water-in-silicone emulsion), the emulsion typically comprises from about 1% to about 99%, preferably from about 15% to about 90%, more preferably from about 40% to about 85%, by weight of the emulsion. When water is the external phase, the emulsion typically comprises from about 1% to about 99%, preferably from about 10% to about 85%, more preferably from about 15% to about 60%, by weight of the emulsion. Highly concentrated emulsions wherein the internal phase comprises a high proportion of the emulsion and wherein the proportion of the external phase is minimized, are very stable and are, therefore, preferred herein.
[0031] The internal phase is typically in the form of droplets which typically range in size from about 0.15 to about 40 microns in diameter, preferably from about 0.20 to about 30 microns and most preferably from about 0.25 to about 20 microns. The particle size of the droplets comprising the internal phase of the emulsion can be determined as described in the “Analytical Methods” section hereinafter.
[0032] It is understood that the oil phase of the emulsions herein (whether as the external phase or as the internal phase) can comprise a wide variety of hydrophobic and other components. Numerous examples can be found in Sagarin, Cosmetics, Science and Technology, 2nd edition, Vol. 1, pp. 32-43 (1972), and Cosmetic Bench Reference, Cosmetics & Toiletries, pp. 1.19-1.22 (1996) herein incorporated by reference. Nonlimiting examples of suitable hydrophobic components for use in the compositions herein include those selected from the group consisting of:
[0033] (i) Mineral oil, which is also known as petrolatum liquid, is a mixture of liquid hydrocarbons obtained from petroleum. See, The Merck Index, Tenth Edition, Entry 7048, p. 1033 (1983) and International Cosmetic Ingredient Dictionary, Fifth Edition, vol. 1, p. 415-417 (1993), which are incorporated by reference herein in their entirety.
[0034] (ii) Petrolatum, which is also known as petroleum jelly, is a colloidal system of nonstraight-chain solid hydrocarbons and high-boiling liquid hydrocarbons, in which most of the liquid hydrocarbons are held inside the micelles or micelle-like self assembled aggregates. See, The Merck Index, Tenth Edition, Entry 7047, p. 1033 (1983); Schindler, Drug. Cosmet. Ind., 89, 36-37, 76, 78-80, 82 (1961); and International Cosmetic Ingredient Dictionary, Fifth Edition, vol. 1, p. 537 (1993), which are incorporated by reference herein in their entirety.
[0035] (iii) Straight and branched chain hydrocarbons having from about 7 to about 40 carbon atoms. Nonlimiting examples of these hydrocarbon materials include dodecane, isododecane, squalane, cholesterol, hydrogenated polyisobutylene, dodecosane (i.e. a C 22 hydrocarbon), hexadecane, isohexadecane (a commercially available hydrocarbon sold as Permethyl® 101A by Presperse, South Plainfield, N.J.). Also useful are the C7-C40 isoparaffins, which are C7-C40 branched hydrocarbons.
[0036] (iv) C1-C30 alcohol esters of C1-C30 carboxylic acids and of C2-C30 dicarboxylic acids, including straight and branched chain materials as well as aromatic derivatives (as used herein in reference to the hydrophobic component, mono- and poly-carboxylic acids include straight chain, branched chain and aryl carboxylic acids). Nonlimiting examples include isononyl isononanoate, methyl isostearate, ethyl isostearate, diisopropyl sebacate, diisopropyl adipate, isopropyl myristate, isopropyl palmitate, methyl palmitate, myristyl propionate, 2-ethylhexyl palmitate, isodecyl neopentanoate, di-2-ethylhexyl maleate, cetyl palmitate, myristyl myristate, stearyl stearate, isopropyl stearate, methyl stearate, cetyl stearate, behenyl behenate, dioctyl maleate, dioctyl sebacate, diisopropyl adipate, cetyl octanoate, diisopropyl dilinoleate.
[0037] (v) Mono-, di- and tri-glycerides of C1-C30 carboxylic acids, e.g., caprylic/capric triglyceride, PEG-6 caprylic/capric triglyceride, PEG-8 caprylic/capric triglyceride.
[0038] (vi) Alkylene glycol esters of C1-C30 carboxylic acids, e.g., ethylene glycol mono- and di-esters, and propylene glycol mono- and di-esters of C1-C30 carboxylic acids e.g., ethylene glycol distearate.
[0039] (vii) Propoxylated and ethoxylated derivatives of the foregoing materials.
[0040] (viii) C1-C30 mono- and poly-esters of sugars and related materials. These esters are derived from a sugar or polyol moiety and one or more carboxylic acid moieties. Depending on the constituent acid and sugar, these esters can be in either liquid or solid form at room temperature. Examples of liquid esters include: glucose tetraoleate, the glucose tetraesters of soybean oil fatty acids (unsaturated), the mannose tetraesters of mixed soybean oil fatty acids, the galactose tetraesters of oleic acid, the arabinose tetraesters of linoleic acid, xylose tetralinoleate, galactose pentaoleate, sorbitol tetraoleate, the sorbitol hexaesters of unsaturated soybean oil fatty acids, xylitol pentaoleate, sucrose tetraoleate, sucrose pentaoletate, sucrose hexaoleate, sucrose hepatoleate, sucrose octaoleate, and mixtures thereof. Examples of solid esters include: sorbitol hexaester in which the carboxylic acid ester moieties are palmitoleate and arachidate in a 1:2 molar ratio; the octaester of raffinose in which the carboxylic acid ester moieties are linoleate and behenate in a 1:3 molar ratio; the heptaester of maltose wherein the esterifying carboxylic acid moieties are sunflower seed oil fatty acids and lignocerate in a 3:4 molar ratio; the octaester of sucrose wherein the esterifying carboxylic acid moieties are oleate and behenate in a 2:6 molar ratio; and the octaester of sucrose wherein the esterifying carboxylic acid moieties are laurate, linoleate and behenate in a 1:3:4 molar ratio. A preferred solid material is sucrose polyester in which the degree of esterification is 7-8, and in which the fatty acid moieties are C18 mono- and/or di-unsaturated and behenic, in a molar ratio of unsaturates:behenic of 1:7 to 3:5. A particularly preferred solid sugar polyester is the octaester of sucrose in which there are about 7 behenic fatty acid moieties and about 1 oleic acid moiety in the molecule. Other materials include cottonseed oil or soybean oil fatty acid esters of sucrose. The ester materials are further described in, U.S. Pat. No. 2,831,854, U.S. Pat. No. 4,005,196, to Jandacek, issued Jan. 25, 1977; U.S. Pat. No. 4,005,195, to Jandacek, issued Jan. 25, 1977, U.S. Pat. No. 5,306,516, to Letton et al., issued Apr. 26, 1994; U.S. Pat. No. 5,306,515, to Letton et al., issued Apr. 26, 1994; U.S. Pat. No. 5,305,514, to Letton et al., issued Apr. 26, 1994; U.S. Pat. No. 4,797,300, to Jandacek et al., issued Jan. 10, 1989; U.S. Pat. No. 3,963,699, to Rizzi et al, issued Jun. 15, 1976; U.S. Pat. No. 4,518,772, to Volpenhein, issued May 21, 1985; and U.S. Pat. No. 4,517,360, to Volpenhein, issued May 21, 1985; all of which are incorporated by reference herein in their entirety.
[0041] (ix) Organopolysiloxane oils. The organopolysiloxane oil may be volatile, non-volatile, or a mixture of volatile and non-volatile silicones. The term “nonvolatile” as used in this context refers to those silicones that are liquid under ambient conditions and have a flash point (under one atmospheric of pressure) of or greater than about 100° C. The term “volatile” as used in this context refers to all other silicone oils. Suitable organopolysiloxanes can be selected from a wide variety of silicones spanning a broad range of volatilities and viscosities. Nonlimiting examples of suitable silicones are disclosed in U.S. Pat. No. 5,069,897, to Orr, issued Dec. 3, 1991, and Cosmetic Bench Reference, Cosmetics & Toiletries, pp. 1.33-1.34 (1996) which are incorporated by reference herein in its entirety. Examples of suitable organopolysiloxane oils include polyalkylsiloxanes, cyclic polyalkylsiloxanes, and polyalkylarylsiloxanes.
[0042] Polyalkylsiloxanes useful in the composition herein include polyalkylsiloxanes with viscosities of from about 0.5 to about 1,000,000 centistokes at 25° C. Such polyalkylsiloxanes can be represented by the general chemical formula R 3 SiO[R 2 SiO] x SiR 3 wherein R is an alkyl group having from one to about 30 carbon atoms (preferably R is methyl or ethyl, more preferably methyl; also mixed alkyl groups can be used in the same molecule), and x is an integer from 0 to about 10,000, chosen to achieve the desired molecular weight which can range to over about 10,000,000. Commercially available polyalkylsiloxanes include the polydimethylsiloxanes, which are also known as dimethicones, examples of which include the Vicasil® series sold by General Electric Company and the Dow Corning® 200 series sold by Dow Corning Corporation. Specific examples of suitable polydimethylsiloxanes include Dow Corning® 200 fluid having a viscosity of 0.65 centistokes and a boiling point of 100° C., Dow Corning® 225 fluid having a viscosity of 10 centistokes and a boiling point greater than 200° C., and Dow Corning® 200 fluids having viscosities of 50, 350, and 12,500 centistokes, respectively, and boiling points greater than 200° C. Examples of suitable alkyl and substituted dimethicones include those represented by the chemical formula (CH 3 ) 3 SiO[(CH 3 ) 2 SiO] x [CH 3 RSiO] y Si(CH 3 ) 3 wherein R is straight or branched chain alkyl having from two to about 30 carbon atoms and x and y are each integers of 1 or greater selected to achieve the desired molecular weight which can range to over about 10,000,000. Examples of these alkyl-substituted dimethicones include cetyl dimethicone and lauryl dimethicone.
[0043] Cyclic polyalkylsiloxanes suitable for use in the composition include those represented by the chemical formula [SiR 2 —O] n wherein R is an alkyl group (preferably R is methyl or ethyl, more preferably methyl) and n is an integer from about 3 to about 8, more preferably n is an integer from about 3 to about 7, and most preferably n is an integer from about 4 to about 6. When R is methyl, these materials are typically referred to as cyclomethicones. Commercially available cyclomethicones include Dow Corning® 244 fluid having a viscosity of 2.5 centistokes, and a boiling point of 172° C., which primarily contains the cyclomethicone tetramer (i.e. n=4), Dow Corning® 344 fluid having a viscosity of 2.5 centistokes and a boiling point of 178° C., which primarily contains a mixture of the cyclomethicone tetramer and pentamer (i.e. n=4 and 5), Dow Corning® 245 fluid having a viscosity of 4.2 centistokes and a boiling point of 205° C., which primarily contains the cyclomethicone pentamer (i.e. n=5), and Dow Corning® 345 fluid having a viscosity of 4.5 centistokes and a boiling point of 217°, which primarily contains a mixture of the cyclomethicone tetramer, pentamer, and hexamer (i.e. n=4, 5, and 6).
[0044] Also useful are materials such as trimethylsiloxysilicate, which is a polymeric material corresponding to the general chemical formula [(CH 2 ) 3 SiO 1/2 ] x [SiO 2 ] y , wherein x is an integer from about 1 to about 500 and y is an integer from about 1 to about 500. A commercially available trimethylsiloxysilicate is sold as a mixture with dimethicone as Dow Corning® 593 fluid.
[0045] Dimethiconols are also suitable for use in the composition. These compounds can be represented by the chemical formulas R 3 SiO[R 2 SiO] x SiR 2 OH and HOR 2 SiO[R 2 SiO] x SiR 2 OH wherein R is an alkyl group (preferably R is methyl or ethyl, more preferably methyl) and x is an integer from 0 to about 500, chosen to achieve the desired molecular weight. Commercially available dimethiconols are typically sold as mixtures with dimethicone or cyclomethicone (e.g. Dow Corning® 1401, 1402, and 1403 fluids).
[0046] Polyalkylaryl siloxanes are also suitable for use in the composition. Polymethylphenyl siloxanes having viscosities from about 15 to about 65 centistokes at 25° C. are especially useful.
[0047] Preferred for use herein are organopolysiloxanes selected from the group consisting of polyalkylsiloxanes, alkyl substituted dimethicones, cyclomethicones, trimethylsiloxysilicates, dimethiconols, polyalkylaryl siloxanes, and mixtures thereof. More preferred for use herein are polyalkylsiloxanes and cyclomethicones. Preferred among the polyalkylsiloxanes are dimethicones.
[0048] (x) Vegetable oils and hydrogenated vegetable oils. Examples of vegetable oils and hydrogenated vegetable oils include safflower oil, castor oil, coconut oil, cottonseed oil, menhaden oil, palm kernel oil, palm oil, peanut oil, soybean oil, rapeseed oil, linseed oil, rice bran oil, pine oil, sesame oil, sunflower seed oil, hydrogenated safflower oil, hydrogenated castor oil, hydrogenated coconut oil, hydrogenated cottonseed oil, hydrogenated menhaden oil, hydrogenated palm kernel oil, hydrogenated palm oil, hydrogenated peanut oil, hydrogenated soybean oil, hydrogenated rapeseed oil, hydrogenated linseed oil, hydrogenated rice bran oil, hydrogenated sesame oil, hydrogenated sunflower seed oil, and mixtures thereof.
[0049] (xi) Animal fats and oils, e.g., lanolin and derivatives thereof, cod liver oil.
[0050] (xii) Other materials: Also useful are C4-C20 alkyl ethers of polypropylene glycols, C1-C20 carboxylic acid esters of polypropylene glycols, and di-C8-C30 alkyl ethers. Nonlimiting examples of these materials include PPG-14 butyl ether, PPG-15 stearyl ether, dioctyl ether, dodecyl octyl ether, and mixtures thereof.
[0051] Preferably, the oil phase comprises silicones. More preferably from about 30% to about 95%, most preferably from about 50% to about 90% of the oil phase is volatile silicones, non-volatile silicones and mixtures thereof. Still more preferably, these silicones are chosen from cyclomethicones, trimethicones, such as methyl trimethicone, dimethicones and mixtures thereof. Thus one of the most preferred oil phases can be considered, and is thus defined as a “silicone” phase. For purposes of the present invention, the terms “water-in-oil emulsions” and “oil-in-water emulsions” encompass water-in-silicone emulsions and silicone-in-water emulsions, respectively.
[0052] B. The Charged Species
[0053] The compositions herein also comprise a charged species that possesses a charge that is opposite that of the charged insoluble solid particles (hereinafter described). This species can be present within the internal phase of the emulsion, at the interface of the emulsion, and/or in the external phase of the emulsion (in bulk). Typically and preferably, a substantial portion of the species are present at the interface of the internal phase and the external phase of the emulsion.
[0054] The species can be for example, hydrogen ion, an acid, a base, an ionic polymer, an ionic surfactant, a lipid or mixtures thereof. Ionic surfactants include cationic, anionic and amphoteric surfactants. Suitable ionic surfactants for use herein are described hereinafter in the subsection entitled “Emulsifiers”.
[0055] In a highly preferred embodiment of the present invention, the species comprises an ionic polymer and is present at the interface between the internal phase and the external phase of the emulsion. In this embodiment of the invention, the emulsion droplet contains an amount of ionic polymer sufficient to cover the surface of the droplet. In particular, the present invention comprises from about 0.1% to about 25%, more preferably from about 0.5% to about 10%, and most preferably from about 0.5% to about 5%, by weight of the composition, of charged species.
[0056] Suitable anionic polymers for use in this embodiment of the invention include, but are not limited to, copolymers of polyacrylate, ammonium polyacrylate, sodium polyacrylate, potassium polyacrylate, ethylene acrylic acid copolymer, hydrolyzed wheat protein polysiloxane copolymer, dimethicone copolyol phosphate, phosphate ester, sodium chondroiton sulfate, sodium hyaluronate, ammonium hyaluronate, sodium alginate, ammonium alginate, diglycol cyclohexanedimethanol isophthalates sulfoisophthalates copolymer and mixtures therof.
[0057] Suitable cationic polymers for use in this embodiment of the invention include, but are not limited to, cellulose derivatives, polysaccharides, chitosan, derivatives of chitosan, chitosan di-pyrrolidone carboxylate, hydroxypropyl chitosan, quaterniums, quaternium-80, quaternium-61, polyquaterniums, hydroxyethyl cetyldimonium phosphate, adipic acid/dimethylaminohydroxypropyl diethyltriamine copolymer, guar hydroxypropyltrimonium chloride, dimethicone copolyol amine(s), amidomethicones, dimethicone salts and mixtures thereof.
[0058] Exemplary lipids include charged lipids which are compatible with skin such as phospholipids, simple carboxylic esters including fats (esters of fatty acids with glycerol), and waxes (sterol esters, esters of fatty acids with alcohols other than glycerol), complex carboxylic esters (glycerophospholipids, glycoglycerolipids, glycoglycerolipid sulfates), complex lipids (lipids containing amides, sphinogolipids, gylcosphingolipids), precursors and derived lipids including phosphatidic acid, bile acids, and bases such as sphinganines, hydrocarbons containing charged moieties (either straight or simple branched chain), lipid vitamins and hormones with multiple functional charged groups, and lipoproteins.
[0059] C. Charged Insoluble Solid Particles
[0060] The composition of the present invention includes charged insoluble solid particles. These charged particles of the present invention preferably have a particle size of less than 200 μm. Typically, the particles will have a particle size from about 0.001 μm to about 50 μm, still more preferably from about 0.005 μm to about 1 μm, and even more preferably from about 0.01 μm to about 0.1 μm in diameter.
[0061] Typical particle levels are selected depending upon the particular purpose of the composition. For example, where it is desired to deliver color benefits, pigment particles conferring the desired hues can be incorporated. Where the desire is to treat or prevent symptoms such as diaper rash, inflammation, and/or other skin disorders, the present invention allows for insoluble skin care agents to be delivered more uniformly to the skin. Determination of the levels and particle types is within the skill of the artisan. Particles that are generally recognized as safe, and are listed in C.T.F.A. Cosmetic Ingredient Handbook, Sixth Ed., Cosmetic and Fragrance Assn., Inc., Washington D.C. (1995), incorporated herein by reference, can be used.
[0062] In the compositions of the present invention, it is preferable to incorporate from about 0.01% to about 80%, more preferably from about 0.1% to about 50%, still more preferably from about 1% to about 30%, and most preferably from about 5% to about 20%, by weight of the composition, of charged insoluble solid particles.
[0063] The particles can be scattering or non-scattering and may or may not impart color. Suitable particles include bismuth oxychloride, titanated mica, fumed silica, spherical silica, polymethylmethacrylate, micronized teflon, boron nitride, acrylate polymers, 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 carbonate, magnesium hydroxide, magnesium oxide, magnesium silicate, magnesium trisilicate, maltodextrin, montmorillonite, microcrystaline cellulose, rice starch, silica, talc, mica, titanium dioxide, zinc laurate, zinc myristate, zinc neodecanoate, zinc rosinate, zinc stearate, polyethylene, 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 particles may be surface treated with lecithin, amino acids, mineral oil, silicone oil, or various other agents either alone or in combination, which coat the powder surface and render the particles hydrophobic in nature.
[0064] Water insoluble solid particles of various shapes and densities are useful. In a preferred embodiment, the particles tend to have a spherical, an oval, an irregular, or any other shape in which the ratio of the largest dimension to the smallest dimension (defined as the aspect ratio) is less than 10. More preferably, the aspect ratio of the particles is less than 8. Still more preferably, the aspect ratio of the particles is less than 5.
[0065] Particles useful in the present invention can be nano, micro, and mixtures thereof, and can be natural, synthetic, or semi-synthetic in composition. Hybrid particles are also useful. Synthetic particles can be made of either cross-linked or non cross-linked polymers. The particles of the present invention can have surface charges or their surface can be modified with organic or inorganic materials such as surfactants, polymers, and inorganic materials. Particle complexes are also useful.
[0066] Non limiting examples of natural particles include various precipitated silica particles in hydrophilic and hydrophobic forms available from Degussa-Huls under the trade name Sipernet. Snowtex colloidal silica particles available from Nissan Chemical America Corporation.
[0067] Examples of synthetic particles include nylon, silicone resins, poly(meth)acrylates, polyethylene, polyester, polypropylene, polystyrene, polyurethane, polyamide, epoxy resins, urea resins, and acrylic powders. Non limiting examples of useful particles are Microease 110S, 114S, 116 (micronized synthetic waxes), Micropoly 210, 250S (micronized polyethylene), Microslip (micronized polytetrafluoroethylene), and Microsilk (combination of polyethylene and polytetrafluoroethylene), all of which are available from Micro Powder, Inc. Other examples include Luna (smooth silica particles) particles available from Phenomenex, MP-2200 (polymethylmethacrylate), EA-209 (ethylene/acrylate copolymer), SP-501(nylon-12), ES-830 (polymethly methacrylate), BPD-800, BPD-500 (polyurethane) particles available from Kobo Products, Inc. and silicone resins sold under the name Tospearl particles by GE Silicones. Ganzpearl GS-0605 crosslinked polystyrene (available from Presperse) is also useful.
[0068] Non limiting examples of hybrid particles include Ganzpearl GSC-30SR (Sericite & crosslinked polystyrene hybrid powder), and SM-1000, SM-200 (mica and silica hybrid powder available from Presperse).
[0069] In one embodiment of the present invention, the particles used in the composition are hollow particles. In a preferred embodiment, the hollow particles are fluid-encapsulated, flexible microspheres. The microspheres are structurally hollow, however, they may contain various fluids, which encompass liquids and gases and their isomers. The gases include, but not limited to, butane, pentane, air, nitrogen, oxygen, carbon dioxide, and dimethyl ether. If used, liquids may only partially fill the microspheres. The liquids include water and any compatible solvent. The liquids may also contain vitamins, amino acids, proteins and protein derivatives, herbal extracts, pigments, dyes, antimicrobial agents, chelating agents, UV absorbers, optical brighteners, silicone compounds, perfumes, humectants which are generally water soluble, additional conditioning agents which are generally water insoluble, and mixtures thereof. In one embodiment, water soluble components are preferred encompassed material. In another embodiment, components selected from the group consisting of vitamins, amino acids, proteins, protein derivatives, herbal extracts, and mixtures thereof are preferred encompassed material. In yet another embodiment, components selected from the group consisting of vitamin E, pantothenyl ethyl ether, panthenol, Polygonum multiflori extracts, and mixtures thereof are preferred encompassed material.
[0070] The particles of the present invention can have surface charges or their surface can be modified with organic or inorganic materials such as surfactants, polymers, and inorganic materials. Particle complexes are also useful. Non-limiting examples of complexes of gas-encapsulated microspheres are DSPCS-I2™ (silica modified ethylene/methacrylate copolymer microsphere) and SPCAT-I2™ (talc modified ethylene/methacrylate copolymer microsphere). Both of these are available from Kobo Products, Inc.
[0071] The surface of the particle may be charged through a static development or with the attachment of various ionic groups directly or linked via short, long or branched alkyl groups. The surface charge can be anionic, cationic, zwitterionic or amphoteric in nature.
[0072] The wall of the particles of the present invention may be formed from a thermoplastic material. The thermoplastic material may be a polymer or copolymer of at least one monomer selected from the following groups: acrylates, methacrylates, styrene, substituted styrene, unsaturated dihalides, acrylonitriles, methacrylonitrile. The thermoplastic materials may contain amide, ester, urethane, urea, ether, carbonate, acetal, sulfide, phosphate, phosphonate ester, and siloxane linkages. The hollow particles may comprise from 1% to 60% of recurring structural units derived from vinylidene chloride, from 20% to 90% of recurring structural units derived from acrylonitrile and from 1% to 50% of recurring structural units derived from a (meth)acrylic monomer, the sum of the percentages (by weight) being equal to 100. The (meth)acrylic monomer is, for example, a methyl acrylate or methacrylate, and especially the methacrylate. Preferably, the particles are comprised of a polymer or copolymer of at least one monomer selected from expanded or non-expanded vinylidene chloride, acrylic, styrene, and (meth)acrylonitrile. More preferably, the particles are comprised of a copolymer of acrylonitrile and methacrylonitrile.
[0073] Particles comprised of polymers and copolymers obtained from esters, such as, for example, vinyl acetate or lactate, or acids, such as, for example, itaconic, citraconic, maleic or fumaric acids may also be used. See, in this regard, Japanese Patent Application No. JP-A-2-112304, the full disclosure of which is incorporated herein by reference.
[0074] Non-limiting examples of commercially available suitable particles are 551 DE (particle size range of approximately 30-50 μm and density of approximately 42 kg/m 3 ), 551 DE 20 (particle size range of approximately 15-25 μm and density of approximately 60 kg/m 3 ), 461 DE (particle size range of approximately 20-40 μm and density 60 kg/m 3 ), 551 DE 80 (particle size of approximately 50-80 μm and density of approximately 42 kg/m 3 ), 091 DE (particle size range of approximately 35-55 μm and density of approximately 30 kg/m 3 ), all of which are marketed under the trademark EXPANCEL™ by Akzo Nobel. Other examples of suitable particles for use herein are marketed under the trademarks DUALITE® and MICROPEARL™ series of microspheres from Pierce & Stevens Corporation. Particularly preferred hollow particles are 091 DE and 551DE 50. The hollow particles of the present invention exist in either dry or hydrated state. The aforesaid particles are nontoxic and non irritating to the skin.
[0075] Hollow particles that are useful in the invention can be prepared, for example, via the processes described in EP-56,219, EP-348,372, EP-486,080, EP-320,473, EP-112,807 and U.S. Pat. No. 3,615,972, the full disclosure of each of which is incorporated herein by reference.
[0076] Alternatively, the wall of the hollow particles useful in the present invention may be formed from an inorganic material. The inorganic material may be a silica, a soda-lime-borosilicate glass, a silica-alumina ceramic, or an alkali alumino silicate ceramic. Non-limiting examples of commercially available suitable low density, inorganic particles are H50/10,000 EPX (particle size range approximately 20-60 μm), S38 (particle size range approximately 15-65 μm), W-210 (particle size range approximately 1-12 μm), W-410 (particle size range approximately 1-24 μm), W-610 (particle size range approximately 1-40 μm), G-200 (particle size range approximately 1-12 μm), G-400 (particle size range approximately 1-24 μm), G-600 (particle size range approximately 1-40 μm), all of which are marketed under the trademarks 3M™ Scotchlite™ Glass Bubbles, 3M™ Zeeospheres™ ceramic microspheres, and 3M™ Z-Light Spheres™ Ceramic Microspheres. Also useful are Silica shells (average particle size 3 μm) available from KOBO Products and LUXSIL™ (3-13 μm mean diameter) available from PQ Corporation.
[0077] Preferably, the wall of the hollow particles useful in the invention are flexible. “Flexible”, as used herein, means that the hollow particles are easy to compress. When pressure is reduced the hollow particles regain their original volume. The flexible hollow particles could alter their shape under an applied stress, or thermal expansion and contraction due to temperature change. Thus, the particles could expand upon heating.
