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FIELD OF THE INVENTION
The invention relates to means for ammunition transport in a repeating weapon. It relates, therefore, to all firearms which automatically take cartridges from a supply and feed these to a barrel.
BACKGROUND OF THE INVENTION
As supplies there serve, for example, cartridge belts or magazines. They can be designed as fixed or as changeable components of a weapon. Fixed storages are found, for example, in repeating rifles, changeable supplies, in contrast, are found in rapid-fire weapons, submachine guns, machine guns or the like.
In the loading process the cartridges are transferred individually from the supply into a barrel or into a cartridge chamber or carrier formed on the barrel. For this purpose they are first in a so-called transfer position in the supply. From there they are thrust or drawn by a breechblock over a transition into the cartridge chamber or carrier.
The number of transfer positions is conditioned by the construction type of the supply. If the cartridges are arranged in a row in the supply, as a rule one transfer position will suffice. If, however, the cartridges are arranged in two or more rows, then two or more transfer positions may be appropriate. An important example for this are double-row magazines. Here one stands before the choice of having both rows converge into one, so that one transfer position would suffice, or choosing a construction with two transfer positions. (The last-mentioned construction has the advantage there over the first that in the same space more cartridges can be store or stocked.)
The transfer position(s) are not located, in general, directly behind the barrel or the cartridge carrier. Instead of this they are frequently arranged under the cartridge carrier or laterally displaced thereto. (Such lateral displacements are necessary when several adjacently lying transition (transfer) positions are provided.) As a very general rule, therefore, a cartridge must cover a construction-conditioned intermediate interval between a transfer position and the barrel or the cartridge carrier.
The intermediate intervals are bridged by a corresponding number of transition. Here it is a matter in the case of known repeating weapons of routings on the barrel receptor, on the barrel or generally on fixed components of the weapon. They serve also for the guidance of the cartridge on its respective path. This is expedient, because a cartridge in a transfer position in known supplies is always fixed in some manner. The breechblock, therefore, can engage the cartridge only in one partial area. This alone would not suffice, however, for an exact guidance. Such a guidance, however, is very important in order to avoid jammings and loading obstructions to loading.
The production of such transitions proves to be problematical in practice. One the one hand, they should correspond as accurately as possible to the desired dimensions, in order to ensure a guidance that is secure and insensitive to shocks. One the other hand, they are ordinarily located at least in part in places difficult to access, so that there is only little space for the processing. The desired precision, therefore, is generally not achieved. As compensation or alternatively, for example expensive guide places are used on the magazine.
SUMMARY OF THE INVENTION
Accordingly, it is a general object of the invention to improve such transitions repeating weaponry and the like. The invention achieves this goal, with an automatic weapon with at least one cartridge supply, a barrel and a transition which bridges at least partially the interval or intervals between the cartridge supply and the barrel or a cartridge carrier formed on the barrel. In the loading process, cartridges are transported in a known manner from the supply into the barrel or into the cartridge chamber or carrier, in which process the transition or transitions serve for the guidance of the cartridges. This transition or transitions is/are constructed as, or in at least one, separate transition component.
For each transition, there can be provided a component of its own. It is also possible, however, for all the transitions to be comprised in one component. For the production any suitable materials can be used. Synthetic material is preferred. The transition component can be milled, for example, from the solid material or can be constructed as a forged