[0078] The particles of the invention may be permeable or non-permeable. “Permeable”, as used herein, means that they permit a liquid or gas to pass through them under given conditions. Preferably, a majority of the particles of the present invention will maintain their structural integrity during normal use of the composition. More preferably, substantially all of the particles maintain their structural integrity during normal use of the composition.
[0079] Prefered particles will also have physical properties which are not significantly affected by typical processing of the composition. Preferably, particles having melting points greater than about 70° C. are used. Still more preferably, particles having a melting point greater than 80° C. are used and most preferrably particles having melting point of greater than about 95° C. are used. As used herein, melting point would refer to the temperature at which the particle transitions to a liquid or fluid state or undergoes significant deformation or physical property changes. In addition, many of the particles of present invention are cross-linked or have a cross-linked surface membrane. These particles do not exhibit a distinct melting point. Cross-linked particles are also useful as long as they are stable under the processing and storage conditions used in the making of the present compositions.
[0080] Because of the interaction between the oppositely charged species present in the emulsion and the insoluble solid particles, essentially none of the charged particles adsorbed at the interface of the internal phase and the external phase are subject to Brownian motion. Thus, the charged particles remain dispersed and are prevented from re-agglomerating in the composition. When the composition is applied to the substrate, the charged insoluble solid particles stay dispersed on the substrate. The term “essentially none” as used herein means less than about 30%, preferably less than about 10%, more preferably less than about 5%.
[0081] Brownian motion can be observed by transmitted light microscopy according to the method set forth hereinafter in the analytical methods section.
[0082] In a preferred embodiment of the present invention, essentially all of the charged species and charged particles accumulate at the interface between the internal phase and the external phase of the emulsion. As used herein, the term “essentially all” means that at least about 70%, preferably at least about 90%, more preferably at least about 95% of the charged pigment particles are accumulated at the interface of the internal phase and the external phase of the emulsion. The accumulation of insoluble solid particles at the interface between the internal phase and the external phase of the emulsion can be observed by light and electron microscopy using the method set forth hereinafter in the Analytical Methods section.
[0083] 1. Charged Pigment Particles
[0084] The charged insoluble solid particles of the present invention may comprise charged pigment particles which may be organic, inorganic, or a mixture thereof. As used herein, the term “pigment” means an insoluble solid particulate material that reflects light of certain wavelengths while absorbing light of other wavelengths, including luminescent solids. Suitable charged pigment particles include organic pigments which are generally various aromatic types including azo, indigoid, triphenylmethane, anthraquinone, 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, titanium dioxide, ultramarine and chromium or chromium hydroxide colors, and mixtures thereof. Useful pigments include, but are not limited to, those which are extended onto inert mineral (e.g., talc, calcium carbonate, clay), or treated with silicone or other coatings (e.g., to prevent pigment particles from re-agglomerating or to change the polarity (or hydrophobicity) of the pigment.
[0085] Pigments are used to impart opacity and/or color to the compositions herein. Any pigment that is generally recognized as safe (such as those listed in C.T.F.A. Cosmetic Ingredient Handbook, 3rd Ed., Cosmetic and Fragrance Association, Inc., Washington D.C. (1982), herein incorporated by reference) can be employed in the compositions herein. Useful pigments include body pigments, inorganic white pigments, inorganic colored pigments, and pearling agents. Also useful herein are pigment and/or dye encapsulates such as nanocolorants and multi-layer interference pigments, such as Sicopearls, both from BASF. Specific examples of suitable pigments include multi-layered effects pigments, lakes, toners, mica, magnesium carbonate, calcium carbonate, magnesium silicate, aluminum magnesium silicate, silica, titanium dioxide, zinc oxide, red iron oxide, yellow iron oxide, black iron oxide, ultramarine, nylon powder, polyethylene powder, methacrylate powder, polystyrene powder, silk powder, crystalline cellulose, starch, titanated mica, iron oxide titanated mica, and bismuth oxychloride. These pigments and powders can be used independently or in combination. Titanium oxide, iron oxides, lakes, toners and mixtures thereof are especially preferred pigments for use herein.
[0086] The pigments are used in a concentration sufficient to provide a pleasing color to the composition in the container in which the cosmetic is sold and to confer the desired coverage and color to the skin when applied. Determination of the specific levels and types of pigment is within the skill of the artisan. The pigments can be used as treated particles or as the raw pigments themselves.
[0087] In order to provide a natural appearance when applied to the skin, the compositions of the present invention suitable for cosmetics will usually contain from about 0.01% to about 50%, preferably from about 1% to about 30%, most preferably from about 5% to about 20%, by weight of the composition, of charged pigment particles.
[0088] The charged pigment particles of the present invention have a primary particle size ranging from about 0.01 μm-200 μm, preferably from about 0.1 μm-100 μm, and more preferably from about 0.05 μm-90 μm. Primary particle size of the charged pigment particles can be determined by using the ASTM Designation E-20-85 “Standard Practice for Particle Size Analysis of Particulate Substances in the Range of 0.2 to 75 Micrometers by Optical Microscopy”, ASTM Volume 14.02, 1993.
[0089] The relative size of the emulsion droplet to that of the charged pigment particles is unimportant so long as the charged pigment particle is not larger than the emulsion droplet. In fact, the benefits of the invention can be achieved even when the emulsion droplets and charged pigment particles form “doublets”, meaning that the emulsion droplet and the charged pigment particle are of the same approximate relative size. The preferred size ratio of emulsion droplet to charged pigment particle ranges from about 1:1 to about 50:1, preferably from about 3:1 to about 30:1, most preferably from about 5:1 to about 15:1.
[0090] As herein before described, the charged pigment particles utilized in the present invention have a charge opposite to the charge of the charged species present in the emulsion. The charge of the pigment particles can be imparted by any conventional means. In a preferred embodiment of the present invention, the pigment particles contain an ionic polymer or ionic surfactant to increase or impart a charge to the pigment particles. This embodiment of the present invention is preferred not only from the standpoint of providing the most uniform coverage of the pigment on the skin, but also from the standpoint of preventing separation or “streaking” of blends of pigments in the product and on the skin. In this embodiment of the invention, the pigment particle contains an amount of ionic polymer sufficient to cover the surface of the particle without excess in bulk.
[0091] Suitable cationic polymers and anionic polymers for use herein are described herein before in section (B) entitled “The Charged Species”.
[0092] The charged pigment materials are available in essentially neat, powdered form, or predispersed in various types of carriers, including but not limited to water, organic hydrophilic diluents such as lower monovalent alcohols (e.g., C 1 -C 4 ) and low molecular weight glycols and polyols, including propylene glycol, polyethylene glycol (e.g., molecular weight 200-600 g/mole), polypropylene glycol (e.g., molecular weight 425-2025 g/mole), glycerol, butylene glycol, 1,2,4-butanetriol, sorbitol esters, 1,2,6-hexanetriol, ethanol, isopropanol, sorbitol esters, butanediol, ether propanol, ethoxylated ethers, propoxylated ethers and combinations thereof. Preferably, the charged pigment materials are predispersed in water, glycerin, butylene glycol, propylene glycol, and mixtures thereof. Examples of charged particulate materials include predispersions of ammonium polyacrylate treated TiO 2 , butylene glycol, water, and ammonium zirconium carbonate, predispersions of chitosan (or a chitosan derivative) treated TiO 2 and butylene glycol, and predispersions of ammonium polyacrylate treated TiO 2 , water, glycerin, and ammonium zirconium carbonate.
[0093] D. Optional Ingredients
[0094] The compositions herein may contain a wide variety of optional ingredients that perform one or more functions useful in products of the type described herein. Such optional ingredients may be found in either the internal phase or the external phase (or any other phase) of the compositions herein. The CTFA Cosmetic Ingredient Handbook , Second Edition (1992) describes a wide variety of nonlimiting cosmetic and pharmaceutical ingredients commonly used in the skin care industry, which are suitable for use in the compositions of the present invention. Examples of these ingredient classes include: abrasives, absorbents, aesthetic components such as fragrances, pigments, colorings/colorants, essential oils, skin sensates, astringents, etc.), anti-acne agents, anti-caking agents, antifoaming agents, antimicrobial agents, antioxidants, binders, biological additives, buffering agents, bulking agents, chelating agents, chemical additives, colorants, cosmetic astringents, cosmetic biocides, denaturants, drug astringents, external analgesics, enzymes, emulsifiers, film formers or materials, e.g., polymers, for aiding the film-forming properties and substantivity of the composition, opacifying agents, other pigments, pH adjusters, propellants, proteins, reducing agents, sequestrants, skin bleaching and lightening agents, skin-conditioning agents (e.g., humectants, including miscellaneous and occlusive), skin soothing and/or healing agents), skin treating agents, structuring agents, organic and inorganic sunscreen agents, thickeners, vitamins and derivatives thereof.
[0095] Nonlimiting examples of optional components include the following:
[0096] 1. Emulsifiers
[0097] The emulsion compositions of the present invention preferably comprise from about 0.1% to about 25%, more preferably from about 0.5% to about 10%, and most preferably from about 0.5% to about 5%, by weight of the composition, of an emulsifier to help disperse and suspend the internal phase within the external phase. Emulsifiers having a hydrophilic-lipophilic balance value (HLB) ranging from about 7 to about 16 are suitable for use in the oil-in-water emulsion compositions described herein. Emulsifiers having a hydrophilic-lipophilic balance value (HLB) ranging from about 1 to about 8 are suitable for use in the water-in-oil emulsion compositions described herein. (See, Wilkinson and Moore, Harry's Cosmeticology, 7th Ed. 1982, p. 738, and Schick and Fowkes, Surfactant Science Series, Vol. 2 , Solvent Properties of Surfactant Solutions , p 607.)
[0098] Emulsifiers for use herein can be selected from the group consisting of anionic, cationic, nonionic, amphoteric, and mixtures thereof. Examples of suitable emulsifiers are set forth in the C.T.F.A. Cosmetic Ingredient Handbook, 3rd Ed., Cosmetic and Fragrance Assn., Inc., Washington D.C. (1982) pp. 587-592; Remington's Pharmaceutical Sciences, 15th Ed. 1975, pp. 335-337; and Cosmetic Bench Reference, Cosmetics & Toiletries, pp. 1.22-1.25 (1996).
[0099] Polymeric ionic surfactants are especially preferred for use as the emulsifier in the oil-in-water emulsion compositions of the present invention. As used herein, the term “polymeric ionic surfactant” refers to charged amphiphilic polymers (i.e., cationic, anionic or amphoteric) which can lower surface tension. It has been found that when polymeric ionic surfactants are employed as the emulsifier in the oil-in-water emulsion compositions herein, that non-agglomeration of the particles in the product and on the substrate is maximized. This occurs when polymeric ionic surfactants are employed as the emulsifier in the oil-in-water emulsions, they coat the emulsion droplet in a manner such that both steric and electrostatic forces work to cause the particles to accumulate at the interface of the internal phase and the external phase of the emulsion. By contrast, when low molecular weight ionic surfactants are employed as the emulsifier in the oil-in-water emulsion compositions herein, they coat the emulsion droplet in a manner such that only electrostatic forces work to cause the particles to accumulate at the interface of the internal phase and the external phase of the emulsion. Likewise, when nonionic surfactants are employed, no electrostatic forces of the surfactant itself promote the accumulation of the particles at the interface of the internal phase and the external phase of the emulsion.
[0100] Cationic surfactants can desirably be employed as emulsifiers in the compositions herein. Useful cationic surfactants include, but are not limited to, alkylamines, alkyl imidazolines, ethoxylated amines, quaternary alkylbenzyldimethylammonium salts, quaternary alkyl betaines, quaternary heterocyclic ammonium salts, quaternary tetraalkylammonium salts and mixtures thereof.
[0101] Specific cationic surfactants useful herein include those disclosed in U.S. Pat. No. 5,151,209, to McCall et al., issued Sep. 29, 1992; U.S. Pat. No. 5,151,210, to Steuri et al., issued Sep. 29, 1992; U.S. Pat. No. 5,120,532, to Wells et al., issued Jun. 9, 1992; U.S. Pat. No. 4,387,090, to Bolich, issued Jun. 7, 1983; U.S. Pat. No. 3,155,591, Hilfer, issued Nov. 3, 1964; U.S. Pat. No. 3,929,678, to Laughlin et al., issued Dec. 30, 1975; U.S. Pat. No. 3,959,461, to Bailey et al., issued May 25, 1976 ; McCutcheon's, Detergents & Emulsifiers , (North American edition 1979) M. C. Publishing Co.; and Schwartz, et al., Surface Active Agents, Their Chemistry and Technology , New York: Interscience Publishers, 1949.
[0102] Anionic surfactants can also be used as emulsifiers in the compositions herein. Useful anionic surfactants include, but are not limited to, acylamino acids and their salts, including acylglutamates, acyl peptides, sarcosinates and taurates, carboxylic acids and their salts, including alkanoic acid and alkanoates, ester carboxylic acids and ether carboxylic acids, phosphoric acid esters and their salts, including acyl isethionates, alkylaryl sulfonates, and sulfosuccinates, and sulfuric acid esters, including alkyl ether sulfates and alkyl sulfates.
[0103] Specific anionic surfactants useful herein include those set forth in U.S. Pat. No. 3,929,678, to Laughlin et al., issued Dec. 30, 1975.
[0104] Amphoteric and zwitterionic surfactants are also useful herein. Examples of amphoteric and zwitterionic surfactants which can be used in the compositions of the present invention are those which are broadly described as derivatives of aliphatic secondary and tertiary amines in which the aliphatic radical can be straight or branched chain and wherein one of the aliphatic substituents contains from about 8 to about 22 carbon atoms (preferably C 8 -C 18 ) and one contains an anionic water solubilizing group, e.g., carboxy, sulfonate, sulfate, phosphate, or phosphonate. Examples are alkyl imino acetates, and iminodialkanoates and aminoalkanoates, imidazolinium and ammonium derivatives. Other suitable amphoteric and zwitterionic surfactants are those selected from the group consisting of betaines, sultaines, hydroxysultaines, alkyl sarcosinates (e.g., C 12 -C 30 ), and alkanoyl sarcosinates.
[0105] Nonionic surfactants can also be used in the compositions herein. Among the nonionic surfactants that are useful herein are those that can be broadly defined as condensation products of long chain alcohols, e.g. C8-30 alcohols, with sugar or starch polymers, i.e., glycosides. These compounds can be represented by the formula (S) n —O—R wherein S is a sugar moiety such as glucose, fructose, mannose, and galactose; n is an integer of from about 1 to about 1000, and R is a C8-30 alkyl group. Examples of long chain alcohols from which the alkyl group can be derived include decyl alcohol, cetyl alcohol, stearyl alcohol, lauryl alcohol, myristyl alcohol, oleyl alcohol, and the like. Preferred examples of these surfactants include those wherein S is a glucose moiety, R is a C8-20 alkyl group, and n is an integer of from about 1 to about 9. Commercially available examples of these surfactants include decyl polyglucoside (available as APG 325 CS from Henkel) and lauryl polyglucoside (available as APG 600 CS and 625 CS from Henkel).
[0106] Other useful nonionic surfactants include the condensation products of alkylene oxides with fatty acids (i.e. alkylene oxide esters of fatty acids). These materials have the general formula RCO(X) n OH wherein R is a C10-30 alkyl group, X is —OCH 2 CH 2 — (i.e. derived from ethylene glycol or oxide) or —OCH 2 CHCH 3 — (i.e. derived from propylene glycol or oxide), and n is an integer from about 6 to about 200. Other nonionic surfactants are the condensation products of alkylene oxides with 2 moles of fatty acids (i.e. alkylene oxide diesters of fatty acids). These materials have the general formula RCO(X) n OOCR wherein R is a C10-30 alkyl group, X is —OCH 2 CH 2 — (i.e. derived from ethylene glycol or oxide) or —OCH 2 CHCH 3 — (i.e. derived from propylene glycol or oxide), and n is an integer from about 6 to about 100. Other nonionic surfactants are the condensation products of alkylene oxides with fatty alcohols (i.e. alkylene oxide ethers of fatty alcohols). These materials have the general formula R(X) n OR′ wherein R is a C10-30 alkyl group, X is —OCH 2 CH 2 — (i.e. derived from ethylene glycol or oxide) or —OCH 2 CHCH 3 — (i.e. derived from propylene glycol or oxide), and n is an integer from about 6 to about 100 and R′ is H or a C10-30 alkyl group. Still other nonionic surfactants are the condensation products of alkylene oxides with both fatty acids and fatty alcohols [i.e. wherein the polyalkylene oxide portion is esterified on one end with a fatty acid and etherified (i.e. connected via an ether linkage) on the other end with a fatty alcohol]. These materials have the general formula RCO(X) n NOR′ wherein R and R′ are C10-30 alkyl groups, X is —OCH 2 CH 2 (i.e. derived from ethylene glycol or oxide) or —OCH 2 CHCH 3 — (derived from propylene glycol or oxide), and n is an integer from about 6 to about 100. Nonlimiting examples of these alkylene oxide derived nonionic surfactants include ceteth-6, ceteth-10, ceteth-12, ceteareth-6, ceteareth-10, ceteareth-12, steareth-6, steareth-10, steareth-12, steareth-20, steareth-21, PEG-6 stearate, PEG-10 stearate, PEG-100 stearate, PEG-12 stearate, PEG-20 glyceryl stearate, PEG-80 glyceryl tallowate, PEG-10 glyceryl stearate, PEG-30 glyceryl cocoate, PEG-80 glyceryl cocoate, PEG-200 glyceryl tallowate, PEG-8 dilaurate, PEG-10 distearate, and mixtures thereof.
[0107] Still other useful nonionic surfactants include polyhydroxy fatty acid amide surfactants corresponding to the structural formula:
[0108] wherein: R 1 is H, C 1 -C 4 alkyl, 2-hydroxyethyl, 2-hydroxy- propyl, preferably C 1 -C 4 alkyl, more preferably methyl or ethyl, most preferably methyl; R 2 is C 5 -C 31 alkyl or alkenyl, preferably C 7 -C 19 alkyl or alkenyl, more preferably C 9 -C 17 alkyl or alkenyl, most preferably C 11 -C 15 alkyl or alkenyl; and Z is a polhydroxyhydrocarbyl moiety having a linear hydrocarbyl chain with a least 3 hydroxyls directly connected to the chain, or an alkoxylated derivative (preferably ethoxylated or propoxylated) thereof. Z preferably is a sugar moiety selected from the group consisting of glucose, fructose, maltose, lactose, galactose, mannose, xylose, and mixtures thereof. An especially preferred surfactant corresponding to the above structure is coconut alkyl N-methyl glucoside amide (i.e., wherein the R 2 CO— moiety is derived from coconut oil fatty acids). Processes for making compositions containing polyhydroxy fatty acid amides are disclosed, for example, in G.B. Patent Specification 809,060, published Feb. 18, 1959, by Thomas Hedley & Co., Ltd.; U.S. Pat. No. 2,965,576, to E. R. Wilson, issued Dec. 20, 1960; U.S. Pat. No. 2,703,798, to A. M. Schwartz, issued Mar. 8, 1955; and U.S. Pat. No. 1,985,424, to Piggott, issued Dec. 25, 1934.
[0109] Preferred among the nonionic surfactants are those selected from the group consisting of steareth-21, ceteareth-20, ceteareth-12, sucrose cocoate, steareth-100, PEG-100 stearate, and mixtures thereof.
[0110] Other nonionic surfactants suitable for use herein include sugar esters, polyesters and polyglycerol esters, alkoxylated sugar esters and polyesters, C1-C30 fatty acid esters of C1-C30 fatty alcohols, alkoxylated derivatives of C1-C30 fatty acid esters of C1-C30 fatty alcohols, alkoxylated ethers of C1-C30 fatty alcohols, polyglyceryl esters of C1-C30 fatty acids, C1-C30 esters of polyols, C1-C30 ethers of polyols, alkyl phosphates, polyoxyalkylene fatty ether phosphates, fatty acid amides, acyl lactylates, and mixtures thereof. Nonlimiting examples of these emulsifiers include: polyethylene glycol 20 sorbitan monolaurate (Polysorbate 20), polyethylene glycol 5 soya sterol, Steareth-20, Ceteareth-20, PPG-2 methyl glucose ether distearate, Ceteth-10, Polysorbate 80, cetyl phosphate, potassium cetyl phosphate, diethanolamine cetyl phosphate, Polysorbate 60, glyceryl stearate, polyoxyethylene 20 sorbitan trioleate (Polysorbate 85), sorbitan monolaurate, polyoxyethylene 4 lauryl ether sodium stearate, polyglyceryl-4 isostearate, hexyl laurate, PPG-2 methyl glucose ether distearate, PEG-100 stearate, and mixtures thereof.
[0111] Another emulsifier useful herein are fatty acid ester blends based on a mixture of sorbitan or sorbitol fatty acid ester and sucrose fatty acid ester, the fatty acid in each instance being preferably C 8 -C 24 , more preferably C 10 -C 20 . The preferred fatty acid ester emulsifier is a blend of sorbitan or sorbitol C 16 -C 20 fatty acid ester with sucrose C 10 -C 16 fatty acid ester, especially sorbitan stearate and sucrose cocoate. This is commercially available from ICI under the trade name Arlatone 2121.
[0112] Emulsions of the present invention can include a silicone containing emulsifier or surfactant. A wide variety of silicone emulsifiers are useful herein. These silicone emulsifiers are typically organically modified organopolysiloxanes, also known to those skilled in the art as silicone surfactants. Useful silicone emulsifiers include dimethicone copolyols or dimethicone copolyol crosspolymers. These materials are polydimethyl siloxanes, which may or may not be crosslinked, and have been modified to include polyether side chains or crosslinked chains such as polyethylene oxide chains, polypropylene oxide chains, mixtures of these chains, and polyether chains containing moieties derived from both ethylene oxide and propylene oxide. Other examples include alkyl-modified dimethicone copolyols, i.e., compounds which contain C2-C30 pendant side chains. Still other useful dimethicone copolyols include materials having various cationic, anionic, amphoteric, and zwitterionic pendant moieties.
[0113] The dimethicone copolyol emulsifiers useful herein can be described by the following general structure:
[0114] wherein R is C1-C30 straight, branched, or cyclic alkyl and R 2 is selected from the group consisting of
—(CH 2 ) n —O—(CH 2 CHR 3 O) m —H,
[0115] and
—(CH 2 ) n —O—(CH 2 CHR 3 O) m —(CH 2 CHR 4 O) o —H,
[0116] wherein n is an integer from 3 to about 10; R 3 and R 4 are selected from the group consisting of H and C1-C6 straight or branched chain alkyl such that R 3 and R 4 are not simultaneously the same; and m, o, x, and y are selected such that the molecule has an overall molecular weight from about 200 to about 10,000,000, with m, o, x, and y being independently selected from integers of zero or greater such that m and o are not both simultaneously zero, and z being independently selected from integers of 1 or greater. It is recognized that positional isomers of these copolyols can be achieved. The chemical representations depicted above for the R 2 moieties containing the R 3 and R 4 groups are not meant to be limiting but are shown as such for convenience.
[0117] Also useful herein, although not strictly classified as dimethicone copolyols, are silicone surfactants as depicted in the structures in the previous paragraph wherein R 2 is:
—(CH 2 ) n —O—R 5 ,
[0118] wherein R 5 is a cationic, anionic, amphoteric, or zwitterionic moiety.
[0119] Nonlimiting examples of dimethicone copolyols and other silicone surfactants useful as emulsifiers herein include polydimethylsiloxane polyether copolymers with pendant polyethylene oxide sidechains, polydimethylsiloxane polyether copolymers with pendant polypropylene oxide sidechains, polydimethylsiloxane polyether copolymers with pendant mixed polyethylene oxide and polypropylene oxide sidechains, polydimethylsiloxane polyether copolymers with pendant mixed poly(ethylene)(propylene)oxide sidechains, polydimethylsiloxane polyether copolymers with pendant organobetaine sidechains, polydimethylsiloxane polyether copolymers with pendant carboxylate sidechains, polydimethylsiloxane polyether copolymers with pendant quaternary ammonium sidechains; and also further modifications of the preceding copolymers containing pendant C2-C30 straight, branched, or cyclic alkyl moieties. Examples of commercially available dimethicone copolyols useful herein sold by Dow Corning Corporation are Dow Corning® 190, 193, Q2-5220, 2501 Wax, 2-5324 fluid, 3225C and 5225C. Cetyl dimethico 1 ne copolyol is commercially available under the tradename ABIL EM-90 or as a mixture with polyglyceryl-4 isostearate (and) hexyl laurate and is sold under the tradename ABIL® WE-09 (both available from Goldschmidt). Cetyl dimethicone copolyol is also commercially available as a mixture with hexyl laurate (and) polyglyceryl-3 oleate (and) cetyl dimethicone and is sold under the tradename ABIL® WS-08 (also available from Goldschmidt). Other nonlimiting examples of dimethicone copolyols also include lauryl dimethicone copolyol, dimethicone copolyol acetate, dimethicone copolyol adipate, dimethicone copolyolamine, dimethicone copolyol behenate, dimethicone copolyol butyl ether, dimethicone copolyol hydroxy stearate, dimethicone copolyol isostearate, dimethicone copolyol laurate, dimethicone copolyol methyl ether, dimethicone copolyol phosphate, and dimethicone copolyol stearate. See, International Cosmetic Ingredient Dictionary , Fifth Edition, 1993.
[0120] Dimethicone copolyol emulsifiers useful herein are described, for example, in U.S. Pat. No. 4,960,764, to Figueroa, Jr. et al., issued Oct. 2, 1990; European Patent No. EP 330,369, to SaNogueira, published Aug. 30, 1989; G. H. Dahms, et al., “New Formulation Possibilities Offered by Silicone Copolyols,” Cosmetics & Toiletries , vol. 110, pp. 91-100, March 1995; M. E. Carlotti et al., “Optimization of W/O-S Emulsions And Study Of The Quantitative Relationships Between Ester Structure And Emulsion Properties,” J. Dispersion Science And Technology, 13(3), 315-336 (1992); P. Hameyer, “Comparative Technological Investigations of Organic and Organosilicone Emulsifiers in Cosmetic Water-in-Oil Emulsion Preparations,” HAPPI 28(4), pp. 88-128 (1991); J. Smid-Korbar et al., “Efficiency and usability of silicone surfactants in emulsions,” Provisional Communication, International Journal of Cosmetic Science, 12, 135-139 (1990); and D. G. Krzysik et al., “A New Silicone Emulsifier For Water-in-Oil Systems,” Drug and Cosmetic Industry , vol. 146(4) pp. 28-81 (April 1990).
[0121] 2. Crosslinked Organopolysiloxane Gel Networks
[0122] The compositions of the present invention may optionally contain one or more crosslinked organopolysiloxane get networks. An example of the production of the organopolysiloxane polymer gel network powder includes the process in which an organopolysiloxane composition (i.e., additional-curable, condensation-curable, or peroxide-curable) is mixed with water in the presence of a surfactant (nonionic, anionic, cationic, or amphoteric), and, after mixing to homogeneity in a homomixer, colloid mill, homogenizer, propeller mixer, etc., this is cured by discharge into hot water (temperature at least 50° C.) and is then dried; the organopolysiloxane composition (addition-curable, condensation-curable, or peroxide-curable) is cured by spraying it directly into a heated current; the powder is obtained by curing a radiation-curable organopolysiloxane composition by spraying it under high energy radiation; the organopolysiloxane composition (addition-curable, condensation-curable, peroxide-curable) or high energy-curable organopolysiloxane composition is cured, the latter by high energy radiation, and the product is then pulverized using a known pulverizer such as, for example, a ball mill, atomizer, kneader, roll mill, etc., to thereby form the powder. Suitable organopolysiloxane polymer network powders include vinyl dimethicone/methicone silesquioxane crosspolymers like Shin-Etsu's KSP-100, KSP-101, KSP-102, KSP-103, KSP-104, KSP-105, hybrid silicone powders that contain a fluoroalkyl group like Shin-Etsu's KSP-200, and hybrid silicone powders that contain a phenyl group such as Shin-Etsu's KSP-300; and Dow Corning's DC 9506.
[0123] Preferred organopolysiloxane gel networks are dimethicone/vinyl dimethicone crosspolymers. Such dimethicone/vinyl dimethicone crosspolymers are supplied by a variety of suppliers including Dow Corning (DC 9040 and DC 9041), General Electric (SFE 839), Shin Etsu (KSG-15, 16, 18 [dimethicone/phenyl vinyl dimethicone crosspolymer] and KSG-21 [dimethicone copolyol crosspolymer]), Grant Industries (Gransil™ line of materials), lauryl dimethicone/vinyl dimethicone crosspolymers supplied by Shin Etsu (e.g., KSG-41, KSG-42, KSG-43, and KSG-44), lauryl dimethicone/dimethicone copolyol crosspolymers also supplied by Shin-Etsu (e.g., KSG-31, KSG-32, KSG-33, and KSG-34). Additional polymers from Shin-Etsu which are suitable fro use in the present invention include KSG-210, -310, 320, 330, and 340. Crosslinked organopolysiloxane polymer gel networks useful in the present invention and processes for making them are further described in U.S. Pat. No. 4,970,252 to Sakuta et al., issued Nov. 13, 1990; U.S. Pat. No. 5,760,116 to Kilgour et al., issued Jun. 2, 1998; U.S. Pat. No. 5,654,362 to Schulz, Jr. et al. issued Aug. 5, 1997; and Japanese Patent Application JP 61-18708, assigned to Pola Kasei Kogyo KK.
[0124] Another organopolysiloxane gel network that is suitable for inclusion into the presently claimed compositions is a polyethersiloxane block copolymer network comprising one or more polyether blocks, each comprising i) two or more structural units of the formula —R 1 O— Preferred organopolysiloxane compositions are dimethicone/vinyl dimethicone crosspolymers. Such dimethicone/vinyl dimethicone crosspolymers are supplied by a variety of suppliers including Dow Corning (DC 9040 and DC 9041), General Electric (SFE 839), Shin Etsu (KSG-15, 16, 18 [dimethicone/phenyl vinyl dimethicone crosspolymer]), and Grant Industries (Gransil™ line of materials). Cross-linked organopolysiloxane elastomers useful in the present invention and processes for making them are further described in U.S. Pat. No. 4,970,252 to Sakuta et al., issued Nov. 13, 1990; U.S. Pat. No. 5,760,116 to Kilgour et al., issued Jun. 2, 1998; U.S. Pat. No. 5,654,362 to Schulz, Jr. et al. issued Aug. 5, 1997; and Japanese Patent Application JP 61-18708, assigned to Pola Kasei Kogyo KK, each of which are herein incorporated by reference in its entirety, wherein each R 1 is independently a divalent hydrocarbon radical or R 2 , wherein R 2 is a trivalent hydrocarbon radical, and ii) one or more polysiloxane blocks, each comprising two or more structural units of the formula —R 3 2 SiO 2/2 — wherein each R 3 is independently a monovalent hydrocarbon radical or R 2 , and wherein at least one polyether block of the copolymer network is bonded to at least one polysiloxane block of the copolymer network by a link according to formula
[0125] wherein the R2O unit of this formula is a unit of the at least one polyether block and the R 2 R 3 SiO 2/2 unit of the structure of this formula is a unit of the at least one polysiloxane unit. This copolymer network is described in further detail in copending U.S. application Ser. No. 09/592,193, filed on Jun. 12, 2000 in the name of Kilgour et al.
[0126] The present compositions comprise from about 0.1% to about 15%, by weight of the composition, of the crosslinked organopolysiloxane gel network. In preferred embodiments, the network is present in the composition in an amount of from about 2% to about 10%, by weight of the composition.
[0127] 3. Waxes/Thickeners
[0128] Optionally, the compositions described herein may contain one or more cosmetically acceptable thickeners in either the oil or water phase to affect viscosity, feel, texture or stability. Examples include cellulose derivatives, organically modified clays, organic thickeners and waxes.
[0129] Waxes are lower-melting organic mixtures or compounds of high molecular weight, solid at room temperature and generally similar in composition to fats and oils except that they contain no glycerides. They can be hydrocarbons, esters of fatty acids or alcohols. Waxes useful in the present invention are selected from the group consisting of animal waxes, vegetable waxes, mineral waxes, natural waxes, synthetic waxes, petroleum waxes, ethylenic polymers, hydrocarbons, silicone waxes, and mixtures thereof.
[0130] Water and oil dispersible clays may be useful to thicken the water or the oil phase of the compositions herein. The water dispersible clays comprise bentonite and hectorite, such as Bentone EW, LT from Rheox; magnesium aluminum silicate, such as Veegum from Vanderbilt Co., attapulgite such as Attasorb or Pharmasorb from Engelhard, Inc.; laponite and montmorrilonite, such as Gelwhite from ECC America, and mixtures thereof. The oil dispersible clays include quaternium-18 bentonite, such as Bentone 34 and 38 from Rheox; the Claytone Series from ECC America; quaternium-18 hectorite, such as Bentone gels from Rheox; and mixtures thereof. Other particulate or organic thickeners may also be used provided they do not compromise the function or aesthetics of the foundation.
[0131] 4. Structuring Agents
[0132] The compositions herein may contain a structuring agent. Without being limited by theory, it is believed that the structuring agent assists in providing rheological characteristics to the composition which contribute to the stability of the composition. For example, the structuring agent tends to assist in the formation of a liquid crystalline gel network structures. The structuring agent may also function as an emulsifier or surfactant. Preferred compositions of this invention comprise from about 1% to about 20%, more preferably from about 1% to about 10%, most preferably from about 2% to about 9%, of one or more structuring agents.
[0133] Preferred structuring agents are those having an HLB of from about 1 to about 8 and having a melting point of at least about 45° C. Suitable structuring agents are those selected from the group consisting of saturated C 14 to C 30 fatty alcohols, saturated C 16 to C 30 fatty alcohols containing from about 1 to about 5 moles of ethylene oxide, saturated C 16 to C 30 diols, saturated C 16 to C 30 monoglycerol ethers, saturated C 16 to C 30 hydroxy fatty acids, C 14 to C 30 hydroxylated and nonhydroxylated saturated fatty acids, C 14 to C 30 saturated ethoxylated fatty acids, amines and alcohols containing from about 1 to about 5 moles of ethylene oxide diols, C 14 to C 30 saturated glyceryl mono esters with a monoglyceride content of at least 40%, C 14 to C 30 saturated polyglycerol esters having from about 1 to about 3 alkyl group and from about 2 to about 3 saturated glycerol units, C 14 to C 30 glyceryl mono ethers, C 14 to C 30 sorbitan mono/diesters, C 14 to C 30 saturated ethoxylated sorbitan mono/diesters with about 1 to about 5 moles of ethylene oxide, C 14 to C 30 saturated methyl glucoside esters, C 14 to C 30 saturated sucrose mono/diesters, C 14 to C 30 saturated ethoxylated methyl glucoside esters with about 1 to about 5 moles of ethylene oxide, C 14 to C 30 saturated polyglucosides having an average of between 1 to 2 glucose units and mixtures thereof, having a melting point of at least about 45° C.
[0134] The preferred structuring agents for the oil-in-water emulsion compositions of the present invention are selected from the group consisting of stearic acid, palmitic acid, stearyl alcohol, cetyl alcohol, behenyl alcohol, stearic acid, palmitic acid, the polyethylene glycol ether of stearyl alcohol having an average of about 1 to about 5 ethylene oxide units, the polyethylene glycol ether of cetyl alcohol having an average of about 1 to about 5 ethylene oxide units, and mixtures thereof. More preferred structuring agents for use in the oil-in-water emulsion compositions of the present invention are selected from the group consisting of stearyl alcohol, cetyl alcohol, behenyl alcohol, the polyethylene glycol ether of stearyl alcohol having an average of about 2 ethylene oxide units (steareth-2), the polyethylene glycol ether of cetyl alcohol having an average of about 2 ethylene oxide units, and mixtures thereof. Even more preferred structuring agents for the oil-in-water emulsion compositions are those selected from the group consisting of stearic acid, palmitic acid, stearyl alcohol, cetyl alcohol, behenyl alcohol, steareth-2, and mixtures thereof.
[0135] 5. Uncharged Insoluble Solid Particles
[0136] The compositions of the present invention may optionally comprise from about 0.1% to about 20%, preferably from about 1% to about 15%, and more preferably from about 1% to about 10%, by weight of the composition, of insoluble solid particles such as those hereinbefore described with the exception that these are not charged.
[0137] 6. Water-Soluble Skin Conditioning Ingredients
[0138] Preferred compositions of the invention can also comprise a water soluble skin conditioning component comprising one or more water soluble skin conditioning compounds. The water soluble skin conditioning component is useful for lubricating the skin, increasing the smoothness and suppleness of the skin, preventing or relieving dryness of the skin, hydrating the skin, and/or protecting the skin. The skin conditioning component enhances the skin appearance improvements of the present invention, including but not limited to essentially immediate visual improvements in skin appearance. The water soluble skin conditioning component is preferably selected from the group consisting of humectants, moisturizers and mixtures thereof. The water soluble skin conditioning component is preferably present at a level of at least about 0.1%, more preferably from about 1% to about 50%, still more preferably from about 2% to about 30% and most preferably from about 5% to about 25% (e.g., about 5% to about 15%).
[0139] Nonlimiting examples of water soluble conditioning compounds include those selected from the group consisting of polyhydric alcohols, polypropylene glycols, dipropylene glycol, polyethylene glycols, ureas, pyrolidone carboxylic acids, ethoxylated and/or propoxylated C3-C6 diols and triols, alpha-hydroxy C2-C6 carboxylic acids, ethoxylated and/or propoxylated sugars, sugars having up to about 12 carbons atoms, sugar alcohols having up to about 12 carbon atoms, and mixtures thereof. Specific examples of useful water soluble conditioning agents include materials such as urea; guanidine; glycolic acid and glycolate salts (e.g. ammonium and quaternary alkyl ammonium); lactic acid and lactate salts (e.g. ammonium and quaternary alkyl ammonium); sucrose, fructose, glucose, eruthrose, erythritol, sorbitol, hydroxypropyl sorbitol, mannitol, glycerol, hexane triol, propylene glycol, butylene glycol, hexylene glycol, threitol, pentaerythritol, xylitol, glucitol, and the like; polyethylene glycols such as PEG-2, PEG-3, PEG-30, PEG-50, polypropylene glycols such as PPG-9, PPG-12, PPG-15, PPG-17, PPG-20, PPG-26, PPG-30, PPG-34; alkoxylated glucose; hyaluronic acid; and mixtures thereof. Also useful are materials such as aloe vera in any of its variety of forms (e.g., aloe vera gel); lactamide monoethanolamine; acetamide monoethanolamine; panthenol; and mixtures thereof. Also useful are ethoxylated glycerols and propoxylated glycerols as described in U.S. Pat. No. 4,976,953, to Orr et al., issued Dec. 11, 1990. Other skin conditioning agents are listed in the Cosmetic Bench Reference, Cosmetics & Toiletries, p. 1.34 (1996).
[0140] 7. Skin Active Ingredients
[0141] Various skin active ingredients can also optionally and desirably be employed in the compositions of the present invention. As used herein, “skin active agents” are cosmetically acceptable materials for application onto human skin, and which provide a therapeutic or prophylactic health or appearance benefit to the skin. For example, such actives may provide anti-acne activity, anti-wrinkling activity, topical anesthetic activity, topical antibacterial activity, topical anti-inflammatory activity, artificial tanning or acceleration, antimicrobial activity, antifungal activity, sun protection, or combinations thereof, upon topical application onto human skin.
[0142] The term “safe and effective amount” as used herein, means an amount of a skin care active ingredient high enough to modify the condition to be treated or to deliver the desired skin benefit, but low enough to avoid serious side effects, at a reasonable benefit to risk ratio within the scope of sound medical judgment. What is a safe and effective amount of the active ingredient will vary with the specific active, the ability of the active to penetrate through the skin, the age, health condition, and skin condition of the user, and other like factors.
[0143] By “cosmetically acceptable” is meant that the ingredient is suitable for use in contact with the skin of humans and other animals without undue toxicity, incompatibility, instability, irritation, allergic response and the like.
[0144] Typically, these actives of the present invention comprise from about 0.001% to about 20%, preferably from about 0.01% to about 10%, and more preferably from about 0.025% to about 5%, by weight of the composition.
[0145] The actives useful herein can be categorized by their therapeutic/prophylactic benefit or their postulated mode of action. It is, however, to be understood that the actives useful herein can in some instances provide more than one therapeutic and/or prophylactic benefits or operate via more than one mode of action. Therefore, classifications herein are made for the sake of convenience and are not intended to limit the active to that particular application or applications listed. Also, pharmaceutically-acceptable salts of these materials are useful herein.
[0146] Nonlimiting examples of skin care actives useful in the present invention include actives for preventing or reducing acne, wrinkles, lines, atrophy, inflammation, as well as topical anesthetics, artificial tanning agents and accelerators, antimicrobial agents, antifungal actives, and sunscreening actives. A wide variety of such actives are known in the art and are suitable for use herein. For example, such actives are disclosed in copending U.S. application Ser. No. 09/439,438.
[0147] In different exemplary embodiments, the skin care actives are selected from peptides (e.g., Matrixyl™ [pentapetide derivative]), farnesol, bisabolol, phytantriol, glycerol, urea, guanidine (e.g., amino guanidine); vitamins and derivatives thereof such ascorbic acid, vitamin A (e.g., retinoid derivatives such as retinyl palmitate or retinyl proprionate), vitamin E (e.g., tocopherol acetate), vitamin B 3 (e.g., niacinamide) and vitamin B 5 (e.g., panthenol) and the like and mixtures thereof, wax-based synthetic peptides (e.g., octyl palmitate and tribehenin and sorbitan isostearate and palmitoyl-oligppeptide), anti-acne medicaments (resorcinol, salicylic acid, and the like; antioxidants (e.g., phytosterols, lipoic acid); flavonoids (e.g., isoflavones, phytoestrogens); skin soothing and healing agents such as aloe vera extract, allantoin and the like; chelators and sequestrants; and agents suitable for aesthetic purposes such as essential oils, fragrances, skin sensates, opacifiers, aromatic compounds (e.g., clove oil, menthol, camphor, eucalyptus oil, and eugenol). desquamatory actives, anti-acne actives, vitamin B 3 compounds, anti-oxidants, peptides, hydroxy acids, anti-oxidants, radical scavengers, chelators, farnesol, anti-inflammatory agents, topical anesthetics, tanning actives, skin lightening agents, anti-cellulite agents, flavonoids, antimicrobial actives, antifungal actives, sunscreen actives, conditioning agents, structuring agents, thickening agents, and combinations thereof. Other additional ingredients are disclosed in U.S. Pat. No. 5,011,681, to Ciotti et al., issued Apr. 30, 1991 and U.S. Pat. No. 5,939,082, to Oblong et al., issued Aug. 17, 1999, both of which are herein incorporated by reference. The above-mentioned vitamin B 3 compounds can be incorporated as re-crystallized crystals that remain in crystalized form in the composition or as partially solubilize crystals (i.e., some of the crystals are dissolved and some remain in crystalline form in the composition.).
[0148] 8. Film Forming Agents
[0149] Film forming agents may be optionally included in the compositions of the present invention to aid film substantivity and adhesion to the skin. Improving the long wear and non-transfer performance of the present compositions is quite desirable. Water-soluble, water insoluble, and water dispersible film forming agents can be used in the internal and external phases of the present compositions to give the desired end benefit.
[0150] Suitable film forming agents include organic silicone resins, fluorinated silicone resins, copolymers of organic silicone resins, e.g., trimethylsiloxysilicate from GE (SR1000), GE's copolymers of silicone resins, e.g., SF1318 (silicone resin and an organic ester of isostearic acid copolymer) and CF1301 (silicone resin and alpha methyl styrene copolymer), Dow Corning's pressure sensitive adhesives—copolymers of silicone resins and various PDMS's (BIO-PSA series); and acrylic and methacrylic polymers and resins, silicone-acrylate type copolymers and fluorinated versions of, including—silicones plus polymer SA70 from 3M, KP545 from Shin-Etsu, alkyl-acrylate copolymers, e.g., KP 561 and 562 from Shin-Etsu. Other suitable film forming polymers include:
[0151] 1) decene/butene copolymer from Collaborative Labs;
[0152] 2) polyvinyl based materials, e.g., PVP, PVP/VA, including Antaron/Ganex from ISP (PVP/Triacontene copolymer), Luviskol materials from BASF;
[0153] 3) polyurethanes, e.g., the Polyderm series from Alzo including but not limited to Polyderm PE/PA, Polyderm PPI-SI-WS, Polyderm PPI-GH, Luviset P.U.R. from BASF;
[0154] 4) polyquaternium materials, e.g., Luviquat series from BASF
[0155] 5) acrylates copolymers and acrylates/acrylamide copolymers, e.g., Luvimer and Ultrahold series, both available from BASF;
[0156] 6) styrene based materials; and
[0157] 7) chitosan and chitosan based materials including cellulose and cellulose-based materials.
[0158] Such film formers are disclosed for example in the International Cosmetic Ingredient Dictionary and Handbook, Seventh Edition, Vol 2, 1636-1638.
[0159] II. Process for Preparing Compositions Herein
[0160] The compositions of the present invention can be generally prepared by conventional methods such as are known in the art of making cosmetic compositions. Such methods typically involve mixing of the ingredients in one or more steps to a relatively uniform state, with or without heating, cooling, application of vacuum, and the like.
[0161] The charged species can be incorporated into the composition by any conventional means. One or more of the components described herein before can be mixed together with the charged insoluble solid particles via conventional methods in any sequence. Typically, the charged or uncharged particles are dispersed in the water phase. To induce a charge on particles, one typically disperses the particles in a polar solvent. The surface charge of the particles can be adjusted by pH or by the addition of a charged species that irreversibly adsorbs at the solvent/particle interface. The dispersion is milled or mixed at high shear until the desired particle size is achieved. See e.g., Everett, D. H., Basic Principles of Colloid Science , Royal Society of Chemistry, Picadilly London, 1988; Lieberman, Herbert A., Rieger, Martin M., and Banker, Gilbert S., Eds., Pharmaceutical Dosage Forms: Disperse Systems , Vol. 1, 2 nd Ed., Marcel Dekker, Inc., New York, 1996 (pp 35-43). The emulsion is formed by slow addition of the internal phase to the external phase with high shear mechanical mixing. The charged species, polyanion, polycation or ionic surfactant, is typically added after the emulsion is formed or incorporated into the oil phase and added during emulsification. Both processes achieve the desired result. Although these are the preferred methods, one is not limited to these processes for incorporating the charged species into the composition in order to achieve the desired result.
[0162] III. Methods for Maximizing Coverage While Providing a Natural Appearance to the Skin
[0163] The compositions of the present invention are useful for providing good coverage to the skin (e.g., minimizing fine lines and wrinkles and covering blemishes or irregularities in pigmentation), while at the same time providing a natural appearance to the skin (avoiding a cakey appearance).
[0164] A wide range of quantities of the compositions of the present invention can be applied to the skin to achieve these advantages. Quantities of the present compositions which are frequently applied per application are, in mg composition/cm 2 skin, from about 0.5 to about 3 mg/cm 2 . Typically applications would be on the order of about once per day.
Analytical Methods
[0165] A. Observation of Particles Accumulated at the Interface of the Internal Phase and the External Phase of the Emulsion
[0166] 1. Light Microscopy Technique
[0167] Equipment/Materials
[0168] Nikon Microphot-SA, equipped with Differential Interference Contrast (DIC) filters
[0169] Nikon PLAN 100/1.25 oil DIC objective
[0170] Eyepiece-CFUWIN 10×/26.5
[0171] Sony 3CCD video camera
[0172] Sony monitor
[0173] Sony Color Video Printer Mavigraph UP525OMD
[0174] Corning No. 1 22 mm sq. cover slips
[0175] Rite-on microscope slides 25×75 mm, thickness 0.93 to 1.05 mm
[0176] Type A immersion oil
[0177] Sample Preparation
[0178] 1. Apply a small sample of product (approximately 1 gram) to the Rite-on microscope slide. Dilute the sample by applying one drop of the external phase (e.g., in a water-in-oil emulsion, water is the dilutent) of the emulsion to the top of the sample once the sample has been applied to the microscope slide.
[0179] 2. Place a microscope cover on top of the sample and apply a drop of immersion oil to the top of this cover.
[0180] 3. Study the sample using a Nikon Microphot-SA (or equivalent) microscope equipped with a 100× oil immersion lens, 10× oculars and DIC. Observe whether the pigment particles appear to be accumulated at the interface of the emulsion droplet. If they appear to be accumulated at the interface, proceed with Cryo-Scanning Electron Microscopy method set forth hereinbelow.
[0181] 2. Cryo-Scanning Electron Microscopy Technique
[0182] a) In-product Analysis
[0183] 1. Place a small amount of sample in the well of a gold or copper specimen holder.
[0184] 2. Rapidly plunge the sample and holder into liquid ethane cooled by a bath of liquid nitrogen.
[0185] 3. Transfer the resulting solid specimen into a cryo-storage vial and store in liquid nitrogen. Note: After freezing, all samples are handled under liquid nitrogen, in a cold nitrogen gas atmosphere, or under vacuum to prevent ice crystal growth in the sample or frost formation on the sample surface.
[0186] 4. Transfer the specimen into the vacuum of an Oxford CT1500 HF Cryo-preparation chamber attached to a Hitachi S4500-I Field-Emission Scanning Electron Microscope (SEM) or its equivalent.
[0187] 5. Cleave or fracture the specimen under vacuum using a sharp probe to initiate the fracture plane so that a surface is created from the internal structure of the product.
[0188] 6. After fracture, sublimination of the solvent (normally water) from the exposed fracture surface (etching) may be conducted to expose additional internal structure (e.g., pigments within the internal water phase). Etched structures should be compared with non-etched structures to identify potential artifacts.
[0189] 7. Using a Denton Planar Magnetron Sputtering Head or its equivalent, coat the sample at −120° C. with a thin film (˜2 nm) of Au/Pd to enhance contrast and reduce specimen charge-up.
[0190] 8. Transfer the sample onto the cold storage inside the SEM and analyze at −110° C. using the upper (high-resolution) detector at 1.5 keV beam acceleration voltage for imaging, and at 10-20 keV for element identification by x-ray analysis. X-ray analysis may be conducted at a single point or an x-ray elemental image may be formed. X-ray analysis is performed with an Isis Energy Dispersive Spectrometer, or its equivalent, with a thin window silicon detector.
[0191] 9. Observe whether the particles appear to be accumulated at the interface of the emulsion droplet. This method can be done definitively by comparing three types of emulsion droplet fractures. The first and most common fracture is a cross-fracture where the fracture plane passes through the cross section of an emulsion droplet. In a cosmetic composition containing pigment particles, these particles can readily be imaged and x-ray mapped around the circumference of the droplet. The other two fractures result from the fracture plane propagating around the surface of the droplet either between the droplet and the pigment particles or between the pigment particles and the bulk phase. In the first case, the pigment particles will be seen lining the depression created by the droplets in the bulk phase (i.e., the negative replica). In the second case, pigment particles will be seen over the surface of the droplet protruding from the bulk phase (i.e., the positive replica). The collaboration of these three tests is definitive.
[0192] B. Observation of Brownian Motion of the Particles
A dimethicone copolyol 15.00 15.10 15.00 15.00 (10%)/cyclomethicone (90%) A Quatemium 80 (cationic) 0.50 — 0.50 — A anionic surfactant — — — 0.65 A isononyl isononanoate 3.00 1.50 3.00 3.00 A sucrose ester fatty acid cottonate 1.00 1.50 — — A propylparaben — 0.25 — — B water 38.54 44.91 40.92 27.20 B yellow iron oxide 1.13 1.13 1.80 1.30 B red iron oxide 0.18 0.26 0.28 0.25 B black iron oxide 0.15 0.15 0.09 0.12 B charged pigment particles: glycerin 7.90 7.90 — — (30%), water (30%), titanium dioxide (39.5%), ammonium polyacrylate (0.1%, ammonium Zr carbonate (0.05%) B charged pigment particles: glycerin 5.40 5.40 — — (12.5%), water (12.5%), titanium dioxide (75%), ammonium polyacrylate (0.1%, ammonium Zr carbonate (0.05%) B charged pigment particles: glycerin 6.00 6.00 — — (25%), water (25%), titanium dioxide (49.5%), ammonium polyacrylate (0.10%), ammonium zirconium carbonate (0.05%) B charged pigment particles: butylene 8.80 glycol (32.5%), water (32.85%), titanium dioxide (34.49%), ammonium polyacrylate (0.10%), ammonium zirconium carbonate (0.06%) B rutile titanium dioxide — — 8.25 8.25 B hydroxypropyl chitosan — — — 12.50
[0193] Using the equipment and procedure hereinbefore described in Analytical Method A, Observation of Particles Accumulated at the Interface of the Internal Phase and the External Phase of the Emulsion—Light Microscopy Technique, prepare a sample and observe under the microscope. If the particles appear to be attached to the surface of the emulsion droplet and appear to be stationary, proceed with Cryo-Scanning Electron Microscopy Technique set forth hereinabove. If the particles appear to be attached to the surface of the emulsion droplet using the Cryo-Scanning Electron Microscopy and appear to be stationary using the Light Microscopy Technique, there is no Brownian motion.
[0194] C. Particle Size of Emulsion Droplets
[0195] 1. Particle Size of Individual Particles
[0196] Using the equipment and procedure hereinbefore described in Analytical Method A, prepare a sample and observe under the microscope. Emulsion droplet size can be measured by calibrating the level of magnification with an objective micrometer. As used herein, particle size is the average particle size of a representative sample of the product.
[0197] 2. Particle Size Distribution
[0198] SEM can be used for qualitative comparisons among samples wherein the particle size of the particles varies substantially. First, select an appropriate magnification based on the particle size and the precision required. Particle size precision is limited to the size of a single image pixel. Therefore, the magnification must be high enough so the size of a single pixel is equal to or less than the precision required for the measurement. If a large range of particle size exists, several magnifications will be required to cover overlapping regions of the particle size range. Random sampling of fields-of-view is the most desirable method, however, known artifactual regions must be excluded. Ideally, the entire sample will be observed prior to selecting representative regions for measurement. The calibrated scale bar of the microscope is used as a reference for either manual or computer-aided measurement of the particles.
EXAMPLES
[0199] Examples 1-4 are nonlimiting examples of water-in-silicone liquid foundation compositions of the present invention:
Example 1 Example 2 Example 3 Example 4 Part Ingredient (wt %) (wt %) (wt. %) (wt. %) A cyclomethicone 5.00 8.60 20.00 19.86 B methylparaben 0.12 0.2 0.12 0.12 B carboxymethyl- — — 0.29 — cellulose B butylene glycol — 2.00 — — B moisturizer 1.50 1.50 6.00 6.00 B phenoxyethanol — 0.30 — — C laureth-7 0.50 — 0.50 0.50 C propylparaben 0.25 — 0.25 0.25 C sucrose ester fatty — 1.5 — — acid behenate C ozokerite wax — 1.5 — — D cationic premix 1.00 — — — (30% quaternium 80, 10% dimethicone copolyol*, 60% cyclomethicone) E dimethicone 3.00 — 3.00 5.00 copolymer U silica 1.00 — — — G ethylene/acrylic 1.00 — — — acid copolymer H fragrance 0.03 — — — H other minor — — ingredients Total 100.00 100.00 100.00 100.00
[0200] Examples 1-4 are prepared as follows:
Example 1
[0201] Premixes:
[0202] Mix the Part A components together and mill with a Silverson L4RT mixer equipped with a 2″ emulsor screen 2000-3000 rpms for 5 minutes. Separately mix the Part B components together and mill for 30 minutes at 9000 rpms, using a Silverson L4RT mixer equipped with a 1″ disintegrating screen. Separately mix the Part C components together and mix by hand until the paraben is dissolved. Separately, mix the Part D components together by hand in a beaker until uniform.
[0203] Compounding:
[0204] Add Part C to Part A and mix at 3000-4000 rpms using a Silverson L4RT mixer equipped with a 2″ emulsor screen for about 5 minutes. Slowly add Part B while mixing at about 6000 rpms using same Silverson setup. Total addition time should be about 10-15 minutes; the temperature should be kept at greater than about 35° C. to about 60° C. Mill the resulting mixture for about 5 minutes, maintaining good turnover. Add Part D and mill at about 6000-8000 rpms until uniform, for about 5 minutes. Add Part E, G and H and mill at 6000-8000 rpms for an additional 10 minutes, to finish product.
Example 2
[0205] Premixes:
[0206] Combine the methyl paraben and butylene glycol and mix by hand until the paraben is dissolved. Add the remaining Part B components and mill on a Silverson L4RT equipped with a 1″ disintegrating screen at 9000 rpms for about 30 minutes. Separately mix the Part A components and mill on a Silverson equipped with a 2″: emulsor screen at 2000-3000 rpms until well mixed. Separately mix the Part C components together heat to 80° C. until melted.
[0207] Compounding:
[0208] Slowly add Part B to Part A over a period of 5-10 minutes, while mixing at 6000 rpms using the Silverson equipped with a 2″ emulsor screen. Transfer to a low shear mixer ˜300-800 rpms (e.g., Caframo, propeller blade). Heat to 80° C. Add Part C, at about 80° C., and mix for about 5 minutes at that temperature. Cool to about room temperature while continuing to mix, to finish product.
Example 3
[0209] Prepare as for Example 1, except that no Part D, G or H are added.
Example 4
[0210] Prepare as described for Example 3.
[0211] The pigment in these foundation compositions is uniformly distributed throughout the foundation composition. When these compositions are applied to the skin, the pigment will be distributed uniformly on the skin and a natural appearance for the skin will be provided.
[0212] Examples 5-7 are oil-in-water liquid foundation compositions of the present invention.
Example 5 Example 6 Example 7 Part Ingredient (wt %) (wt %) (wt. %) A cyclomethicone — 23.74 38.00 A silicone fluid — 5.92 — A propylparaben — 0.25 0.25 A fragrance — 0.03 0.03 A polyoxyethylenesorbitan monolaurate 8.75 — — A sorbitan monostearate 3.75 — — A methylparaben 0.12 — — A water 12.38 — — B cyclomethicone 17.47 — — B sucrose ester fatty acid cottonate 2.00 — — B sucrose monooleate — — 2.50 B glycerin — 1.00 1.00 B polyoxyethylene (23) lauryl ether — 0.25 — B water — 14.39 13.75 B methylparaben — 0.12 0.12 B titanium dioxide dispersed in silicone fluid (75% 3.00 — — dispersion) B fragrance 0.03 — — B propylparaben 0.25 — — B isononyl isononanoate 1.25 — — B dimethicone copolyol 0.5 — — B trimethlsilyamodimethicone 0.5 — — C Quatemium 80 (cationic) — 0.25 0.25 C ethylene/acrylic acid copolymer — 4.00 — C charged pigment particles: butylene glycol (32.5%, 22.86 water (32.85%), titanium dioxide (34.5%), ammonium polyacrylate (0.10%), ammonium zirconium carbonate (0.06%) C glycerin 1.50 — — C yellow iron oxide 0.95 — — C red iron oxide 0.22 — — C black iron oxide 0.11 — — C water 20.36 — — D yellow iron oxide — 0.95 0.57 D red iron oxide — 0.28 0.21 D black iron oxide — 0.10 0.08 D water — 24.46 20.03 D charged pigment particles: butylene glycol (28%), — 23.26 — water (28%), titanium dioxide (43.5%), ammonium polyacrylate (0.10%), ammonium Zr carbonate (0.06%) D charged pigment particles: glycerin (30%), water — — — (30%), titanium dioxide (39.5%), ammonium polyacrylate (0.1%, ammonium Zr carbonate (0.05%) D charged pigment particles: glycerin (12.5%), water — — — (12.5%), Titanium dioxide (75%), ammonium polyacrylate (0.1%, ammonium Zr carbonate (0.05%) D charged pigment particles: butylene glycol (32.5%, — — 21.21 water (32.85%), titanium dioxide (34.5%), ammonium polyacrylate (0.10%), ammonium zirconium carbonate (0.06%) D rutile titanium dioxide — — 2.00 D ethylene acrylates copolymer 4.00 — — E hydroxypropylcellulose — 1.00 — Total 100.00 100.00 100.00
[0213] Examples 5-7 are prepared as follows:
Example 5
[0214] Premixes:
[0215] Combine Part C components and mill at 9000 rpms for 30 minutes using a Silverson L4RT equipped with a 1″ disintegrating screen. Separately mix the Part B ingredients together and stir for 10 minutes at 6000 rpms using Silverson L4RT equipped with a 2″ emulsor screen. Separately mix the Part A components together, heat to 45-60C. and stir for 20 minutes at 1000 rpms on a Silverson L4RT equipped with a 2″ emulsor screen (to form a white paste containing liquid crystals as viewed under a microscope).
[0216] Compounding:
[0217] Slowly add Part B to Part A at 10 ml/minute at 1000 rpm with a Silverson 2″ emulsor screen. Add Part C at 20 ml/minute at 3000 rpm with a Silverson 2″ emulsor screen. Add Part D. If needed, continue mixing to obtain desired emulsion size, e.g., about 3 additional minutes at 8000 rpm with a Silverson 2″ emulsor screen.
Example 6
[0218] Premixes:
[0219] Combine Part D components and mix at 9000 rpm for 30 minutes using a Silverson L4RT equipped with a 1″ disintegrating screen. Combine Part C ingredient/s. Combine Part B ingredients, heat to 45-60C. and mix until uniformly dissolved. Combine the Part A components, heat to 60-70° C. and mix using a stirring bar until dissolved.
[0220] Compounding:
[0221] Slowly add Part A to Part B with a pipette over about 10 minutes, with 20 mixing at 5000 rpms with a Silverson equipped with a 2″ emulsor screen, and maintaining the temperature at about 60-74° C. Cool to about 30-35° C. Add Part C to the mixture and stir the mixture at 5000 rpm for 2 minutes with the Silverson 2″ emulsor screen. Heat to 60C. while mixing. Slowly add Part D at 5000 rpm with the Silverson 2″ emulsor head. While adding, cool to 30-35C. Add Part E and stir for 10 minutes at 5000 rpm on the Silverson 2″ emulsor head. If needed, continue mixing to obtain desired emulsion size, e.g., about 3 additional minutes at 8000 rpm with a Silverson 2″ emulsor screen.
Example 7
[0222] Prepare like Example 6 except that no Phase E is added.
[0223] Examples 8-10 are non limiting examples of water-in-oil solid emulsion foundations of the present invention.
Example 8 Example 9 Example 10 Part Ingredient (wt %) (wt %) (wt %) A cyclomethicone 22.13 26.16 6.50 A cyclo/dimethicone copolyol 14.49 10.00 20.0 A isononyl isononanoate 3.0 3.0 3.0 A Abil Quat 3272 (Quaternium 80) 1.0 1.0 0.5 B Laureth-7 0.5 0.5 0.5 B propylparaben 0.25 0.25 0.25 B ethylene brassylate 0.03 0.0 0.03 C charged pigment particles (39.5% 7.9 7.9 7.9 titanium oxide, 30.0% glycerin, 30.35% water, 0.1% ammonium polyacrylate, 0.05% ammonium zirconium carbonate) C charged pigment particles (74.5% 9.4 9.4 5.4 titanium oxide, 12.5% glycerin, 12.85% water, 0.10% ammonium polyacrylate, 0.05% ammonium zirconium carbonate) C charged pigment particles (49.5% 6.0 6.0 6.0 titanium oxide, 25% glycerin, 23.35% water, 0.10% animonium polyacrylate, 0.05% ammonium zirconium caronate) C yellow iron oxide 0.96 1.3 1.13 C red iron oxide 0.70 0.25 0.18 C black iron oxide 0.18 0.12 0.15 C methylparaben 0.12 0.12 0.12 C water 20.50 23.00 35.84 D dimethicone treated talc 3.0 0.0 0.0 D polytrap 1.34 3.0 0.0 D nontreated talc 0.0 2.0 0.0 D ethylene acylic acid copolymer 2.0 2.0 2.0 D PVP K-30 (17% mix with water) 3.0 0.0 0.0 F Ozokerite wax 3.5 4.0 5.0 F silicone wax 0.0 0.0 4.0 Total 100.00 100.00 100.00
[0224] Examples 8-10 are silicone in water compositions and are prepared as follows:
[0225] Premixes:
[0226] Combine the Part A ingredients and mix with a Silverson L4RT equipped with a 2″ emulsor screen at 3000 rpm until ingredients are visibly homogeneous. Separately mix the Part B components until the paraben is essentially dissolved. Separately combine and mix the Part C ingredients using a Silverson L4RT mill at high speed (9000-10,000 rpm) using a 1″ disintegrating screen for at least 30 minutes.
[0227] Compounding:
[0228] Add Part B to Part A and mix at 3000-4000 rpm using a Silverson L4RT equipped with a 2″ emulsor screen. Slowly add Part C and mix with the Silverson 2″ emulsor screen at about 6000 rpm over a time period of about 10-15 minutes. Mill maintaining a good turnover, about 10 minutes. Add Part D components mill for an additional 5 minutes (when used, heat the PVP K-30 to 80° C. until melted and cool to 30° C. prior to addition). Heat to 80° C. and add Part F components, mix until uniform, remove air and package.
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The present invention relates to particle stabilizing compositions suitable for use in fabric care products, home care products, diapers, incontinence articles, feminine care products, pharmaceuticals, oral care products, antiperspirants, deodorants, personal cleansing products, skin care products and hair care products comprising: a) an emulsion comprising from about 1% to about 99% by weight of the emulsion of an internal phase and from about 1% to about 99% by weight of the emulsion of an external phase; b) a charged species that is present in the emulsion; and c) charged insoluble solid particles which are dispersed in the emulsion wherein the charged species possesses a charge which is opposed to that of the charged insoluble solid particles and wherein essentially all of the charged species and charged insoluble solid particles accumulate at the interface of the emulsion and wherein Brownian motion is not exhibited by the charged insoluble solid particles.
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PROVISIONAL APPLICATION
The present application claims priority under 35 U.S.C. § 119(e) of a provisional application 60/427,741, filed on Nov. 20, 2002 the entirety of which is hereby incorporated by reference.
FIELD OF THE INVENTION
The field of the invention generally relates to optical amplifying devices. More particularly, the invention relates to optical amplifying devices and methods with gain control.
BACKGROUND OF THE INVENTION
Conventional optical amplifiers may be operated under variable control to achieve an amplifier response that is flat over a wide gain range. Amplifiers may also be operated in constant gain mode in which the pumps are controlled such that the amplifier gain is constant with the result being that the output power closely tracks the input power.
In optical systems, it is desirable to launch a constant power per channel into the fiber. This may be achieved by operating the amplifier in a constant gain mode. In constant gain mode, any change in the input power of a constant gain amplifier produces a proportional change in the output power of the amplifier. Thus any change in the input due to change in channel count (i.e. addition and deletion of channels), will cause a proportional change in the output power of the amplifier, keeping the per channel launch power nominally constant.
While this method is useful for tracking changes in channel count, there are drawbacks. The amplifier has no means of differentiating between changes in input power caused by channel count changes and other events such as change in fiber loss, component losses etc. While these changes may be small over a single span, these changes will accumulate along multiple sections of fibers and amplifiers to a detrimental effect.
Consider a chain 100 of optical amplifiers 102 -X shown in the block diagram of FIG. 1 . The input power per channel to the first amplifier 102 - 1 is P 1 . The average losses of the fiber sections 104 - 1 to 104 -N are shown as L 1 , L 2 , . . . L N . If the launch power per channel is assumed to be same at each fiber section (and same as at the output of the first amplifier), the gains G 2 , . . . G N of the amplifiers 102 - 2 . . . 102 -N track the average loss of the fiber section preceding the amplifier (L 1 , L 2 . . . L N ). The time dependent variation in fiber loss given by ΔL 1 , ΔL 2 , . . . ΔL N and the variation in input power is assumed to be ΔP 1 .
As noted above, conventional optical amplifiers operate in a simple constant gain mode. In this case, the control circuitry keeps the gain of the amplifier at target value G CG . A control mechanism for the conventional amplifier in constant gain mode is shown in the flow chart 200 of FIG. 2 . In FIG. 2 , P in is the input power to an amplifier, and P out is the output power from the amplifier. It is assumed that the power values are in a logarithmic scale for ease of calculation.
In step 210 , the target gain G CG for the amplifier is set. This value is provisioned in the constant gain mode and typically corresponds to the gain of a particular stage or multiple stages of the chain of amplifiers. In step 220 , input and output powers P in and P out are measured and the actual gain G meas is calculated from the measured power values. Step 230 determines whether or not a deviation G error from the target gain G CG exists. If so, the amplifier's output P out is adjusted by G error in step 240 and the method returns to step 220 . If the deviation is determined not to exist in step 230 , the output is not adjusted and the method returns to step 220 .
FIG. 3 graphically illustrates the tracking of the output power of the amplifier as a function of the input power. The amplifier is assumed to be operating at a target set gain of 25 dB. As shown, the output power of the amplifier tracks the input as closely as possible.
It can be seen that substantial output power variations occur if the constant gain control is utilized. Such power fluctuations accumulate over a chain of amplifiers to a detrimental effect as pointed out above.
BRIEF DESCRIPTION OF THE DRAWINGS
Features of the present invention will become more fully understood to those skilled in the art from the detailed description given hereinbelow with reference to the drawings, which are given by way of illustrations only and thus are not limitative of the invention, wherein:
FIG. 1 is a block diagram illustrating a chain of conventional constant gain mode optical amplifiers;
FIG. 2 is a flow chart illustrating a control mechanism of a conventional constant gain optical amplifier;
FIG. 3 is a graphical illustration of tracking of input to output of a conventional constant gain optical amplifier;
FIG. 4 is a block diagram illustrating an exemplary control mechanism of an optical amplifying device according to an embodiment of the present invention;
FIG. 5 is a block diagram of an optical amplifying device according to an embodiment of the present invention;
FIG. 6 is a flow chart illustrating an exemplary control mechanism of an optical amplifying device according to an embodiment of the present invention;
FIG. 7 is an exemplary graphical illustration of power output of an optical amplifying device according to an embodiment of the present invention; and
FIG. 8 is a block diagram of an EDFA optical amplifying device according to an embodiment of the present invention.
DETAILED DESCRIPTION
For simplicity and illustrative purposes, the principles of the present invention are described by referring mainly to exemplary embodiments thereof. The same reference numbers and symbols in different drawings identify the same or similar elements. Also, the following detailed description does not limit the invention. The scope of the invention is defined by the claims and equivalents thereof.
As noted previously, a simple constant gain mode amplifier amplifies not only the desired input signal, but also amplifies the accumulated imperfections of the optical system.
Such imperfections in the input signal generally occur slowly over time and typically are low in magnitude (also known as signal drift or simply “drift”). For example, variations in span losses and variation in laser powers used for inputting signals to the amplifiers can occur due to polarization dependence of optical components. Also, mechanical and/or thermal effects can cause time dependent loss variations in optical fibers. Another source of noise that can couple into the system include any noise that can couple into the amplifier pump electronics and consequently into the amplifier output.
While all of these variations are usually fairly small, it is desirable that these variations are squelched at each amplifier and not allowed to accumulate along the system. For example, in order to minimize any noise coupling into the pump, it is desirable to operate the pumps using a constant current drive for the pumps.
FIG. 4 is a high level block diagram 400 of a control mechanism of an exemplary optical amplifying device of the present invention. As shown, the optical amplifying device operates in one of two modes—constant power mode 410 (gain threshold mode) or constant gain mode 420 (gain control mode). The explanation is as follows.
As noted above, variations in the power of the input to the amplifying device that is relatively small in magnitude are more likely due to the imperfections in the system rather than variations in the actual input signal. In this type of a situation, it is desired that the amplifying device be suppressed from reacting to the input variations. By operating the optical amplifying device in the constant power mode 410 , the suppression may be achieved. In the above constant power mode can mean both constant output power or constant pump power (by delivering constant pump current to pumps). For example, natural erbium doped fiber amplifier (EDFA) behavior may be utilized to suppress any low frequency, low magnitude changes to the input.
Conversely, large variations in power are more likely due to the changes in the actual input signal itself. For example, adding or dropping channels of a wavelength division multiplexed (WDM) signal will typically cause a large power variation. Switching operations may cause large power variation as well. Under this type of a circumstance, it is desired that the amplifying device track the input. By operating the optical amplifying device in the constant gain mode 420 , tracking may be achieved.
The optical amplifying device may switch from one mode to another appropriately through the use of a gain threshold. For example, assume that the optical amplifying device is currently operating in the constant power mode 410 . An actual gain G MEAS =P OUT −P IN may be determined from the output and input powers of the amplifying device. Then, the gain error G ERROR =G CG −G MEAS (where G CG is the target gain) may be determined. If the absolute value of G ERROR exceeds a predetermined threshold value G TH , i.e. if |G ERROR |−G TH >0, then the amplifying device may switch to the constant gain mode 420 (arrow 430 in FIG. 4 ). Otherwise, the amplifying device may remain in the constant power mode 410 (arrow 440 ). The constant power mode 410 may also be described as constant power with gain threshold mode or simply “gain threshold mode.”
In an embodiment of the present invention, the optical amplifying device operates in constant gain mode 420 for a brief lock out period (10 seconds for example) and returns to back to gain threshold (CP) mode 410 . It should be noted that the lock out period may be set at any period appropriate for the situation.
If no transient events occur during the lock out period, then the optical amplifying device may be switched to operate in the gain threshold mode (i.e. gain threshold can be re-enabled) 410 (arrow 450 ). In an embodiment, the transient event may be defined as the output power of the amplifying device deviating from a reference power level by more than a preset amount within prescribed time, such as the lock out period. In another embodiment, the transient event may be defined as the level of the output power fluctuating by more than a preset amount within the prescribed time. In general, the transient event is an indication that the output of the amplifying device is in a state of flux and the optical system has not reached a desired stability.
If one or more transient events do occur, which indicates that the optical system has not stabilized, then the lock out period may be reset and the optical amplifying device may remain in the constant gain mode 420 (arrow 460 ).
Other criteria can also be used to return the optical amplifying device to the gain threshold mode. For example, instead of detecting transient events as described above, an alternative may be simply set the lock out at a “long enough” period and return to the gain threshold mode after the lock out period without regard to transient events occurring. However, it is preferred that the optical amplifying device be returned to the gain threshold mode after determining that the optical system has stabilized.
FIG. 5 is a block diagram of an optical amplifying apparatus 500 according to an embodiment of the present invention. The apparatus includes an optical amplifying device 510 , a controlling device 520 , and a measuring device 530 . The optical amplifying device 510 receives input signal and outputs an output signal. The measuring device 530 is configured to measure power levels on a plurality of points within the optical amplifying device 510 including input and output power levels P IN and P OUT . Both the optical amplifying device 510 and the measuring device 530 communicate with the controlling device 520 .
The controlling device 520 controls the operation of the optical amplifying device 510 based on the power levels measured by the measuring device 530 . The controlling device 520 controls the optical amplifying device 510 to operate either in the gain threshold mode ( 410 of FIG. 4 ) or the constant gain mode ( 420 of FIG. 4 ).
As an example, in the gain threshold mode, the controlling device 520 calculates the actual gain of the optical amplifying device 510 based on the input and output power levels P IN and P OUT —more specifically, the gain may be determined as P OUT −P IN (logarithmic scale). If the absolute value of the gain error does not exceed a preset threshold, then the controlling device 520 adjusts the gain of the optical amplifying device 510 so that output power level P OUT is substantially equal to a preset level.
In the constant gain mode, the controlling device 520 determines whether or not a transient event occurred within a lock out period. If so, the controlling device 520 continues to operate the optical amplifying device 510 in the constant gain mode and resets the lock out period.
The controlling device 520 also switches the mode as necessary. As an example, the controlling device 520 switches the operation of the optical amplifying device 510 from the gain threshold mode to the constant gain mode when the absolute value of the gain error of the optical amplifying device 510 exceeds the preset gain threshold. The controlling device 520 switches the operation from the constant gain mode to the gain threshold mode if it determines that no transient event occurs within the lock out period.
FIG. 6 is a flow chart illustrating an exemplary control mechanism of an optical amplifying device according to an embodiment of the present invention. In step 610 , target gain G CG and threshold gain G TH are set. In step 620 , the optical amplifying device enters the gain threshold mode. In this step, input and output powers P IN and P OUT are measured and the gain G MEAS =P OUT −P IN is determined. In step 630 , the gain error G ERROR =G CG −G MEAS is determined and compared against the threshold gain G TH .
If the absolute value of the gain error G ERROR exceeds the threshold gain G TH , then the constant gain mode is entered (see step 640 ). In step 640 , the input power P IN the optical amplifying device is appropriately amplified by G CG and output as P OUT . The optical amplifying device remains in the constant gain mode as long as one or more transient events occur within a preset lock out period as described above (see step 650 ). If no transient event occurs within the lock out period, then the optical amplifying device enters the gain threshold mode (see step 620 ).
If the absolute value of the gain error G ERROR is within the threshold gain G TH in step 630 , then the optical amplifying device remains in the gain threshold mode.
FIG. 7 is an exemplary graphical illustration 700 of power output of an optical amplifying device utilizing the gain threshold described above. In this non-limiting example, the target gain G CG for the amplifying device is set at 25 dB and the gain threshold G TH is set at 0.2 dB. It should be noted that the target gain G CG and the gain threshold G TH are not limited to the above values and may be set to any values as deemed appropriate.
In the gain threshold mode, for example between time t 0 and t 1 , the gain of the optical amplifying device varies according to the input power so that the output power P OUT is substantially constant.
When the absolute value of the gain error G ERROR exceeds the threshold G TH , i.e. when |G ERROR |−G TH >0 becomes true, the optical amplifying device enters the constant gain mode, for example between times t 1 and t 2 and between times t 3 and t 4 . During these times, the output power P OUT is appropriately amplified as shown.
Assuming no transient events occur, the optical amplifying device reenters gain threshold mode, for example between times t 2 and t 3 and beyond time t 4 .
As shown, during gain threshold mode, the gain is adjusted to provide the output power P OUT at a substantially constant level. During the constant gain mode, the gain is kept substantially constant so that output power P OUT tracks the input power P IN .
An optical amplifying devices may include a service channel, one or more variable optical attenuators (VOA), signal monitors, optical monitors, input isolator, output isolator, output back reflection monitor, gain flattening filter, pumps, on-board electrical control circuits including communication port, etc. FIG. 8 is a block diagram of a three stage optical amplifying device 800 according to an embodiment of the present invention. For example, the amplifying device 800 may include EDFA amplifiers. Of course, it should be noted that the EDFA is but one of several amplifiers made of optically active materials that may be used. In addition, erbium doped waveguide amplifier (EDWA) may be used as well.
The device 800 includes various power monitoring points as shown that are monitored by the measuring device (see FIG. 5 ). The device 800 may include first, second, and third optical amplifier stages 810 - 1 , 810 - 2 , and 810 - 3 connected in series fashion. The device 800 may also include a VOA 820 and connected as shown. The VOA 820 may be manipulated to control the gain of the device 800 . While not shown, it should be noted that other VOAs may be added to finely tune the operation of the device 800 .
The device 800 may also include an optional dispersion compensation fiber (DCF) 830 . The DCF is desirable to provide periodic dispersion compensation for high frequency signals, typically 10 Gb/s or higher.
In general, an optical amplifying device may include a plurality of amplifier stages connected in series, one or more VOAs connected in series with the plurality of optical amplifier stages such that each VOA receives an output of one optical amplifier and outputs to a next optical amplifier. At least least one VOA is controlled by the controlling device. In addition, the optical amplifying device may include one or more DCFs, with each DCF receiving an output of an amplifier and outputting to a next amplifier.
A simpler implementation of an optical amplifying device would include one or more amplifier stages and a VOA. The gain of the amplifier may be controlled by adjusting the VOA. Alternatives include adjusting power supplied by the pump(s) and by controlling other VOA(s) of the amplifier.
While the invention has been described with reference to the exemplary embodiments thereof, it is to be understood that various modifications may be made to the described embodiments without departing from the spirit and scope of the invention thereof. The descriptions used herein are set forth by way of illustration only and are not intended as limitations.
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Optical amplifying method and apparatus are proposed. Constant gain amplifiers operate such that the output power of the amplifier generally tracks the input power. However, optical systems are not perfect and the input to the optical amplifier stage includes not only the desired signal, but also includes accumulated effects of the imperfections. The imperfections include losses of the fiber sections, variations in laser powers, and drifts. Thus, simple amplification not only amplifies the desired signal, but also amplifies accumulated imperfections. Such imperfections occur over time and are generally small in magnitude. By operating the amplifier such that amplification of small variations is suppressed while allowing for tracking of large input variations, amplifying the accumulated imperfections is minimized.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to the synthesis of N-[N-(3,3-dimethylbutyl)-L-α-aspartyl]-L-phenylalanine 1-methyl ester (neotame) by reductive alkylation and crystallization/isolation in methanol and water. This method of producing neotame results in high purity and is more simple and more economical than the typical preparation of neotame.
2. Related Background Art
N-[N-(3,3-dimethylbutyl)-L-α-aspartyl]-L-phenylalanine 1-methyl ester (neotame) is a high potency dipeptide sweetener (about 8000× sweeter than sucrose) that has the formula
The chemical synthesis of neotame is disclosed in U.S. Pat. Nos. 5,480,668, 5,510,508, 5,728,862 and WO 00/15656, the disclosure of each of which is incorporated by reference herein.
U.S. Pat. No. 5,480,668 describes the formation of neotame in methanol, followed by methanol removal, formation of an aqueous hydrochloric acid solution of the neotame, filtration, drying and recrystallization from an ethanol/water mixture.
U.S. Pat. No. 5,510,508 describes the formation of neotame in aqueous acetic acid and methanol, followed by methanol removal, filtration, drying and washing.
U.S. Pat. No. 5,728,862 describes the formation of neotame in methanol, followed by filtration, washing, methanol reduction, addition of water, methanol distillation, filtration, washing and drying.
WO 00/15656 describes the formation of neotame using Z-aspartame (N-benzyloxycarbonyl-L-α-aspartyl-L-phenylalanine-1-methyl ester) in a methanolic solvent, followed by partial evaporation of the organic part of the solvent, optional addition of water before and/or during and/or after the partial evaporation of the organic part of the solvent, separation of the neotame formed and drying.
In addition to being complicated by various methanol removal and/or distillation steps, these chemical processes may produce several troublesome impurities, including N,N-di(3,3-dimethylbutyl)-L-aspartyl-L-phenylalanine methyl ester (dialkylated aspartame), α-methyl hydrogen-3-( 3,3-dimethylbutyl)-2-L-(2,2-dimethylpropyl)-5-oxo-α-L-(phenylmethyl)-1,4(L)-imidazolidine diacetate (dialkylated imidazolidinone), N-[N-(3,3-dimethylbutyl)-L-α-aspartyl]-L-phenylalanine (demethylated α- or β-neotame) and methyl ester of N-[N-(3,3-dimethylbutyl)-L-α-aspartyl]-L-phenylalanine 1-methyl ester (methylated α- or β-neotame). These impurities are represented respectively by the structural formulae:
Since neotame is mainly employed in foods for human consumption, it is extremely important that neotame exist in a highly purified state.
U.S. Pat. No. 5,728,862 outlines a purification method by which neotame is precipitated out of an aqueous/organic solvent solution, wherein the aqueous/organic solvent solution has an amount of organic solvent of about 17% to about 30% by weight.
Copending U.S. patent application Ser. No. 09/448,671, filed on Nov. 24, 1999, relates to methods of purifying neotame by crystallization in a variety of organic solvent/aqueous organic solvent mixtures. Each of these methods which uses an organic solvent and water mixture contemplates a solvent distillation step.
Thus, it is clear that there is a need to economically and efficiently produce pure N-[N-(3,3-dimethylbutyl)-L-α-aspartyl]-L-phenylalanine 1-methyl ester.
SUMMARY OF THE INVENTION
The present invention relates to the efficient, low cost and high purity synthesis of N-[N-(3,3-dimethylbutyl)-L-α-aspartyl]-L-phenylalanine 1-methyl ester. According to the present inventive method, neotame is synthesized by preparing a mixture of aspartame and a catalyst in a solvent consisting of water and methanol; adding 3,3-dimethylbutyraldehyde to the mixture in the presence of hydrogen to produce N-[N-(3,3-dimethylbutyl)-L-α-aspartyl]-L-phenylalanine 1-methyl ester; removing the catalyst; adding water to the mixture to reach a desired crystallization solvent concentration; holding the mixture for a time and at a temperature sufficient to hydrolyze dialkylated imidazolidinone; and crystallizing N-[N-(3,3-dimethylbutyl)-L-α-aspartyl]-L-phenylalanine 1-methyl ester.
In certain preferred embodiments of the present invention, crystallized N-[N-(3,3-dimethylbutyl)-L-α-aspartyl]-L-phenylalanine 1-methyl ester is separated from the mixture.
In a certain embodiment of the present invention, the mixture may be seeded prior to crystallization.
DETAILED DESCRIPTION
The present invention relates to the optimization of the synthesis of N-[N-(3,3-dimethylbutyl)-L-α-aspartyl]-L-phenylalanine 1-methyl ester (neotame) by reductive alkylation in a water/methanol solvent in order to produce substantially pure neotame.
According to the present invention, N-[N-(3,3-dimethylbutyl)-L-α-aspartyl]-L-phenylalanine 1-methyl ester is synthesized by preparing a mixture of aspartame and a catalyst in a solvent consisting of water and methanol; adding 3,3-dimethylbutyraldehyde to the mixture in the presence of hydrogen to produce N-[N-(3,3-dimethylbutyl)-L-α-aspartyl]-L-phenylalanine 1-methyl ester; removing the catalyst; adding water to the mixture to reach a desired crystallization solvent concentration; holding the mixture for a time and at a temperature sufficient to hydrolyze dialkylated imidazolidinone; and crystallizing N-[N-(3,3-dimethylbutyl)-L-α-aspartyl]-L-phenylalanine 1-methyl ester.
According to the first step of the present inventive method, a mixture of aspartame and a catalyst is prepared in a solvent consisting of water and methanol. The ratio of water to methanol in the solvent is from about 5:95 to about 70:30, and preferably from about 30:70 to about 50:50.
The concentration of aspartame in the water and methanol mixture is from about 5% to about 25%, and preferably about 17%. The aspartame used in the present inventive process can be wet with water or dry. Aspartame can also be used in situ from any N-protected aspartame derivative prepared by known methods.
The catalyst suitable for use in the present invention may be selected from catalysts based on palladium or platinum including, without limitation, platinum on activated carbon, palladium on activated carbon, platinum black or palladium black. Other catalysts include, without limitation, nickel on silica, nickel on alumina, Raney nickel, ruthenium black, ruthenium on carbon, palladium hydroxide on carbon, palladium oxide, platinum oxide, rhodium black, rhodium on carbon and rhodium on alumina. The catalysts based on palladium or platinum are preferred.
The catalyst is present in an amount effective to produce neotame in an acceptable yield. Generally, the weight ratio of catalyst (on a dry basis) to aspartame is about 0.01:1 to about 0.25:1, preferably about 0.10:1. It is important to note that about a 10% catalyst loading is required to minimize the undesirable yield of dialkylated aspartame.
According to the second and third steps of the present invention, 3,3-dimethylbutyraldehyde is added to the mixture and reacted with aspartame in the presence of the catalyst and in the presence of hydrogen for a time and at a temperature sufficient to produce neotame. 3,3-Dimethylbutyraldehyde can be added slowly or all at once to the reaction mixture. When the aldehyde is gradually added, typically it is added over the course of about 2 to 8 hours, preferably from about 4 to 6 hours. It is important to note that the reactants, i.e., aspartame, catalyst, aldehyde, can be added in any order.
Aspartame (L-α-aspartyl-L-phenylalanine 1-methyl ester) and 3,3-dimethylbutyraldehyde are readily available starting materials, which are typically combined in a substantially equivalent molar ratio, i.e., about 1:0.95 to 1:1.
Excess molar amounts of aspartame are not preferred due to waste and cost. Higher molar amounts of the aldehyde are likely to lead to the generation of impurities. Further, the 3,3-dimethylbutyraldehyde used in the present process should be highly pure. Small impurities in the 3,3-dimethylbutyraldehyde may produce odor. Higher molar ratios of aldehyde may cause the entrapment of the aldehyde during the crystallization of neotame and produce odor; alternatively, excess aldehyde may be oxidized to the corresponding t-butyl acetic acid which also produces odor. The odor can be removed by washing the final product with organic solvents (such as heptane, ethyl acetate, t-butylmethyl ether, hexane, etc.) or by extruding the final product. The excess aldehyde may also react with neotame to give dialkylated imidazolidinone. This may also be crystallized along with neotame and will hydrolyze to give neotame and aldehyde.
The aldehyde and the aspartame are reacted for a time and at a temperature sufficient to produce neotame. Generally, the time ranges from about 1 to about 24 hours, preferably from about 2 to about 4 hours after the addition of the aldehyde is complete. If the 3,3-dimethylbutyraldehyde is added to the reaction mixture all at once, then the time sufficient to produce neotame preferably ranges from about 6 to about 24 hours. Generally, the temperature sufficient to produce neotame according to the present invention ranges from about 20° C. to about 60° C., preferably from about 22° C. to about 40° C.
The reaction of the present invention is carried out in the presence of hydrogen. Generally, the pressure of the hydrogen ranges from about 5 psi to about 100 psi, preferably from about 30 psi to about 40 psi.
In the next step of the present inventive method, the catalyst is removed from the mixture. The catalyst may be separated by a variety of solid-liquid separation techniques that include, without limitation, the use of sparkler, crossflow, nutsche, basket, belt, disc, drum, cartridge, candle, leaf and bag filters. Furthermore, catalyst separation performance may be enhanced through the use of gravity, pressure, vacuum and/or centrifugal force. Additionally, the catalyst separation rate and removal efficiency may be enhanced through the use of any number of various filter media that include, without limitation, woven cloth fabrics, woven metal fabrics, porous metal substrates and synthetic or naturally occurring membranes. The separation device and media can be permanent, replaceable or disposable. The catalyst solid alone may be separated, or separation may be assisted by the use of porous cellulosic fiber or diatomaceous silica type filter aids, which are used as a media precoat and/or directly with a catalyst slurry. The separation device can be operated in an automated or manual mode for solid media washing, solid discharging and/or solid and media back flushing. The catalyst can be washed and discharged from the filter media using gas, liquid or mechanical means. The catalyst alone or catalyst with filter aid can be partially or totally recycled for used in subsequent hydrogenation reactions.
In the fourth step of the present invention, water is added to the mixture to reach a desired solvent concentration. The ratio of water to methanol in the crystallization solvent is from about 85:15 to about 65:35, and preferably from about 75:25 to about 70:30.
In the next step of the present process, the mixture is held for a time and at a temperature sufficient to hydrolyze dialkylated imidazolidinone to α-neotame and 3,3-dimethylbutyraldehyde. The reaction mixture is generally held for about 0.5-24 hours at a temperature of about 20-50° C. In a preferred embodiment of the present invention, the reaction mixture is held for about 2-4 hours.
In the final step of the present inventive process, neotame is crystallized. Typically this is accomplished by cooling the mixture to about 0-250° C., preferably to about 5-10° C., over the course of about 0.5-2 hours, preferably about 1-2 hours.
Seeding prior to or during crystallization can initiate a controlled crystal growth rate according to the present invention. Hence, the reaction mixture may optionally be seeded in an amount from 0.0001%-10%, by weight of the N-[N-(3,3-dimethylbutyl)-L-a-aspartyl]-L-phenylalanine 1-methyl ester in the solution, preferably from 0.1% to 1% and most preferably from 0.1% to 0.5%. Seeding is typically performed at 25-35° C. and preferably at 28-30° C.
The reaction mixture or the solution containing neotame may be unstirred or stirred during the crystallization processes of the present invention.
The crystallized neotame may be separated from the solvent solution by a variety of solid-liquid separation techniques that utilize centrifugal force, that include, without limitation, vertical and horizontal perforated basket centrifuge, solid bowl centrifuge, decanter centrifuge, peeler type centrifuge, pusher type centrifuge, Heinkel type centrifuge, disc stack centrifuge and cyclone separation. Additionally, separation may be enhanced by any of pressure, vacuum, and gravity filtration methods, that include, without limitation, the use of belt, drum, nutsche type, leaf, plate, Rosenmund type, sparkler type, and bag filters and filter press. Operation of the neotame solid-liquid separation device may be continuous, semi-continuous or in batch mode. The neotame solid may also be washed on the separation device using various liquid solvents, including, without limitation, water, methanol and mixtures thereof. The neotame solid can also be partially and totally dried on the separation device using any number of gases, including, without limitation, nitrogen and air, to evaporate residual liquid solvent. The neotame solid may be automatically or manually removed from the separation device using liquids, gases or mechanical means by either dissolving the solid or maintaining the solid form.
The product isolated from this method is the monohydrate, which may be dried to produce an anhydrous form.
The crystallized and isolated neotame solid may be further purified by a variety of drying methods. Such methods are known to those skilled in the art and include, but are not limited to, the use of a rotary vacuum dryer, fluid bed dryer, rotary tunnel dryer, plate dryer, tray dryer, Nauta type dryer, spray dryer, flash dryer, micron dryer, pan dryer, high and low speed paddle dryer and microwave dryer.
The above-described process of the present invention achieves a number of advantages as compared to conventional neotame synthetic routes. In particular, methanol removal or distillation steps are eliminated. On a manufacturing scale, this results in at least a 2-3 days processing time savings, as well as a significant cost savings. Dialkylated imidazolidinone hydrolysis time is also reduced to only two hours according to the present invention. Further, additional reduction in cost is achieved due to the higher aspartame concentration employed in the present invention.
Additionally, as compared to methods using 100% methanol, safety concerns are lessened and the amount of α-methyl hydrogen-3-(3,3-dimethylbutyl)-2-L-(2,2-dimethylpropyl)-5-oxo-α-L-(phenylmethyl)-1,4(L)-imidazolidine diacetate (dialkylated imidazolidinone) is significantly lower.
The Examples which follow are intended as an illustration of certain preferred embodiments of the invention, and no limitation of the invention is implied.
EXAMPLE 1
One hundred grams aspartame was charged to a 1.0 L RC 1 glass vessel having an agitator operating at 100 rpm. Twenty-six grams 5% Pd/C catalyst (10% loading on dry basis; 61.45% wet) was then charged to the vessel. One hundred grams water and 375 g methanol were also charged to the vessel. The vessel was then purged with nitrogen (4×). While under 10 psig nitrogen, the vessel was heated to 40° C. Then the vessel was purged with hydrogen (4×) and charged to 40 psig hydrogen. The agitator was set to 800 rpm. Then 33.2 g 3,3-dimethylbutyraldehyde was pumped into the vessel over 5 hours. The 3,3-dimethylbutyraldehyde container, the pump and the lines were rinsed with approximately 5 ml methanol (3×). The mixture was stirred for an additional 2 hours at 40 psig and 40° C.
At the completion of the reductive alkylation, the vessel was vented and purged with nitrogen (4×). The catalyst was removed by filtration through a layer of powdered cellulose using a Buchner glass filter. The vessel was rinsed with 335 ml deionized water; this water was used to wash the catalyst and combined with the filtrate.
An HPLC (high pressure liquid chromatography) analysis of the crude mixture thus obtained indicates the following: 91.0% neotame, 4.0% aspartame, 1.23% dialkylated aspartame, 0.26% dialkylated imidazolidinone and 0.25% methylated neotame. The filtrate containing this crude mixture was then placed in a jacketed flask, heated to 40° C. and held for 2 hours to hydrolyze the dialkylated imidazolidinone. The solution was then cooled to 28° C. and seeded with 0.17 g neotame. After seeding, the crystallizer was cooled to 5° C. over 1.5 hour. The neotame slurry was held at 5° C. for 1 hour. Then the neotame was filtered, and the wet cake was washed with 70 ml cold deionized water. The isolated neotame was dried at 40° C. under vacuum with nitrogen purge for 48 hours.
Neotame was obtained in 70.74% yield. An HPLC analysis of the final product indicated the following: >98% neotame, 0.0% aspartame, 0.03% dialkylated aspartame, 0.00% dialkylated imidazolidinone and 0.04% methylated neotame.
EXAMPLE 2
One hundred grams aspartame was charged to a 1 L stirred vessel. Twenty-six grams of 5% Pd/C catalyst (61.45% water) was charged to the reactor. Two hundred fifty grams water followed by 375 g methanol were added to the reactor. The vessel was purged with nitrogen (4×). While under nitrogen pressure (10 psig), the contents of the vessel were heated to 40° C. Then the vessel was purged with hydrogen (4×) and charged to 40 psig with hydrogen. The agitator was set to 800 rpm. Then 33.2 g of 3,3-dimethylbutyraldehyde was pumped into the vessel over 5 hours. The pump and transfer lines were rinsed with 3 ml methanol (3×) to ensure complete and accurate charging. The mixture was stirred for an additional two hours at 40 psig and 40° C.
After completion of the reductive alkylation, the vessel was vented and purged with nitrogen (4×). The catalyst was removed by filtration through powdered cellulose on a Buchner funnel. The vessel was rinsed with 185 g deionized water. This rinse was also used to wash the catalyst and combined with the filtrate. After addition of the water, the solution is heated to 40° C. for two hours to hydrolyze the dialkylated imidazolidinone. The product was isolated as described in Example 1.
Neotame was obtained in 70% yield. An HPLC analysis of the final product indicated the following: >98% neotame, <0.05% dialkylated aspartame and <0.05% methylated neotame.
Other variations and modifications of this invention will be obvious to those skilled in this art. This invention is not to be limited except as set forth in the following claims.
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N-[N-(3,3-dimethylbutyl)-L-α-aspartyl]-L-phenylalanine 1-methyl ester is produced by reductive alkylation and crystallization/isolation in methanol and water. The production method is efficient and low cost, as compared with conventional N-[N-(3,3-dimethylbutyl)-L-α-aspartyl]-L-phenylalanine 1-methyl ester synthesis and results in high purity N-[N-(3,3-dimethylbutyl)-L-α-aspartyl]-L-phenylalanine 1-methyl ester.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a method and apparatus for use in drilling a well from an offshore floating vessel, the vessel having a marine riser interconnected between the vessel and a subsea wellhead assembly.
2. Description of the Prior Art
An increasing amount of offshore deepwater exploratory well drilling is being conducted in an attempt to locate oil and gas reservoirs. These exploratory wells are generally drilled from floating vessels. As in any rotary drilling operation, drilling fluid must be circulated through the drill bit in order to cool the bit and to carry away the cuttings. This drilling fluid is normally returned to the floating vessel by means of a large diameter pipe, known as a riser, which extends between a subsea wellhead assembly and the floating vessel. The lower end of this riser is connected to the wellhead assembly which is generally adjacent the ocean floor, and the upper end usually extends through a centrally located hull opening of the floating vessel. A drillstring extends downward through the riser into earth formations lying below the body of water, and drilling fluids circulate downwardly through the drillstring, out through the drilling bit, and then upwardly through the annular space between the drillstring and riser, returning to the vessel.
As the water depths for these drilling operations continue to increase, the length of the riser and subsequently its unsupported weight also increases. The riser has the same structural buckling characteristics as a vertical column, such that riser structural failure may result if compressive stresses occur over a long length of the riser. To avoid the possibility of this occurrence, riser tensioning systems are installed on board the vessel, which apply an upward force to the upper end of the riser, usually by means of cable and sheave mechanisms connected between the vessel and the upper elements of the riser.
Since the drillstring rotates as it extends downward through the riser, any inclination of the riser away from a vertical plane defined from the drilling equipment located on the vessel to the wellhead assembly will cause the drillstring to contact the interior surface of the riser. Continuous drillstring rotation will cause chafing at the points of drillstring and riser contact. Any unnecessary bends or "dog-legs" in the riser therefore need to be avoided.
Where the riser's lower end connects to the wellhead assembly, the riser must be aligned vertically, to prevent the rotating drillstring from chafing and thereby damaging the blowout prevention equipment located immediately above the wellhead assembly. The well blowout prevention equipment must be maintained in an operable condition at all times.
To align the riser vertically at the wellhead assembly, when the riser is subjected to strong ocean currents, the vessel must be offset from, or moved away from, a location directly above the wellhead assembly. This offset position is necessary to compensate for the slight bend that develops in the entire riser assembly due to the ocean currents. For example, a riser 6000' in length may require a vessel offset of 100 to 400 feet.
Due to this vessel offset, the upper elements of the riser tend to develop an angle of inclination from the vertical. But the upper end of the riser is typically secured vertically to the vessel, to allow vertical insertion and removal of the drillstring. The inclined position of the riser directly below the riser's vertical oriented vessel attachment point is permitted by the installation of a flexible coupling called a ball joint or flex joint, beneath the vessel attachment point. With the vessel offset 200 to 300 feet from the wellhead assembly in a water depth of 5000' to 6000', the inclination of the upper end of the riser may easily be 4° or more, causing this amount of misalignment between the inserted drilling equipment and the upper end of the riser.
But if the drillstring continuously rotates within this flexible coupling while the coupling is misaligned 4° end-to-end, chafing and subsequent damage will result, with possible separation of the drillstring and/or the riser. Any separation of either the drillstring or the riser will require expensive retrieval and repair operations with subsequent delays in field development.
An apparatus and method need be developed that reduces the angle of misalignment of the riser's upper section with the vessel's drilling equipment, to prevent failure of either the riser or the drillstring.
SUMMARY OF THE INVENTION
The present invention comprises a riser angle control apparatus, having a second flexible coupling operatively engaged with the riser approximately 100' to 200' below the first flexible coupling carried at the upper end of the riser, and also a tensioned member attached to the second flexible coupling. The original misalignment angle which existed solely at the first flexible coupling may now, by application of lateral force to the second flexible coupling, be "averaged" or "split" between the first and second flexible couplings.
A 4° angle of misalignment which existed solely at the first flexible coupling may now be reduced to a 2° angle of misalignment, with the other 2° of misalignment being absorbed by the second flexible coupling. The averaging of these angles between the two flexible couplings reduces "dog-legs" in the riser, thereby reducing the possibility of the rotating drillstring chafing the interior of the riser and/or being damaged by fatigue.
Specifically, the apparatus of the present invention comprises second flexible coupling means operatively engaged with a portion of said upper elements of said riser below said first flexible coupling means, flexible element prime mover means carried by said vessel, and at least one flexible element means having a first end and a second end, said first end operatively engaged with said second flexible coupling means, said second end operatively engaged with said flexible element prime mover means.
More specifically, the method of the present invention of reducing the angle of misalignment of a riser's upper elements relative to a floating vessel operatively engaged to the upper end of said riser, said riser having first flexible coupling means located adjacent the upper end of said riser, said vessel being provided with riser angle control apparatus including second flexible coupling means operatively engaged with said upper elements of said riser below said first coupling means, flexible element prime mover means carried by said vessel, and at least one flexible element means having a first end and a second end, said first end operatively engaged with said second flexible coupling means, said second end operatively engaged with said flexible element prime mover means, said method comprising orienting said flexible element means adjacent said second flexible coupling means opposite the direction of the normal angle of misalignment of said riser, actuating said flexible element prime mover means to tension said flexible element means, thereby distributing the angle of misalignment between the riser upper elements.
An object of the invention is to provide a method and apparatus to reduce the angle of misalignment from the vertical of a riser's upper elements relative to a vessel which supports the upper end of the riser, to prevent damage to the riser and a rotating drillstring carried within the riser.
A further object of the invention is to provide a riser angle control apparatus which is simple in design, rugged in construction, and economical to manufacture.
The various features of novelty which characterize the invention are pointed out with particularity in the claims next to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and specific object obtained by its uses, reference should be made to the accompanying drawing and descriptive matter in which there are illustrated preferred embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWING
The FIGURE is a schematic representation of a floating vessel conducting an underwater drilling operation in which a riser is shown connected between a floating vessel and a subsea wellhead assembly.
DESCRIPTION OF THE PREFERRED EMBODIMENT
As shown in the FIGURE, a vessel 10 is floating in a body of water 26 above a subsea wellhead assembly 29 located upon the ocean floor 20. A riser 42 comprised of riser upper elements 23 and riser lower elements 40 connects the vessel 10 with the subsea wellhead assembly 29. A drillstring 21 is carried within the riser 42, the drillstring 21 being manipulated by the drillstring and riser lift mechanism 34 and the rotary table 11, carried by the vessel 10, in order to drill formations located beneath the ocean floor 20 by means well known to the art. Riser tensioning equipment 14, 14A in the form of hydraulic pistons, cylinders, and cable sheave assemblies is secured to the upper elements of the riser 23. This riser tensioning equipment 14, 14A applies an upward lifting force to the upper elements of the riser 42 in order to prevent compressive structural failure of the lower elements of the riser 40.
Directional positioning thrusters 24, 24A and vessel propulsion means 22 assist in maintaining the vessel 10 above the wellhead assembly 29 while subjected to ocean currents 32 impacting the vessel 10 and riser 42 from a particular direction.
The riser upper elements 23 are shown connected at their upper end to vessel connection means 41, such as a bearing plate or truss support structure well known to the art. Located below and adjacent the vessel connection means 41 is the first flexible coupling means 36 incorporated into the riser upper elements 23, such as a "ball joint" or "flex joint" well known to the art which allows the riser 42 to deflect from a vertical orientation. The first flexible coupling means 36 has an opening defined through the central axis to allow the drillstring 21 to pass through.
The riser lower elements 40, similar to the riser upper elements 23, are shown connected at the lower end to blowout prevention equipment 39 carried by the wellhead assembly 29. The blowout prevention equipment 39 incorporates hydraulically driven rams and isolation valves (not shown) that, if necessary, isolate the subsea environment from downhole pressures and fluids. The proper operation of this equipment relies upon the mating of close tolerance surfaces and maintaining the integrity of the valve bodies. The rotating drillstring 21 is therefore maintained in a vertical orientation while passing through the blowout prevention equipment 39 to prevent damage to these mating surfaces and bodies, usually by offsetting the vessel 10 an offset distance 38 from the wellhead assembly 29. The direction of offset distance 38 is opposite the direction of the ocean current 32 direction, to compensate for the bend developed in the riser 42 from the ocean current 32.
The amount of offset distance 38 is primarily dependent upon the force imposed upon the riser 42 by the ocean current 32 and the overall length of the riser 42. The overall length of the riser 42 is approximately indicated by riser length dimension 37.
In the case of a water depth dimension 37 of 5000' to 6000', an offset distance 38 to 100' to 400' can be anticipated. This offset will cause a normal angle of misalignment 28 in the riser upper elements 23, which are shown in phantom positioned in the FIGURE before the activation of the apparatus of the present invention. This angle of misalignment 28 causes a corresponding angle to develope in the first flexible coupling means 36, causing chafing of the drillstring 21 with the interior of the riser upper elements 23.
In the preferred embodiment of the present invention, a second flexible coupling means 12 similar to the first flexible coupling means 36 is incorporated into the riser upper elements 23 a selective distance 44 below the first flexible coupling means 36. The actual spacing between couplings may be in 50 to 300-ft. range. This spacing can be determined by analysis of bending moments in the drill string and the contact forces between the riser bore and the drill string O.D. If the spacing is too large, the horizontal component of the force exerted on the flexible coupling means 12 by the flexible element means 25 will become small and render the device ineffective. Flexible element means 25 such as a chain or steel cable is operatively engaged with the second flexible coupling means 12 and the flexible means 25. Attachment means 30 by may take the form of chain or cable fastening devices well known to the art.
The other end of the flexible element means 25 is operatively engaged with flexible element prime mover means 13 such as a hydraulic piston and cylinder assembly well known to the art. The prime mover means 13 may be carried at any convenient location by the vessel 10, such as upon the vessel deck 43. A control panel 18 and control lines 19 supply pressurized hydraulic fluid to the prime mover means 13 to selectively move the flexible element means 25 and consequently the second flexible coupling means 12.
The flexible element means 25 are slideably engaged with rotatable element means such as pulleys 15 and 16 in the preferred embodiment. Pulleys 15 and 16 assist in routing the flexible element means 25 from the prime mover means 13 to the second flexible coupling means 12. The connection operation pulley 17 may be utilized during installation or removal of the second flexible coupling means 12 through the hull opening 33 in order to prevent abrasion of the flexible element means 25 attached to the coupling 22 due to contact with the vessel 10 bottom. Of course, the proper orientation and alignment of pulleys 15 and 16 depends upon the positioning of the flexible element prime mover means 13 in relation to the second flexible coupling means 12 location which is determined as discussed earlier.
In operation, when the vessel 10 is offset from above the wellhead assembly 29 to compensate for ocean currents 32, a normal angle of misalignment 28 will be ascertainable at the upper end of the riser 42. When the angle 28 exceeds, for example, approximately 2°, continued rotation of the drillstring 21 will damage the interior of the riser upper elements 23. The present embodiment of the invention must be actuated to prevent this damage. The flexible element means 25 adjacent the second flexible coupling means 12 is oriented opposite the direction of the normal angle of misalignment 28 of the riser upper elements 23. If the ocean current 32 impacts the riser's 42 northern face, the riser 42 will bend in a southerly direction. To compensate for this southern misalignment, the flexible element means 25 are orientated to apply a tensile force to the northern face of the riser 42. The flexible element prime mover means 13 are then actuated to tension the flexible element means 25, thereby causing a reduction of the normal angle of misalignment 28 of the riser upper elements 23.
The resultant adjusted angle of misalignment 27 of, for example, approximately 2° or less will prevent internal damage to the riser upper elements 23 and drillstring 21. In this fashion the original angle 28 of approximately 4° may be averaged between the first flexible coupling means 36 and the second flexible coupling means 12. Of course, if both flexible couplings 36, 12 are not sufficient to reduce the adjusted angle of misalignment 27 for each section of riser 42 below 2°, in an alternative embodiment additional flexible couplings with associated tensioning equipment (not shown) may be added along the length of the riser 42.
In the present embodiment, since the flexible element means 25 are actuated from a bow mounted prime mover means 13, the vessel 10 may be turned to face into the direction of the ocean current 32 to properly align the flexible element means 25 in the desired direction.
The angles of misalignment 28 and 27, offset distance 38, and riser length 37, all being geometrically related to each other, will vary according to the particular geometry of each vessel 10, riser 42, and wellhead assembly 29 encountered in different water depths 37.
In an alternative embodiment, the flexible element prime mover means 13 may be moveably mounted about the vessel deck 43 of the vessel 10. In this fashion, the vessel 10 may stay orientated in its original position and the flexible element means 25 moved relative to the riser upper elements 23. In any event, tensioning the flexible element means 25 after proper orientation will cause a decrease in the normal angle of misalignment 28.
Many other variations and modifications may be made in the apparatus and techniques hereinbefore described by those having experience in this technology, without departing from the concept of the present invention. Accordingly, it should be clearly understood that the apparatus and methods depicted in the accompanying drawings and referred to in the foregoing description are illustrative only and are not intended as limitations on the scope of the invention.
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Method and apparatus for use in drilling a well from an offshore drilling vessel having a riser extending from the vessel down to a subsea wellhead. The apparatus of the invention comprises a flexible coupling installed in the riser's upper elements, with a tensioned cable connected between the flexible coupling and the vessel. The angle of misalignment of the riser's upper elements due to ocean currents impacting the riser and/or vessel may be maintained within acceptable limits by adjusting the tension applied to the flexible coupling.
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RELATED APPLICATIONS
[0001] The present application claims priority to U.S. Patent Application Ser. No. 60/079,302 filed Mar. 25, 1998 ('302 application).
FIELD OF THE INVENTION
[0002] The present invention relates to content delivery over a large computer network, and more particularly to a computer network architecture which integrates management components such as a reservation system, a funds flow system, a metering system, and a security system for preventing unauthorized use of courseware and other content.
TECHNICAL BACKGROUND OF THE INVENTION
[0003] More and more paintings, pictures, books, songs, other performances, texts, diagrams, recordings, video clips, and courses utilizing them for instructional purposes and/or entertainment are becoming available in machine readable forms. In particular, many computer-assisted lessons, training materials, and other instructional courses include works which can be protected under intellectual property laws, such as visual works, audio works, texts, examinations, simulations, and other works. Some sensory works experienced while using computers, such as the physical motions performed with a flight simulator, may also be protected. Still other computer-aided sensory experiences are foreseeable but not yet commercially implemented, such as smells that could enhance a fire fighting course or a course on the detection of illegal drugs. These will also benefit from protection.
[0004] “Computerized training”, “computer-assisted instruction”, “computer-aided learning”, “web-based training”, “intranet-based learning”, “web courses”, “virtual university”, “computerized curriculum delivery system”, “courseware delivery system”, “instructional management system”, “interactive educational method”, and similar phrases are used by various people in various ways, but each of these terms refers to efforts to use computers to help educate students. As used here, “students” are not necessarily traditional students enrolled in high schools, colleges, universities, and the like, but are rather people who receive instruction through courseware. Courseware may be used by traditional students, but it may also be used by employees of government agencies and corporations, for instance.
[0005] To better understand the present invention in the context of existing computer-assisted educational efforts, it will helpful to understand certain distinctions, including without limitation the following:
Course authoring vs. course content delivery; Stand-alone computer-based training vs. networked instruction; Synchronous sharing vs. asynchronous sharing; Commercial systems vs. academic systems; and Technical vs. legal means for securing intellectual property. Courseware vs. other content
Authoring vs. Delivery
[0012] Many uses of computers to facilitate education focus on providing authoring tools and authoring environments. For instance, tools for authoring include tools for re-formatting text into HTML format and adding hyperlinks; tools for integrating audio and/or video content with text content; and tools for creating interactive forms to obtain information from students and provide appropriate responses. In short, authoring tools help instructors create courseware content.
[0013] By contrast, delivery tools help deliver courseware to students. In the case of “web-based training”, “intranet-based learning”, and “web courses”, delivery tools typically include TCP/IP networks and web browsers. Computer workstations themselves may also be viewed as delivery tools, particularly when the courseware is written to be used on a stand-alone computer rather than being delivered over a network connection.
[0014] Many existing approaches to computer-aided teaching include both authoring and delivery components. However, the problems and solutions associated with authoring are not necessarily the same as those associated with delivery. The present invention is concerned primarily with delivery as opposed to authoring.
[0000] Stand-alone vs. Networked Instruction
[0015] Many computer-based training systems do not require a network connection in order to function. All necessary courseware content is stored on a computer disk, CD-ROM, or other medium which is directly accessible to the computer being used by the student, making it unnecessary to send any content over a network connection. The tools and techniques for managing courseware content in such stand-alone systems are basically the same as the tools and techniques for managing application programs, operating systems, and other types of software installed on user workstations, namely written licenses, disk copy-protection schemes, license serial numbers, and the like.
[0016] By contrast, network-based training approaches either take advantage of a network connection if one is available, or else they require such a connection. Different network-based systems use the network in different ways. Sometimes courseware content is stored on a server and delivered over the network to users as needed. In some cases, part or all of the content is stored on the local network node but licensing is enforced through a server. For instance, the content stored locally might be encrypted, and the decryption key might be available only from the server and then only after the user is authenticated. Some network-based educational systems allow students to interact with one another and/or with the instructor through email or chat rooms. Some systems administer tests by having the student send test answers to a server, which grades the test and notifies the student of the results. Some systems provide instructors with access over the network to a database of administrative information such as student grades and a list of the students who have viewed a given lesson. Of course, many systems combine one or more of these features and some also use networks in other ways.
[0017] The present invention is concerned with network-based courseware delivery systems, as opposed to stand-alone courseware delivery systems.
[0000] Synchronous vs. Asynchronous Sharing
[0018] Networked courseware delivery systems may share content between multiple users synchronously or asynchronously. With synchronous sharing, users and/or instructors exchange information in a real-time or interactive way. Examples of synchronous sharing include telephone conversations, video conferencing, and chat rooms. By contrast, asynchronous sharing involves an exchange of information in which the participants expect substantial delays, or they involve a one-way flow of information rather than an exchange. Examples of asynchronous sharing include downloading a previously created multimedia presentation, listsery exchanges, and Usenet postings. Email does not fit neatly in either category, because it can be either synchronous or asynchronous in practice.
[0019] Some aspects of the present invention are concerned with asynchronous sharing, and in particular with asynchronous delivery of previously created courseware content. However, other aspects of the invention are concerned with synchronous information exchanges, such as funds transfers.
[0000] Commercial Systems vs. Academic Systems
[0020] As noted, some courseware students attend traditional institutions of higher education. In many cases, those students pay for their use of courseware by paying tuition to the institution. If the institution is not the owner of the courseware, the institution then makes separate arrangements for payment to the owner. Likewise, students who are employees of a government agency or corporation generally receive access to courseware through their employer without personally making arrangements to pay the courseware owner directly. In either case, at the time a student sits down to actually use the course-ware it may be necessary to authenticate the student to the system but it is not necessary for the student to provide a credit card number or similar payment mechanism. For convenience, courseware management systems which do not require direct payment from students are referred to herein as “academic systems”.
[0021] By contrast, in “commercial systems” some provision must be made for funds transfer before a student is given full access to courseware content (although a demo might be available at no charge). For instance, each student may be required to provide a credit card number, to pre-pay for access by giving cash or a check to an attendant, or to provide individual billing information if credit is being extended.
[0022] The present invention is concerned primarily with commercial courseware delivery systems as opposed to academic courseware delivery systems.
[0000] Technical vs. Legal Security
[0023] As time passes, personal computers and other computational devices are able to record into machine readable form more and more complex presentations or experiences. For example, personal computers in the 1980's mainly manipulated words, numbers, and characters; in the 1990's manipulation of icons, images, audio and video has become commonplace. The next step may include widespread use of motion, as in simulators, and perhaps smell or other additions. As the complexity of the process needed to place these words, images, and other sensory experiences into machine readable form increases, the value of computer software that presents these experiences increases. This increases in turn the value of a security system which enforces courseware license agreements.
[0024] Intellectual property rights are provided by copyright and other laws to encourage creative effort by artists, authors, and other people who create paintings, photographs, animations, musical works, instructional texts, and other works. These works can be stored, presented, and utilized in many ways. With the increasing availability of powerful computers, many works that were traditionally available on paper, canvas, or tape are now stored in computer hard drives and computer RAM (random access memory), and are displayed on computer monitors such as cathode ray tube screens and liquid crystal displays.
[0025] Early computers provided minimal technical security means. On early personal computers, for instance, typing “copy *.*” would direct the computer to copy every file or program in a directory. Further simple keystrokes, such as “copy C:/*.* A:/*.*” would direct the computer to place the new copies in a new physical location, perhaps copying everything from a disk directory in drive C to a portable disk in drive A. Even today most personal computers routinely provide an environment that makes it relatively easy to copy electronic information in the form of files.
[0026] Of course, technical means are not the only way to protect intellectual property rights; legal tools in the form of license agreements are widely used. Perhaps the most widespread license agreement is a single workstation agreement. In exchange for a license fee or an outright purchase price, a set of disks or a CD-ROM containing digitized works and/or executable code is transferred to the purchaser, often with books and/or instructions on paper. Sometimes the works are transferred over a network such as the Internet in digital form. The purchaser is typically informed that the code or information may be used an unlimited number of times on a single workstation or other computer.
[0027] This approach worked fairly well in the day of the stand-alone personal computer. It does require that the producer of the code or other protectable work place some trust in the buyer, since the buyer often could copy the code or information onto more than one computer. The barriers were mainly legal, not technical. In locations where intellectual property was not a well-established and respected concept, widespread copying of information and executable code reduced income and profits to producers of computer based information and applications by diverting income and profits to illicit “factories” which reproduced computer disks and CD-ROMs without permission from the rightful owner.
[0028] Many technical protection schemes were developed to combat the ability of the market to reproduce information without payment to the owner. Some “copy-protection” schemes made it difficult to make copies, regardless of the legitimacy (e.g. for unauthorized resale versus for proper backup) of the copies.
[0029] Other schemes defined zones of control on a CD-ROM and made a “key” necessary to read the zones. For instance, if a CD-ROM had 600 megabytes of information on it, a person might buy the legal right to see, view, or use 100 megabytes for $50.00. Information would be available in the first 100 megabyte zone regarding the contents and cost of information in the second or third 100 megabytes. For an additional fee or fees, the viewer could obtain the key to additional segments of the CD-ROM. For instance, a second $50 might buy the right to use the second 100 megabytes and a third $50 fee might permit the use of the third 100 megabytes.
[0030] A problem with this approach (and with copy-protection schemes) is that once a single purchase has been made of all the information, or access to all the information on the disk or CD-ROM has been obtained once, the information could be reproduced at will. An unauthorized factory could produce thousands of copies to be resold with no benefit to the rightful owner of the intellectual property.
[0031] Similar problems exist with the site license approach to protecting intellectual property. A licensed site such as a corporation or a government agency obtains the right to use a program or digitized information from the intellectual property owner, and is given a set of disks, CD-ROMs, or file-server-based copies of the licensed work for authorized internal use. The intellectual property owner relies upon the corporation or agency not to share the information or program outside the bounds of the license. But the major tool for enforcing the license agreement was not technical. Instead, it was respect for the law and the agreement. Unfortunately, some corporations and even some government agencies were staffed, at least in part, by people willing to take home a copy of the software or other licensed work and share it or sell it to an illegal copying factory.
[0032] Under a common relationship between works of intellectual property and the Internet, users view courseware and other information for free. The information is shared for free because providing the information helps the work's owner sell a product, or saves the owner money by reducing technical support costs, for example. In the research community, huge sets of information are regularly exchanged via file transfer protocol or other digital means. Similarly, information in courses can be made available on the web, and can be viewed via a browser.
[0033] The present invention relates to protecting content both by technical means and by legal mechanisms. Although some information may be shared for free within a system according to the invention, much of the information available through the inventive system is provided only in exchange for license fees or the like paid by students or their employers.
[0000] Courseware v. Other Content
[0034] Those of skill in the art will recognize that many of the comments above apply not only to courseware, but also to other types of digital content, including without limitation musical recordings, visual images, and the like. Such content may appear as components of multimedia courseware, but it may also be distributed independently of courseware and/or for purposes other than education. As used herein, “content” includes both courseware and other kinds of digital content.
Additional Considerations
[0035] In addition to the considerations above, certain trends are worth noting. Many courses are available on the web, yet in general the more attractive the course is (visually, in activity, motion, video, sound, and so on), the more time it takes to refresh the computer screen at the user's workstation. To reduce download time, more and more bandwidth is requested. Users go from a POTS (“plain old telephone system”) line, to an ISDN line to a T1 line, with increasing costs at each stage. However, the cost of computer storage is dropping rapidly. As most machine readable classes remain less than a gigabyte in size, the cost of forward storing a machine-readable class to the personal computer owner wishing to take the class is dropping rapidly.
[0036] As the speed of market developments in the computer industry increase, the delay and cost of obtaining legal remedies increase, and the technical ease of copying and distributing electronic information increases dramatically with the interconnections available via the Internet, improved tools for managing courseware are needed.
[0037] As discussed above, a wide range of computer-assisted educational features and capabilities have been explored, at least to some extent. However, existing approaches have been less successful at combining these features and capabilities into an architecture which securely and effectively shares commercial courseware. Accordingly, it would be an advancement in the art to provide an improved computer architecture for sharing commercial courseware and other content over a network.
BRIEF SUMMARY OF THE INVENTION
[0038] The present invention provides improved capabilities for managing courseware and other content in a shared use operating environment such as a computer network. In particular, the invention provides a commercial networked content delivery method and system which does not exclude synchronous sharing but is focused on asynchronous sharing.
[0039] One method of the invention operates in a network containing a registration server, a content server connected to the registration server, and several client work-stations connected to the content server. After a user registers with the registration server and requests access, the content server authenticates the request and serves the content to the client workstation for presentation to the user. Content may be moved by the system between content servers in response to actual or anticipated user requests; users may reserve courses for later viewing. If the target content server lacks room to receive the incoming content, the system makes a recommendation to the local administrator as to which content should be deleted from the content server in order to make additional room.
[0040] Courseware and other content managed by the system may contain one or more “critical portions” which have been treated to prevent their unauthorized use and thereby enhance the protection of intellectual property rights in the content by technical means. For example, the treating step may insert disabling code into an executable portion of courseware, may encapsulate the critical portion in a database table, may compress the critical portion, and/or may encrypt the critical portion. In addition, the content server and/or client workstation may disable use of a critical portion if an expected security handshake is not received. Caching and other disk writes at the client may also be disabled to prevent a permanent copy of the critical portion from being created at the client. To take advantage of low cost telephone connections, part or all of the content may be downloaded to the client workstation one or more hours before serving the critical portion.
[0041] The system also monitors the connection between content server and client, and meters use of the content so that the user pays only for actual use. Pre-existing works can be metered without being modified. In some cases, however, a metering security module is injected by linking or recompilation into the machine readable form of a work that contains legally protectable intellectual property. Adding the metering security module alters the system, such as by inserting disabling code, so that the system will not play or display the content unless the metering security module is operating. “Playing” a work includes displaying it, executing it, digitally manipulating it, or otherwise performing an act governed by the license agreement or by relevant intellectual property law. Unless the metering security module is engaged and authorizes the use, a monitor will not display certain protected words or images or motion images, speakers will not play certain protected sounds, motion simulators will not perform certain protected motions, and so forth.
[0042] The user receives an invoice for use of the courseware or other content. A local administrator can be authorized to adjust invoices in response to user requests. For instance, the administrator may determine that the user did not finish viewing the course in question, or accidentally started the wrong course, and then reduce the charges on that basis. If the user previously provided a credit card payment authorization to permit payment by credit card, a funds flow manager makes appropriate adjustments to the credit card charges.
[0043] In short, the architecture of the present invention provides improved security, efficiency, and convenience for the management of courseware or other content in a shared operating environment such as a network or a collection of loosely coupled networks. For instance, additional security is provided by separating registration information from content, by identifying and treating critical portions, and by monitoring the connection over which content is supplied to a client. Convenience and efficiency are provided by optional early downloading, by reservation capabilities, and by a combination of automatic and local administrator control. Additional features and advantages of the present invention will become more fully apparent through the following description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0044] To illustrate the manner in which the advantages and features of the invention are obtained, a more particular description of the invention will be given with reference to the attached drawings. These drawings only illustrate selected aspects of the invention and thus do not limit the invention's scope. In the drawings:
[0045] FIG. 1 is a diagram illustrating a network architecture according to the present invention, including a registration server, several content servers, and several clients.
[0046] FIG. 2 is a diagram further illustrating a portion of the network architecture of FIG. 1 , including a content server and several clients.
[0047] FIG. 3 is a diagram further illustrating a registration server.
[0048] FIG. 4 is a diagram further illustrating a content server.
[0049] FIG. 5 is a diagram further illustrating a client of a content server.
[0050] FIG. 6 is a flowchart illustrating methods of the present invention, including steps for providing enhanced security to protect intellectual property rights in critical portions of content.
[0051] FIG. 7 is a flowchart illustrating methods of operation in the present invention, from the point of view of a courseware user.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0052] The present invention relates to methods, systems, and configured storage media for managing courseware and/or other content in a shared use operating environment. Courseware includes digital instructional and/or entertainment content in the form of software, digitized sounds, digitized images, digitized motion paths, digitized chemical compounds, and other works which can be transmitted over a computer network for presentation to a user and which contain intellectual property that is protectable by copyright, patent, trade secret, trademark, trade dress, moral rights, common law rights, contract, and/or other sources of legal authority. Courseware is sometimes referred to herein as a “course” or “class” or “work” or “content”; “content” and “work” are used interchangeably to describe material of which courseware is just one example. Specific examples of courseware and other content are given to illustrate aspects of the invention, but those of skill in the art will understand that other examples may also fall within the scope of the invention.
[0053] A shared use operating environment is an environment in which more than one person can use content, without necessarily sharing a specific copy of that content, with the assistance of a computer network or a collection of coupled networks. As used here, “network” includes local area networks, wide area networks, metropolitan area networks, and/or various “Internet” networks such as the World Wide Web, a private Internet, a secure Internet, a value-added network, a virtual private network, an extranet, or an intranet.
Overview of the Architecture
[0054] FIG. 1 illustrates generally an architecture 100 of a shared use operating environment according to the present invention. The architecture 100 includes at least three levels which are defined according to the functionality and data that are present and/or intentionally omitted from each level. Those of skill in the'art will appreciate that the levels may be being named differently in various embodiments, but for clarity they are referred to herein as a registration server level 102 , a content server level 104 , and a client level 106 .
[0055] The registration server level 102 includes at least one registration server 108 . The functionality and data associated with the registration server(s) 108 are described in detail below. At this point, it is sufficient to note that each registration server 108 includes a remote registration manager and a registration database for new user registration, and that each registration server 108 is free of courseware or other deliverable content that is managed by the architecture 100 . In particular, courseware is not stored on the registration server 108 .
[0056] The content server level 104 includes at least one content server 110 . For clarity of illustration, three content servers 110 are shown, but an embodiment of the invention may include one or more servers 110 . Each content server 110 is linked by a link 112 for network communications with a registration server 108 . In an embodiment containing a single registration server 108 , such as the embodiment illustrated, each content server 110 thus has a network connection 112 (or may readily obtain such a connection) to that registration server 108 . In embodiments containing more than one registration server 108 , different content servers 110 may communicate over one or more network links 112 with one or more of the registration servers 108 . Each network link 112 may involve a dedicated link, a virtual circuit, a tunnel through one or more intervening networks, or one or more other types of network communication links known to those of skill in the art.
[0057] Each content server 110 contains courseware and/or other works managed by the architecture. Like the registration server 108 , a content server 110 may also contain data which is not managed by the architecture and which is thus of no concern here unless it interferes with operation of the system 100 . Each content server 110 serves the managed content for presentation to registered users, that is, users who have previously been registered with the registration server 108 . At a minimum, registration provides users with a unique user name or user ID; it may also coordinate a password or otherwise manage access control. With the possible exception of registration for free demonstrations, which may be available in some embodiments, registration also obtains billing or payment information such as the user's credit card information, purchase order, and/or sponsor identity.
[0058] The registration server 108 and the content server(s) 110 may be implemented with a combination of computer hardware (e.g., disk or other non-volatile storage, RAM or other volatile storage, one or more processors, network interface cards, supporting I/O equipment) and computer software (e.g., operating system software, networking software, web browser software, and inventive software as described herein). In particular, suitable software for implementing the invention is readily provided by those of skill in the art using the teachings presented here and programming languages and tools such as Java, Pascal, C++, C, CGI, Peri, SQL, APIs, SDKs, assembly, firmware, microcode, and/or other languages and tools. A given computer may host several content servers 110 , or it may host several registration servers 108 , but a content server 110 and a registration server 108 may not reside on the same computer because that would violate the requirement that registration servers 108 not contain courseware.
[0059] The client level 106 includes at least one client workstation 114 , and typically includes multiple workstations 114 . Each client workstation 114 is connectable to a content server 110 by a client-server network communications link 116 , such as a local area network link. At some point, each client workstation 114 is able to present, to at least one registered user, courseware and/or other content which is served over the link 116 by the content server 110 . The content may be conventional content, or it may be modified by treating critical portions as described herein, or it may be a combination of untreated and treated works. Although clients 114 are referred to as workstations in deference to the expected typical situation, it will become clear that laptops and other computers may also serve as clients 114 .
[0060] Registration servers 108 , content servers 110 , and clients 114 are further illustrated in FIGS. 3 , 4 , and 5 , respectively. However, before describing those three Figures the relationship between content servers 110 and clients 114 is discussed with reference to FIG. 2 , and the relationship between registration servers 108 and content servers 110 shown in FIG. 1 is described in greater detail.
A Network of Content Servers and Clients
[0061] FIG. 2 further illustrates one of many possible client-server networks 200 suitable for use according to the invention. The network 200 includes one content server 110 and four clients 114 . Other suitable content-server-client networks 200 may contain other combinations of content servers 110 , clients 114 , and/or peer-to-peer nodes which perform as content servers 110 and/or clients 114 according to the invention; with appropriate software, a given computer may function both as a client 114 and as a server 110 . The computers 110 , 114 connected in a suitable network 200 may be workstations, laptop computers, disconnectable mobile computers, uniprocessor or multi-processor machines, mainframes, so-called “network computers” or “lean clients”, personal digital assistants, or a combination thereof. Nonvolatile storage 202 , printers (not shown), and other devices may also be connected to the network 200 .
[0062] The network 200 may include communications or networking software such as the software available from Novell, Microsoft, Artisoft, SCO, and other vendors, and may operate using TCP/IP, SPX, IPX, and other protocols over connections 116 that include twisted pair, coaxial, or optical fiber cables, telephone lines, satellites, microwave relays, modulated AC power lines, and/or other data transmission “wires” known to those of skill in the art. The network 200 may encompass smaller networks and/or be connectable to other networks through a gateway or similar mechanism.
[0063] As suggested by FIG. 2 , at least one of the computers 110 , 114 is capable of using a floppy drive, tape drive, optical drive, magneto-optical drive, or other means to read a storage medium 204 . A suitable storage medium 204 includes a magnetic, optical, or other computer-readable storage device having a specific physical configuration. Suitable storage devices include floppy disks, hard disks, tape, CD-ROMs, PROMs, random access memory, and other computer system storage devices. The physical configuration represents data and instructions which cause the computer system to operate in a specific and predefined manner as described herein. Thus, the medium 204 tangibly embodies a program, functions, and/or instructions that are executable by computer(s) to assist content management generally, and license enforcement in particular, substantially as described herein. As used herein, “executable” includes “interpretable”; executable code thus includes compiled code as well as codes like Java byte codes or interpreted BASIC statements.
A Network of Registration Servers and Content Servers
[0064] As noted, the network 200 involves at least one content server level 104 computer and one or more client level 106 computers 114 . Some of the characteristics of the network 200 may also apply to networks, such as that shown in the upper two-thirds of FIG. 1 , which involve the registration server level 102 and the content server level 104 .
[0065] For instance, the computers 108 , 110 may be workstations, uniprocessor or multi-processor servers, mainframes, or a combination thereof such as a cluster. Nonvolatile storage such as a disk array and/or other devices may be connected to the computers 108 , 110 . The computers 108 , 110 may be linked by communications or networking software such as the software available from various vendors and may operate using TCP/IP and/or other protocols over connections 112 that include data transmission “wires”, as described above. The computers 108 , 110 may likewise be part of a network which encompasses smaller networks and/or is connectable to other networks. Finally, the computers 108 , 110 may be capable of using a drive or other means to read a configured storage medium 204 .
[0066] One example of a network 200 suitable for a metered security relationship is a network holding several thousand machine readable courses. A conventional approach charging one fee for unlimited use of each machine readable course by a single personal computer 114 or a single location (e.g., a corporation or agency) would be prohibitively expensive. In an embodiment according to the invention, the secured courseware or other content can be shared by various users, and each minute of use is counted and billed to the user or to the sponsor of the user (e.g., the corporation or agency employing the user). Unlimited use is not required, and the license fee is reduced accordingly.
Registration Server
[0067] FIG. 3 further illustrates a registration server 108 . The registration server 108 includes at least a portion of a registration manager 300 and of a corresponding user registration database 302 . Collectively, the manager 300 and the database 302 form a registration module which provides at least unique user IDs and user password support. The registration module may also obtain and store in the database 302 information such as the identity of a corporate or government sponsor that employs the user, and the user's email address for use in notifications of upcoming services or events.
[0068] The proposed user ID and password are checked against existing registration information in the database 302 to make certain they are unique throughout the architecture 100 embodiment. This provides security to users so that charges for services will be valid and services cannot be stolen by an unknown or duplicate user and then charged to the wrong user ID. Of course, users must still be careful to keep their own password information confidential and to choose passwords which are not simply a copy of their username or other easily guessed information. User login and authentication tools and techniques familiar to those of skill in the art may be used.
[0069] Security is enhanced by making all new registrations go through the registration server 108 . New user registration information is processed on the registration server 108 ; user registrations cannot be created by any content server 110 . The updated registration database 302 is replicated in a read-only format to content servers 110 so they can recognize registered users, but a new user registration cannot be created directly on a content server 110 . One advantage of this approach to users is that they need not repeat registration information each time they log onto a client 114 . Registration database 302 replication may be performed using Oracle 8.0 enterprise software or other familiar means.
[0070] As illustrated in FIGS. 3 and 4 , in one embodiment of the architecture 100 a portion of the registration module resides on each registration server 108 and a portion resides on each content server 110 . Other embodiments may distribute registration module functionality differently between the three levels 102 , 104 , 106 , subject to the appended claims. Those of skill in the art will readily implement the registration manager 300 based on commercially available tools and languages such as C++ or Java and the description given herein. The database 302 may likewise be implemented as an Oracle database or in another familiar database format. In one embodiment, Java software in the registration manager 300 is used to write new user registration information to an Oracle database 302 .
[0071] The registration server further includes a reservation manager 304 and a reservation database 306 . Collectively, the manager 304 and the database 306 form a reservation module which permits registered users to reserve courseware or other content. In combination with the funds flow system described herein, the reservation module allows a user to book a guaranteed seat, a classroom, or another service, secure in the knowledge that it will be held for them until the specified time. In some embodiments, the funds flow system will charge users for such guaranteed resource reservations regardless of whether the resource is actually used, because the resource was kept unavailable for use by others. The reservation module can present a user with a menu or a schedule of courseware presentation events in various classrooms or other locations. It can also tell the user whether a given courseware event or piece of content is available at a given time and whether a particular work is already scheduled for use at that time.
[0072] Other embodiments may distribute reservation module functionality differently than shown between the three levels 102 , 104 , 106 , subject to the appended claims. In one embodiment, the reservation module includes commercial off-the-shelf scheduling software provided by AC&E Ltd. of Chantilly, Va.; in other embodiments, other scheduling software may be used. The reservation manager 304 may also be implemented using commercially available tools and languages such as C++ or Java and the description given herein. The database 306 may be implemented as an Oracle database or in another familiar database format.
[0073] The illustrated registration server 108 also includes at least part of a funds flow manager 308 which manages content usage payment information. As illustrated in FIGS. 3-5 , in one embodiment of the architecture 100 a portion of the funds flow manager 308 resides on each client workstation 114 , a portion resides on each content server 110 , and a portion resides on each registration server 108 . Other embodiments may distribute funds flow management functionality differently between the three levels 102 , 104 , 106 , subject to the appended claims.
[0074] The funds flow manager 308 accepts payment information such as a purchase order number or a credit card authorization. If payment is to be made by credit card, the funds flow manager 308 places a hold with the credit card provider or bank before the courseware and/or other content is presented. In connection with sending the user the final invoice, the funds flow manager 308 contacts the bank to transfer funds from the user's account or the sponsor's account to the service provider's account or the content owner's account.
[0075] The funds flow manager 308 makes customer interactions with the system 100 faster and more effective. For example, upon first using the system 100 , the user may provide a billing code such as a corporate purchase order number or credit card number. Once this information is accepted by the funds flow manager 308 , the user may make it the default payment option to be applied when logging out after future service purchases.
[0076] The funds flow manager 308 may also provide a custom menu to users. For instance, the system 100 may be configured so that only courses approved by a particular entity are displayed if the user identified that entity as its sponsor while signing on. If this same user wishes to see other courses, the user may log out and then login again as an individual client, after which all courses available for individuals (whether employed by the sponsor in question or not) will be displayed as possible selections.
[0077] The illustrated registration server 108 also includes at least part of a content movement manager 310 which moves courseware and/or other content to content servers 110 in response to actual or anticipated requests from users for access. As illustrated in FIGS. 3 and 4 , in one embodiment of the architecture 100 a portion of the content movement manager 310 resides on each content server 110 and a portion resides on each registration server 108 . Other embodiments may place all content movement management functionality at the content server level 104 .
[0078] The content movement manager 310 interacts with scheduling software such as the reservation module and a launch manager 404 which is discussed below. When a user selects courseware and/or other content for use at a given location, the scheduler determines whether the content is already resident on a content server 110 at or near the requested location. This determination may be made by reference to a database which tracks content locations, or by making an inquiry to the local content server(s) 110 .
[0079] If the content is not resident at the desired location, the scheduler places a call to the content movement manager 310 . The content is automatically packaged for shipment from another content server 110 by FTP (file transfer protocol) or other familiar means, with appropriate encryption and/or compression. The source content server 110 may be a typical content server 110 as described above, or it may be a master content server 110 . Each master content server 110 serves primarily as a content repository for other content servers 110 , as opposed to serving primarily as a source of content for directly attached clients 114 .
[0080] The content movement manager 310 checks with the target content server 110 to determine whether sufficient disk space is available to receive the incoming content. If there is not enough space, the content movement manager 310 makes a recommendation to a local administrator regarding which content to delete to make room for the incoming content. The recommendation may be based on various factors, including storage requirements and which courseware at the target server 110 was used most recently or is scheduled for use. For instance, if a course has not been used for several months and has not been reserved, the content movement manager 310 is more likely to recommend that it be deleted than if it was used more recently or has been reserved. In one embodiment, the content movement manager 310 cannot delete content; only the local site administrator can.
[0081] Some embodiments of the architecture 100 include a backup registration server 108 which contains data mirrored from the primary registration server 108 shown in FIG. 1 . As usual with mirrored systems, the backup server 108 will generally be in a different physical location than the primary server 108 . Data mirroring tools and techniques familiar in the art may be used.
[0082] In addition to the functionality described above, the registration server 108 may provide advertising and other inducements for Web walkers and potential users of the system 100 to become familiar with the system 100 , and to register for services provided through the system 100 .
Content Server
[0083] FIG. 4 further illustrates a content server 110 . The content server 110 includes operating system software and networking software, such as Windows NT operating system software, UNIX or Linux operating system software, Ethernet or NetWare networking software, and/or other software discussed in connection with FIG. 2 .
[0084] Unlike the registration server 108 , the content server 110 contains courseware and/or other managed content 400 . The content 400 may take a variety of forms, including software, video, audio and other types of digital content. The content 400 may also be treated according to the present invention by identifying critical portions and providing enhanced security for those portions. Security for the content 400 as a whole is also provided by a security manager 402 , which monitors use of the content 400 . In the illustrated embodiment, a portion of the security manager 402 resides on each client workstation 114 and a portion resides on each content server 110 . In alternative embodiments, the security manager 402 may reside entirely on the content server 110 or entirely on the client 114 .
[0085] As illustrated, a portion of the registration manager 300 resides on the content server 110 . At the content server level 104 , the registration manager 300 only needs to recognize registered users and provide them with access to content 400 . New users are created at the registration server level 102 . In one embodiment, the registration manager 300 includes dynamic HTML and/or commercially available Oracle Web Application Server software, from Oracle Corporation of Redwood Shores, Calif. Use of the Oracle software may require that a portion of the registration manager 300 also reside on each client 114 and/or on the registration server 108 .
[0086] Critical portions of the content 400 may reside in database tables managed by the security manager 402 . For example, executable portions of content or synchronization information for coordinating audio and video in content may be stored in a database table. Database table names do not necessarily reflect content in the straightforward manner in which more typical content file names can reflect file content. Also, database tables may be difficult to access directly through the file system; it may be necessary to go through the database management software. Accordingly, placing content 400 in database tables tends to make it more difficult for unauthorized users to locate and use the content 400 .
[0087] In addition, when content 400 is moved between computers (be they clients 114 , servers 110 , or a mixture), critical portions of the content 400 may be divided between two or more data tables so that theft of any single data table will not provide satisfactory service. As a further precaution, in one embodiment the security manager 402 sends one or more critical portions of content (possibly in data table format) only to a client 114 's volatile memory rather than sending all critical portions to nonvolatile memory such as a client 114 disk. Critical portions sent only to client 114 RAM may be scrambled or erased when the client 114 shuts down or is rebooted, making it even more difficult to make illicit copies of the content 400 .
[0088] Each illustrated content server 110 also includes a launch manager 404 for launching presentations of courseware 400 . The launch manager 404 coordinates initial activity such as course 400 selection by the user, any necessary course 400 movement to bring the course 400 to the server 110 using the content movement manager 310 , initializing security arrangements with the security manager 402 , making the network connection 116 if necessary, and initiating presentation of the course 400 by launching its executable portion or downloading it to the client 114 , for instance. In alternative embodiments the launch manager 404 functionality is part of a meter manager 406 or part of the security manager 402 .
[0089] The meter manager 406 meters content usage. In some embodiments, the metering manager also monitors the connection 116 ; in other embodiments monitoring is performed by the security manager 402 . Regardless, the metering manager 406 keeps track of elapsed time as a measure of the user's use of the content. A portion of the meter manager 406 resides on each client workstation 114 and a portion resides on each content server 110 . The two portions of the meter manager 406 create a link which is carried over the connection 116 . That is, the metering link rides on top of an Ethernet or other conventional communications link.
[0090] In one embodiment, the meter manager 406 creates a start note (event) when courseware is successfully launched. The meter manager 406 will associate this start note with a corresponding end note within one minute (or other defined interval) of the time the user chooses to finish this course 400 presentation. The difference in time between launching the presentation and finishing or interrupting the launched presentation is the metered difference, which will serve as the basis for the invoice presented to the user or to the user's sponsor.
[0091] The meter manager 406 may track several open notes for a given client 114 , since clients 114 may use operating system software that allows several executables to run at the same time. Metering statistics may be administered using an Oracle database 408 or other database 408 to provide system-wide statistics and system-wide information reports. In one embodiment, meter manager 406 records are constructed in a format that allows their use in conjunction with a rate table, thereby allowing the funds flow manager 308 to create an invoice based on both the particular content 400 used and the elapsed time.
[0092] Every rate in the rate table may be associated with a destination account, such as the account of a content 400 vendor or the account of a content-providing site 200 manager. The funds flow manager 308 supports automatic payment using familiar and industry standard credit card payment methods. The funds flow manager 308 accepts electronic billing information from the meter manager 406 , and accepts electronically stored payment information such as credit card numbers from the registration module.
[0093] The meter manager 406 and/or security manager 402 provide several security features. First, the client 114 desktop is disabled so that the user can only obtain service through the metered and monitored connection 116 . Second, each element of potential service such as multimedia content, executables, and courseware tests, is defeated so that its executable portion will not run even if it is located by an unauthorized user. The executables are modified'to require security handshakes from the meter manager 406 and/or security manager 402 so the service 400 will not operate at all, or will operate for only a limited period of time, if the metered connection 116 or the meter manager 406 and security manager 402 are not present.
[0094] In one embodiment, the client 114 desktop will turn off if the meter manager 406 on the client 114 is not in touch with the meter manager 406 on the content server 110 on a minute-by-minute basis. For the convenience of the user and to ease administration of the system 100 , the meter manner 406 can be adjusted to invoke this “dead man's switch” at various time intervals other than one minute. An aggressive approach makes the workstation 114 freeze if a single minute passes with no contact. A more lenient approach may freeze functionality within five minutes after the connection is lost.
[0095] In one embodiment, the same polling software element in the meter manager 406 which triggers the dead man's switch also provides a periodic update to the database 408 that is used by the funds flow manager 308 for billing. Each minute that the polling function of the meter manager 406 returns a message from the client 114 to the server 110 indicating that the user ID remains active on the client 114 , the database 408 is updated to reflect an additional minute of use for billing purposes.
[0096] Polling updates each open request, such as each open courseware presentation. For instance, if in the first minute the user ID requests a login and then makes one open service 400 request, an open event is updated for this user ID in the database 408 table for the time elapsed. If the same user ID then requests a second courseware 400 presentation, each courseware 400 event ID is associated with the login by this user and this client desktop 114 , and two time events occur to update the database 408 . Thus, subsequent courseware or other service offerings which are opened in the client 114 browser 502 can be added to the time table in the database 408 using the same polling function. The polling function operates similarly for sequential (as opposed to concurrent) activity. If the user ID for a given login closes a courseware presentation 400 or other event ID but retains the login, then while the login time continues to update (enabling billing for use of the personal computer 114 ), the first courseware 400 offering will end and a new courseware 400 offering can begin during the same login session.
Client
[0097] FIG. 5 further illustrates a client 114 . As noted above, the client 114 may be a client in the traditional server-client network sense (further configured to operate according to the invention), or the client 114 may be a node in a peer-to-peer network. The client 114 is always a client in the sense that it receives courseware 400 or another service from at least one content server 110 .
[0098] The client 114 includes operating system software and networking software 500 such as Windows 3.1, Windows 95, Windows 98, Windows 2000, or Windows NT software, Ethernet software, and/or other software discussed in connection with FIG. 2 .
[0099] The client 114 also includes a browser 502 , such as a Microsoft Internet Explorer or a Netscape browser, through which courseware and/or other content 400 is presented to the user. In addition, the registration module may be browser-based or Oracle-based and browser-transported, so that any client 114 which supports an Internet connection and a Web browser 502 can be used to contact the registration server 108 to create a new user registration.
[0100] As previously discussed, the client 114 receives courseware and/or other content 400 from the content server 110 . The content 400 may be provided in portions 504 which are defined in one or more of the following ways. First, portions 504 may be critical portions which have been treated for enhanced intellectual property protection as discussed elsewhere herein. Second, the portions 504 may be non-critical portions or a mixture of critical and non-critical portions, which are downloaded early in preparation for later presentation to the user. Early downloading may take advantage of the relatively low cost of telephone connections as opposed to other connections. Finally, content portions 504 may be a mixture of critical and non-critical portions such as episodes or chapters in a presentation, which are sent from the content server 110 to the client 114 in sequence as the user proceeds through the content 400 presentation.
[0101] Other components of the client 114 , including the security manager 402 , meter manager 406 , and funds flow manager 308 , are discussed elsewhere herein.
Methods Generally
[0102] FIGS. 6 and 7 further illustrate methods of the present invention. FIG. 6 illustrates generally intellectual property license enforcement methods of the present invention, while FIG. 7 illustrates operational methods of the system 100 from the perspective of a courseware user. Although particular method steps embodying the present invention are expressly illustrated and described herein, it will be appreciated that system and configured storage medium embodiments may be formed according to methods of the present invention. Unless otherwise expressly indicated, the description herein of methods of the present invention therefore extends to corresponding systems and configured storage media, and the description of systems and configured storage media of the present invention extends likewise to corresponding methods.
License Enforcement Methods
[0103] In describing FIG. 6 , an overview is provided first. Then the individual steps are revisited and discussed in greater detail. During an identifying step 600 , at least one critical portion of the content 400 is identified; courseware is one example of the “work” referred to in the corresponding section of the '302 application to which the present application claims priority. The critical portion is separated, encapsulated, encrypted, compressed, created and added, and/or otherwise treated to enable enhanced protection during a treating step 602 .
[0104] At some later time, a user requests access to the treated content 400 during a requesting step 604 . If the content is not already present on a local content server 110 , it may be moved to such a server 110 during a step 606 . The non-critical portion of the content may be downloaded to the user's location during an optional early downloading step 608 .
[0105] The user's right to access the critical portion is verified during an authenticating step 610 , a metering and monitoring step 612 is started, and the critical portion is then provided to the user during a monitored downloading step 614 . If the ongoing or recurring monitoring step 612 detects a violation of the license, a disabling step 616 occurs to prevent or inhibit further use of the treated content. Total license fees based on the metering are calculated and charged during an accounting step 618 . Each of these steps will now be described in greater detail.
[0106] During the identifying step 600 , one or more critical portions of the content 400 are identified. The critical portions should be small enough for rapid treatment during step 602 and rapid downloading during step 614 , but critical enough to make most users pay the license fees charged during step 618 rather than use only the non-critical portions. In a multimedia course, for example, critical portions might include executable files or the answers to interactive tests. If the executable is large, critical portions might be part of the executable such as a jump table or .a proprietary dynamically linked library file needed to perform I/O operations. Critical portions may be preexisting elements of the content 400 , or they may be created and inserted in the content 400 . For instance, handshake code may be added to an executable to require periodic successful handshakes with a server 110 ; if the handshake fails, execution is aborted.
[0107] In content 400 that contains no executable computer code, but merely contains audio, visual or other data, critical portions could be initialization or synchronization information, or particular text or images that convey important information to a user or provide important entertainment value. Two of the many possible examples include a final scene of a mystery in which the murderer is revealed, and a checklist summarizing the main steps in a diagnostic technique being taught by courseware 400 .
[0108] During the treating step 602 , critical portions of the content 400 are treated to restrict their unauthorized use. Possible treatments include creating and inserting security codes, separating pre-existing critical portions so they are not downloaded with the non-critical portions, encrypting. critical portions, compressing critical portions with a proprietary method (which effectively combines compression and encryption), and/or encapsulating critical portions. One form of encapsulation places the critical portion in a database table, such as a relational database table in a commercial database format used by Oracle, Sybase, Informix, or another familiar vendor. This has the advantage of making critical portions easier for the system 100 to track, and the advantage of hiding critical portions from unauthorized discovery by file system tools that rely on filenames, such as directory listing and directory search tools.
[0109] The requesting step 604 may be performed using user login procedures, courseware and/or content selection tools such as menus, and network communication means and methods familiar to those of skill in the relevant arts, including those discussed above in connection with FIG. 1 and/or FIG. 2 . The user may also be asked for an account password, a credit card number, or similar guarantee that the license fees for use of the content 400 have been or will be paid. During the requesting step 604 , the user is also shown the license agreement terms and conditions, and is then asked to actively accept or decline being bound by the license agreement.
[0110] During a content moving step 606 , content 400 may be moved from another content server 110 (which may reside in another network 200 or which may be a repository content server 110 as discussed herein) to the local content server 110 which serves the client 114 that is being used (or that will be used) by the user in question. This is accomplished as described in connection with the content movement manager 310 .
[0111] Content 400 which requires significant download time can be loaded early during the step 608 , at least in part, to minimize the delay experienced by users. As the cost of telecommunications services has remained largely constant over time, while the price of memory and computational power have doubled in cost-effectiveness about every eighteen months, the invention allows one to reduce or eliminate the serving of machine readable classes in real-time over the web or the Internet or from a file server. Instead, content 400 is downloaded during step 608 using telecommunications connections which are slow but relatively inexpensive and often billed according to a flat rate rather than connection time.
[0112] For instance, knowing that tomorrow is the first day of class in a new course, the multimedia sound and images in the course 400 could be downloaded by students during the night before the course 400 is presented. Critical portions such as the executable code, audiovisual synchronization, or order of presentation could then be downloaded on an as-needed-and-still-authorized basis the next day during step 614 .
[0113] During the step 612 , a timing meter is started in cases where the license fee is not a flat per-use fee but is based instead on the connection time. Monitoring and metering may be separate steps in other methods according to the invention; monitoring is concerned primarily with preventing unauthorized use, while metering is performed as a basis for calculating license fees. Regardless, a system according to the invention starts monitoring the connection 116 to ensure that the use is still authorized and to prevent attempts to obtain a complete copy of the content which is not protected by treatment of critical portions. In particular, initial or further downloading of critical portions during step 614 is not allowed (because part of disabling step 616 occurs) if the monitoring step detects any of the following conditions:
1. The user logged in is not an authorized user (step 604 authentication failed); 2. The user site is not at an expected, authorized network 200 (IP or LAN or MAC or Ethernet and/or socket or port) address; or
[0116] 3. The user site 114 failed to return an expected periodic security handshake value.
[0117] With further reference to the treating step 602 and the monitoring and metering step 612 , the present invention allows an intellectual property owner to insert a meter and/or security code into any information set, executable application, image, video, or other computer based work 400 containing intellectual property, and to require a permanent relationship between such works and the metering software 406 which is located on a machine 110 remote from the user site 114 . The relationship is preferably simple, lowering the processor and bandwidth requirements of the network communication path 116 between the metering server 110 and the user's site 114 . The relationship ensures in most cases that a copy of the work 400 will not be fully available except for licensed time periods and at licensed user sites.
[0118] In some embodiments, the content 400 has embedded in it a time stamp, a date stamp, a copy stamp, an Internet Protocol (“IP”) address stamp, and/or code enforcing a requirement that the treated content only execute or display on the client 114 CRT when the computer 114 receiving the copy is in a recognized relationship with the computer 110 which sent the course. This relationship is via a POTS line 116 , or any telecommunications link 116 which provides constant or reliable presence.
[0119] A constant or reliable presence allows a handshake once per configurable time interval or configurable repeated event. The handshake verifies that the user computer 114 in contact with the server 110 is still the same user computer 114 , using its IP address or the IP address of its gateway and the password into the gateway required by its Internet service provider. On a local area network 200 , the handshake may use the LAN address.
[0120] In some embodiments, in addition to the consistent verification that the content 400 is resident on the same user computer 114 connected via the same Internet service provider gateway IP address, both the server 110 with the meter 406 and the computer 114 with the content 400 have identical “random” number generators. These random or pseudo-random numbers must match each interval, or at least be in the same order (it is understood that the content recipient computer 114 may be hundreds of milliseconds away from the server 110 when a connection required for a course 400 travels over part of the Internet).
[0121] The random number pairing is once per client-server pair 114 , 110 ; per work-station 114 ; or per connection 116 , depending on the embodiment. In one embodiment, for example, each connection 116 spawned from a content server 110 will have the same random paired number set. One set runs on the server 110 , and the same set runs on each user computer 114 which is receiving the content 400 essentially simultaneously. To confirm that the sequence is the same, each computer 110 , 114 has a date/time stamp program 402 running, and each date/time stamp must agree at least once per minute. Thus, any computer 114 presenting a course 400 in this way must reset its date/time clock to agree with the content server 110 date/time stamp.
[0122] In addition to, or instead of, metering content executables, the present invention can also meter “data transfer executables”. Examples of data transfer executables include applications used to operate or access video conferencing cards, network interface cards, CD-ROM controllers, fax systems, modems, and other data transfer devices that can be used in multimedia, audio, or video presentations. For instance, the use of codec (compression-decompression) software and/or hardware which is used to transfer audio or visual data between data formats can be metered according to the invention.
[0123] Such metering and authentication systems and methods allow any course 400 to be downloaded to the personal computer 114 of the person who will be taking the course 400 . The user's computer 114 may be located at the user's place of employment or at the user's home or at a training facility. An external hard drive can be rented with the course 400 and authentication software mounted. This hard drive can be connected to a personal computer 114 running Windows 95, Windows 2000, Windows NT, Macintosh, or other familiar operating system software, via comm port one or the like (WINDOWS 95, WINDOWS 2000, and WINDOWS NT are marks of Microsoft; MACINTOSH is a mark of Apple). Any personal computer user not needing additional hard drive space can simply make an FTP request, set up the request before going to bed, and find the course 400 (or most of it if critical portions are not available for early downloading) available in the morning. By having much or all of the course 400 available on his or her personal computer 114 , much or all of the course 400 will run at the speed of the backplane of that computer 114 , which is often substantially faster than an Internet or other network link 116 transfer rate.
[0124] In one embodiment, the only information going back and forth via the Internet or via a POTS line connection 116 to the server 110 will be handshaking such as repeats of the IP address of the gateway, pinging, and a stream of paired random numbers to authenticate that the content 400 was obtained from this server 110 . The name and password of the student will be sent each minute (or other predetermined interval) as well. Thus, each minute an IP address is sent, a name, a password, and a sequence of paired random or, quasi-random numbers. In well under one kilobyte of communication data, the content 400 will be authenticated for another interval of use. As noted, the present invention provides the ability to disable the courseware or other content 400 on the student's personal computer 114 whenever the link 116 with the content server 110 is broken or lost.
[0125] To assist in the apprehension of someone who attempts to violate the security system of the present invention, the security system will record where the copy was obtained. A series of copy locations hidden in the content 400 , or similar digital watermark information, maintain a record of IP gateway information, password information, and user ID information on how the copies were made, what order the copies were made in, and the time and date stamp of each copy of the content 400 . The information can be maintained in a circular buffer holding N records, with information for the N-plus-first copy being copied over the information related to the first copy so that the buffer file size remains the same.
[0126] User View of Operational Methods
[0127] FIG. 7 illustrates methods for operating the architecture 100 from the point of view of a user. During a registering step 700 , the user sits down at a client 114 , locates the service provider Web site which is hosted by the registration server 108 , and then provides registration information to the registration manager 300 . Suitable registration information may include, for instance, the user's name, address, sponsor, password (the password may also be generated by the registration manager 300 rather than be provided by the user), and payment information such as a purchase order number or credit card number.
[0128] The registration manager 300 verifies that the username and password are unique by checking the database 302 , and then adds a new user registration record to the database 302 . Finally, the registration manager 300 notifies the user that registration is complete. If a sponsor was identified by the user, the registration manager 300 optionally also notifies a course administrator at the sponsor by email.
[0129] During an optional reserving step 702 , the registered user reviews menus of available content and associated times and locations, and places one or more reservations with the reservation manager 304 . The reservation manager 304 verifies availability and enters the reservation, using the reservations database 306 . If a reserved course is subsequently canceled, some embodiments of the reservation manager 304 send a notice to the registered user by email.
[0130] During a payment authorizing step 704 , the registered user provides credit card information, and provided implicit or explicit authorization to bill the credit card for services provided. As noted above, this step may be part of the registering step 700 . The payment authorizing step 704 may also be performed later, if the necessary information was not available at the time of beginning registration, for instance, or if the user wishes to identify a different credit card after initially registering.
[0131] More generally, the method steps illustrated in the Figures and discussed in the text may be performed in various orders, except in those cases in which the results of one step are required as input to another step. For instance, a user must be registered in order to view courseware 400 except to the extent that a particular embodiment provides demonstration courseware at no charge to unregistered users. Likewise, steps may be omitted unless called for in issued claims, regardless of whether they are expressly described as optional in this Detailed Description. For instance, users who are sponsored by a corporation or agency need not provide credit card information during a step 704 . Steps may also be repeated (e.g., running several courses), or combined (e.g., providing credit card information during registration), or named differently (e.g., running a course may be referred to as “receiving services”).
[0132] During a login step 706 , a registered user logs into the content server 110 . The initial login step 706 may be performed automatically when the user first registers during step 700 . Later login steps 706 may be performed each time the user begins a new session at a client 114 . During the login step, the user provides a username and password to the security manager 402 , which verifies that the corresponding user record exists in the registration database 302 replica on the content server 110 .
[0133] In addition, if the user has indicated that payment will be by credit card, then the funds flow manager 308 checks the credit card and places a hold on the credit card for an amount which may depend on the prior history of the user, the user's sponsor, the courseware 400 requested, and similar information. In some embodiments, users are not allowed to complete the login process 706 unless the payment information provided by the user or by the user's sponsor has been accepted as valid by the funds flow manager 308 .
[0134] A user may wish to bill part of a sitting to one account, such as an individual account or a particular employer, and bill a second part of the same day's training to a second account. This may be achieved by logging in under the first account, receiving the first part of the desired services, logging out, and then logging in again with a different user ID and/or password before receiving the second part of the desired services.
[0135] During a selecting step 708 , the user may select one or more courses 400 to be presented at the client 114 . In some cases, the course selection will already have been made by the user's sponsor. Courses 400 may be selected using menus and/or other user interface tools and techniques familiar in the art, which contain course 400 description, cost, and availability data copied from the reservation database 306 .
[0136] During a step 710 , the course 400 is presented to the user at the client 114 . This involves sending courseware content 400 from the local content server 110 to the client 114 for viewing during a step 712 by the user. It may also include interaction between the user and other users and/or an instructor during a step 714 . Interaction may be provided, for example, by using email, chat rooms, live audio, and/or live video carried over the network connection(s) 116 . In addition, during an optional step 716 the user may take one or more interactive tests or quizzes. These may be graded by courseware 400 which is resident on the workstation 114 , or the user responses may be transmitted to the content server 110 for grading there, with the results then being sent back to the client 114 and/or to the instructor.
[0137] Presentation of courseware during step 710 may be interrupted by a step 718 in response to a key press, mouse click, or other action by the user. For instance, the user may decide not to continue the remainder of the presentation 400 at the present time, or may wish to terminate this presentation and start viewing a different course 400 . The user may also simply want to take a temporary break, and then resume the presentation during a subsequent step 720 .
[0138] During a step 722 , the user receives an invoice for services rendered. This may be done in conjunction with a logout during step 722 , or loping out may be delayed until a step 726 in which the invoice is paid. From the system's point of view, once a user decides to log out, the meter manager 406 completes the database 408 time table for the user ID, including each event ID associated with each courseware offering, test offering or other service provided during the session. The funds flow manager 308 then uses the database 408 time table and the database 408 rate table to present an invoice on the computer screen in the browser 502 .
[0139] The user may accept or decline the stated invoice. If the user accepts the invoice, the funds flow manager 308 in the content server 110 communicates that acceptance to the funds flow manager 308 in the registration server 108 , which in turn contacts the bank to clear the hold previously placed during step 702 , 704 , 708 and have the bank apply the credit card charges to the user's card.
[0140] If the user declines the invoice, the user may seek an invoice adjustment during a step 724 . The local network 200 administrator tries to answer any questions the user has about the invoice and to obtain user acceptance of the invoice, possibly after an adjustment. The local network 200 administrator or other local site personnel are authorized to make adjustments to the bill during step 618 . A new invoice amount will then be passed to the funds flow manager 308 for credit card or other payment activity based on the payment terms presented during user registration and this particular session, and the results of any adjustment discussions.
Additional Comments on Security
[0141] In the architecture 100 , security may be provided in several ways including those expressly noted above. Allowing one and only one person to have a given user ID helps ensure that persons who use content 400 are properly billed for such use, as noted above. But in addition, the user ID and the credit card information help protect the reservation module. If reservations were available without a credit card hold or similar protection, a malicious user could reserve seats in a network 200 (or even reserve all seats in the entire architecture 100 ) with no legitimate intent to use them. By requiring a credit card for reservation, the reservation module is protected because adequate credit must be available to pay for all reservations placed.
[0142] Because content is not stored on the registration server 108 , security precautions can be taken that might not otherwise be available. For instance, access to the home page can be disabled so that outsiders cannot input messages or modify HTML code on the registration server 108 . Dynamically produced Web pages based on information provided by the user, and created by Oracle or similar software, are also more difficult to modify than static HTML pages. Firewalls, encryption, and other means can also be used to protect credit card numbers of users in time-limited secure transactions without reducing security to allow continual courseware 400 usage from the same server 108 . In one embodiment, the registration server 108 exports credit card information to other servers with heightened security; once the export is complete, the credit card information is deleted from the registration server 108 .
Summary
[0143] The present invention provides systems, devices, and methods for technical enforcement of intellectual property right agreements. A security enforcer is inserted into deliverable content, or a small but critical portion of the content is treated to make it unusable without authorization (unable to execute, for instance), or both treatments are performed. A relationship over time is created between a meter and the treated (secured) content; without the relationship, use of the content is hindered or disabled. The critical portion is never placed in a user's persistent (nonvolatile) storage, such as a disk or tape storage, or alternatively is never placed in persistent storage in usable (executable, runnable, viewable, legible, audible) form. At least part of the meter is remote from the user, being located on a network server 110 while the user uses a client computer 114 . The meter is made unique to the content server 110 , through the use of IP addresses, coordinated random numbers, and the like. The meter stops running, and the content stops being fully usable, if the client 114 is disconnected for longer than a predetermined period or if the security handshake fails for some other reason.
[0144] As used herein, terms such as “a” and “the” and item designations such as “client” are inclusive of one or more of the indicated item. In particular, in the claims a reference to an item means at least one such item is required. When exactly one item is intended, this document will state that requirement expressly.
[0145] The invention may be embodied in other specific forms without departing from its essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. Headings are for convenience only. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope.
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Methods, devices, and systems are provided in a multi-level computer architecture which provides improved capabilities for managing courseware and other content in a shared use operating environment such as a computer network. In particular, the invention provides a commercial networked instruction content delivery method and system which does not exclude synchronous sharing but is focused on asynchronous sharing. Security means in the architecture provide content property holders with the ability to know how many minutes of use an individual made of licensed material and with increased certainty that their material cannot be used, copied, or sold in usable form unless and until a user site is connected or reconnected to a minute-by-minute counter which is located off the premises of the user. This security link helps protect software and other works which are being sold or licensed to an individual, organization, or entity, and creates income opportunities for owners of such content.
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This is a continuation-in-part of Ser. No. 07/298,561, filed Jan. 17, 1989, now abandoned.
BACKGROUND
1. Field of Invention
This invention relates generally to removable keyboard protectors for keyboard instruments such as pianos, electronic pianos, organs, synthesizers, samplers, and the like, and especially to keyboard instruments that do not have built-in keyboard covers, for use in protecting the keys and operating mechanism from dust, dirt, dampness, and other contaminants and for performing a wide variety of other functions.
2. Description of Prior Art
Many, if not most users of keybaord instruments prefer a removable cover for their instruments in order to protect the keys and operating mechanism from dust, dirt, and other contaminants without elaborate and complicated application and removel procedures and mechanisms.
Heretofore a wide variety of keyboard protectors have been proposed and implemented for keyboard instruments.
One such device, U.S. Pat. No. 4,419,921 issued to Simanski teaches a shield for obstructing a players line of sight to a portion of the keyboard when the shield is attached. This provided an artificial aid to force the learner to rely upon the touch system in locating keys. Users, however, regarded this type of cover as unsatisfactory for protecting the keys from dust and dirt, and useful only in the limited application of shielding a players hands from his vision.
Another type of keyboard protector, U.S. Pat. No. 4,040,335 issued to Oliver et al, comprised a cover made from lightweignt rigid plastic, and contoured to fit the console walls embracing the keyboard of an electronic organ. This type of cover required the shape of the organ to be such as to accommodate the rigid plastic cover thereby limiting its applications, or alternatively, that the organ be retrofitted with additional parts so that the cover would fit properly. Users, however, found this type of cover to be cumbersome, complicated, difficult to apply and remove, and susceptible to scratches from dust, dirt, and other contaminants.
A different approach, U.S. Pat. No. 3,072,006 issued to Jurkowski teaches a keyboard cover for small organs or pianos comprising spring loaded parallel tubular rods with fabric attached thereto to cover the keys.
Users found this type if cover unsatisfactory due to the tendency of the spring mechanism to lose tension over time, and the cumbersome application and removal process associated with use of this cover. A further problem users found with this cover was that the rods to which the fabric was attached, being heavier than that of the fabric, caused the fabric to become taut when in a resting or applied position, which in turn caused tension to be constantly applied to the key tips. This feature is detrimental to the key spring tension mechanism of modern instruments which do not have built-in counter tension mechanical action levers to resist the downward force applied by the rods. As a result the keys are prone to losing their built-in tension and are susceptible to becoming partially depressed.
A still different approach, U.S. Pat. No. 594,012 issued to Hedgeland comprised a fallboard foldable upon itself and incorporated onto the keyboard instrument at the time of initial construction. This type of fallboard is unsatisfactory as a keyboard protector for modern instruments that do not have space inherent in their construction to accommodate the array of hinges, levers, and pivots employed in attaching the fallboard to the instrument. Furthermore, this type of fallboard was permanently attached to the instrument and was neither portable nor removable. Such fallboards were cumbersome, weighty, and required periodic maintenance including lubrication of moving parts. Additionally, this type of fallboard is not usable on modern keyboard instruments utilizing electronic means as their source of sound generation which consequently do not have space for sounding devices or action levers, thereby making such design obsolete and unsatisfactory for use as a keyboard protector.
Most users, therefore, would find it desirable to have a keyboard protector for their keyboard instrument which is easy to apply and remove, adaptable to a broad spectrum of instruments, and capable of protecting the keys and keyboard operating mechanism from a wide variety of contaminants without concomitant damage to the keyboard mechanism.
OBJECTS AND ADVANTAGES
Accordingly I claim the following as the objects and advantages of my invention: to provide a keyboard protector for keyboard instruments that is easily applied and removed, to provide a cover that can be made from flexible, lightweight material which conforms to the keys and protects both the keys and operating mechanism from dust, dirt, and other contaminants to provide such a cover that is easy to store and clean, and to provide such a cover which requires a minimum of skill and training to use.
In addition I claim the following additional objects and advantages to provide a cover for keyboard instruments which is attractive and unobtrusive, to provide such a cover with simple attachment means which does not require extensive modification of the keyboard prior to application, and to provide such a cover also suitable as an alternative choice of keyboard protector for the conventional piano.
Readers will find further objects and advantages of the invention from a consideration of the ensuing description and accompanying drawing.
DRAWING FIGURES
FIG. 1 shows an exploded isometric view of a keyboard cover according to the invention separated from the keyboard to which it is to be attached, but oriented in a position for easy placement thereto.
FIG. 2 shows a sectional view of a keyboard instrument having such cover attached, illustrating the cover in use and depicting one manner of attachment, a portion of the keyboard in plan view.
FIG. 3 shows a sectional view of such cover depicting another manner of attachment, a portion of the keyboard in plan view.
FIG. 4 shows a topographical view of a keyboard instrument having such cover attached, illustrating the cover in use.
FIG. 5 shows an exploded view of a fastening track keeper over black key of keyboard and in position to be attached thereto.
FIG. 6 shows an exploded view of a fastening wedge in position securing keyboard protector to the keyboard according to the preferred embodiment.
DESCRIPTION OF THE INVENTION
FIG. 1 shows a keyboard protector 17 according to the preferred embodiment of the invention and a keyboard instrument designated 10 with cabinets 11 having a front 12 and sidewalls 13 and 14 as well as an offset top 15 confining a keyboard 16. The keyboard protector 17 of this invention is formed from a flexible lightweight material such as felt or other fabric, but may also be composed of plastic, urethane, or other lightweight, flexible material. The protector 17 includes an upwardly and rearwardly inclined rear section 20 to which an interfacing layer of protective material 28, as shown in FIG. 2, permanently bonded to keyboard protector 27. The protective material 28 may be cloth, plastic, urethane, or the like, either fusable or nonfusable, woven or nonwoven, and functions to prevent the passage of dirt, dust, or other contaminants. In the preferred embodiment fastening means are provided by a plurality of fastening wedges 33 that conform to the space in between the black keys of the keyboard as illustrated in FIG. 6. The keyboard protector rests on the black keys 16 of the keyboard 10 while the fastening wedges secure the keyboard protector thereto by frictional tension or pressure to the black keys. This allows for uniform placement of the protector with fastening wedges 33 adapted to conform to the space between the black keys, thereby attaching the protector at the surface level of the black keys. The fastening wedges 33 may be made of urethane, plastic, acetate, or the like. The fastening wedges 33 are attached to the keyboard protector 10 by two sided adhesive tape 29 or alternatively may be glued or otherwise secured onto the keyboard protector. In another embodiment closed cell fastening track keepers 31 as shown in FIG. 3 and FIG. 5 may be used as fastening means. The closed cell fastening track keeper in this embodiment of the invention is attached to the keyboard protector by two sided adhesive tape 29 or alternatively may be glued or otherwise secured onto the keyboard protector. The fastening track keeper 31 is adapted to conform to, and fit over the upraised black keys 16 of the keyboard. The track shape of the fastening track keeper 31 is shown in FIG. 5. The track or groove shape of the fastening track keeper 31 secures the keyboard protector to the keys by friction and drag and is easily attached or removed. An alternative configuration of the fastening track keeper is shown in FIG. 2. In this embodiment the fastening track keeper 30 is L-shaped and is adapted to conform to the top rear portion of the black keys 16 and the space immediately behind them as shown in FIG. 2. In still another embodiment various fastening type means such as opposing hook and loop fastening tape may be used to secure the keyboard protector to the keyboard instrument. Intermediate section 22 is joined to rear section 20 by a rear laterally extending edge 21. A substantially horizontal, planar central section 24 forms a continuous extension of intermediate section 22 through intermediate laterally extending edge 23 to the rear, and forms a continuous extension with a downwardly and forwardly inclined frontal section 26 through a laterally extending edge 25 terminating in frontal laterally extending edge 27. The keyboard protector 17 can be easily fabricated by cutting a substantially planar sheet of felt or other suitable material, molding it into the desired shape, and attaching said loop or hook fasteners thereto.
Keyboard Protector--Operation
The keyboard protector of this invention may be applied to all varieties of keyboard instruments including pianos, organs, synthesizers and the like. Referring specifically to FIG. 1 the keyboard protector 17 is shown in its desired orientation for placement on the keyboard 10. Specifically, the rear section 20 is positioned so that it rests on cabinet 11. Thereafter the protector is rotated gently to cause the planar central section 24 to rest on keyboard 16 and frontal section 26 to occupy the position shown in FIG. 2 and FIG. 3. In the preferred embodiment of this invention said fastening wedges 33 secure the protector in place by attachment to the black keys of the keyboard as shown in FIG. 6.
The keyboard protector 17 can be easily removed from the keyboard by simply raising it away from the keyboard thereby detaching the fastening wedges 33 from the keyboard keys 16.
Users will find the protector of FIG. 1 to 6 advantageous since it can be adpated for use with any type of keyboard instrument, and can be easily applied and removed with minimal effort.
While the above description contains many specificities, the reader should not construe these as limitations on the scope of the invention but merely as exemplifications of preferred embodiments thereof. Those skilled in the art will envision many other possible variations are within its scope. For example skilled artisans will readily be able to change the dimensions and shapes of the various embodiments. They will be able to make the protector of alternative materials such as cloth, plastic or molded urethane. They can make variations in the placement, sizes, and materials which comprise the fasteners and can substitute alternative attachment means such as fastening tape. It is understood that the present disclosure has been made by way of example and that numerous changes can be made withourt departing from the spirit and scope of the invention. Accordingly the reader is requested to determine the scope of the invention by the appended claims and their legal equivalents, and not by the examples which have been given.
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A removable unitary keyboard protector with attachment means adaptable to a broad spectrum of keyboard instruments. The protector includes a rear section with fastening means comprising fastening wedges adapted to conform to the space in between the black keys of the keyboard thereby attaching the keyboard protector thereto, a central cover position, and a frontal section fashioned to protect the keys and keyboard mechanism from contaminants or destructive forces to which such keyboard is accidentally or intentionally subjected.
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The invention described herein may be manufactured and used by or for the Government of the United States of America for governmental purposes without the payment of any royalties thereon or therefor.
BACKGROUND OF THE INVENTION
The present invention relates to the field of circulation control rotor (CCR) helicopters. Briefly, a CCR helicopter is one wherein the blades are rigidly fixed to the hub and lift is controlled by controlling the circulation of air around each blade (see U.S. Pat. No. 3,713,750). The primary advantage of a CCR helicopter is the reduction of weight of the entire rotor and reduction in number of moving parts associated with the blades; both of these result from the fact that the lift of each blade is modified by changing the circulation of air around it rather than by changing its angle of attack. The resulting rotor is lighter in weight, allowing a greater payload for the craft, and more reliable. CCR helicopters, however require a valve that will direct pulses of air into the rotor blades at a rate that does not vary appreciably with respect to the rate of rotation of the rotor. For this reason, most CCR valves are mechanically operated by a cam or other means on the rotor shaft; the air valves are thereby automatically opened at the proper azimuthal position of the rotor.
There are two main types of valves; those that are entirely within the hub, and those that are within the blades (except for the actuating mechanism, which is within the hub). Each type has advantages and disadvantages; a valve that is entirely within the hub is subjected to very low centrifugal forces and is quite compact, but this type of valve does not distribute lift control air (or other fluid) evenly along the length of the blade. That is, when a pulse of air is directed into the blade some of it immediately goes out through that part of the circulation control slot nearest the hub; this reduces the air pressure within the blade, so that less air goes out through the next part of the slot. The net result of this is an uneven airflow distribution pattern with a maximum at the hub and a minimum at the tip. A valve that extends the length of the slot in the blade solves the problem of uneven air distribution, but introduces problems due to centrifugal forces and to forces developed by unbalanced pressures on the operating part of the valve. An example of this latter would be a valve wherein the closure element is a flat plate that covers the circulation control slot along its entire length; the plate is hinged along one side, and is rotated about the hinge to uncover the slot. The unbalanced pressure force on this plate is the pressure on the inside (or plenum) surface of the plate minus the pressure on the outside (or slot) surface of the plate multiplied by the area of the slot; since the blade may be quite long, the area and hence unbalanced force may be quite large. What is needed, therefore, is a valve that extends the length of the blade but which is designed to overcome the problems due to unbalanced pressure forces on the closure element.
SUMMARY OF THE INVENTION
Briefly, the present invention is a valve for a CCR blade which extends the length of the blade. The closure element is a U-shaped member that is spring biased to a closed position, and opened by a swash plate and follower assembly in the hub. The two legs of the "U" straddle the entrance to the circulation control slot; when the closure element is reciprocated to its closed position air pressure acts on opposite legs of the "U" in opposite directions, thereby preventing the generation of forces due to unbalanced pressures.
OBJECTS OF THE INVENTION
Accordingly, it is an object of the present invention to provide a valve for a CCR blade which extends the length of the blade.
It is a further object of the present invention to provide a valve for a CCR blade wherein forces due to unbalanced pressures are not generated.
It is a further object of the present invention to provide a valve for a CCR blade wherein the closure element is reciprocated by means of a swash plate and follower mechanism.
Other objects and advantages of the present invention will be apparent from the following specification and accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a partly sectional view of a helicopter rotor according to the present invention.
FIG. 2 is taken along line 2--2 of FIG. 1.
FIG. 3 shows the swash plate and follower mechanism.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows a helicopter rotor 10 which incorporates the present invention. Rotor hub 12 is shown as having four blades 14 attached thereto; however, it is to be understood that any number of blades may be utilized in a rotor which incorporates the present invention.
FIG. 2 is a cross-section of one of blades 14 showing valve assembly 16 within blades 14. Valve assembly 16 comprises U-shaped member 18, cam 20, and spring 22. U-shaped member 18 straddles guide 24, which causes U-shaped member 18 to reciprocate in its proper path. Guide 24 is attached to the structure defining channel 34 by means of struts spaced along its length. One end of spring 22 bears against the bottom of U-shaped member 18; the other end rests against pedestal 26 which can be an integral part of spar 28 as shown. Spring 22 is one of a series of springs placed along pedestal 26; the number and strength of the springs are determined by the requirements of the individual design. Spar 28 has a series of holes 30 through it for the passage of air as will be explained later.
The contour of cam 20 is shown as being approximately elliptical; its actual profile, however, will depend on the application since cam 20 determines the amount of air that flows each time that valve 16 is opened.
Blade 14 has on its surface slot 32 through which circulation control air is ejected; slot 32 is fed by channel 34, the entrance to which is controlled by valve 16.
The valve of the present invention is controlled by a swash plate as shown in FIG. 1. The swash plate of the present invention is basically the same as those which are old in the art; it is comprised of an annular member 36 whose position can be adjusted by means of extensible members 38. Swash plate 36 can be translated axially or can be set at an angle with respect to shaft 40, as is well known in the art.
Swash plate 36 has a groove or channel 42 around its outer circumference. Follower 44, which is attached to one end of crank arm 46, rides in groove 42. The other end of crank arm 46 is rigidly attached to the hub end of cam 20. Crank arm 46 can be either rigidly or rotatably attached to follower 44 as will be explained later.
Operation of the valve is as follows: Rotor assembly 10 is caused to rotate by means not shown. Air or other lift control fluid comes up within shaft 40, and into plenums 48 and 50 of hollow blades 14. Holes 30 allow communication between plenums 48 and 50. The admission of air to channel 34 is controlled by U-shaped member 18, which is reciprocated by cam 20. When valve 16 is fully closed as shown in FIG. 2, the force on one leg of U-shaped member 18 due to the higher pressure within plenum 50 is counterbalanced by the same pressure acting on the same area of the opposite leg of U shaped member 18 which produces a force in the opposite direction. Thus the forces due to pressure cancel each other out, and the only force required to be overcome is that due to spring 22. Obviously, then, operation of valve 16 is not influenced by the level of the pressure within plenum 50 or the ambient air pressure existing in channel 34. Since the direction of motion of U-shaped member 18 is perpendicular to the direction of the centrifugal stresses exerted on the blade due to its rotation, operation of the valve is likewise not affected by the speed of rotation of the rotor.
When swash plate 36 is horizontal, follower 44 will travel in a horizontal plane around it. If one edge of swash plate 36 is elevated, when follower 44 approaches the elevated point it will be forced to rise up; however, since cam 20, which is attached to follower 40 by means of crank arm 46, cannot move up or down but can merely rotate, follower 46 will therefore cause cam 20 to rotate. As cam 20 rotates, U-shaped member 18 is reciprocated toward pedestal 26; this allows air to flow into channel 34 from both sides of U-shaped member 18. When follower 44 passes the point of peak height of swash plate 36 and begins to follow the downward sloping part, cam 20 will be rotated back to its initial position, and spring 22 will force U-shaped member 18 back to the closed position. Crank arm 46 can be rotatably connected to follower 44; alternatively, crank arm 46 can be rigidly connected to follower 44, and then crank arm 46 and follower 44 will rotate as a unit with respect to swash plate 36.
The amount of lift developed by a CCR helicopter is determined by the amount of lift control air that comes out of slots 32. If swash plate 36 is translated horizontally upward, crank arm 46 of each blade will be rotated through an equal angle and each valve 16 will be opened an equal amount; the rotor will thus develop collective lift, but no cyclic lift. Cyclic lift is developed by elevating that portion of swash plate 36 which corresponds to the azimuthal position at which cyclic lift is desired. When each blade passes this point, its follower 44 and crank arm 46 will be rotated a maximum amount which will open its valve 16 a maximum at that point. Thus the rotor will then develop cyclic lift as well as collective lift.
When swash plate 36 is held stationary, pulses of air will be produced at only one frequency. However, in order to spread the lift out over the full rotor disc and to counteract certain vibrations, it is desirable to generate pulses of air at harmonics of the primary frequency. In the rotor of the present invention this is done by making swash plate 36 and its associated actuators rotate independently of shaft 40. The swash plate assembly would be geared to the rotor assembly to rotate at integral multiples of the rotor's frequency, both in the same direction and in the opposite direction. In this manner each follower 44 would pass the high point of swash plate 36 more than once for each revolution of that particular rotor blade; the air pulses would then be produced at the primary frequency and at one or more harmonics of that frequency. Obviously many modifications and variations of the present invention are possible in the light of the above teachings. It is therefore to be understood that within the scope of the appended claims the invention may be practiced otherwise than as specifically described.
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An airflow control valve for a circulation control rotor helicopter blade wherein the airflow path is equally distributed about the closure element so as to prevent the generation of unbalanced pressure forces.
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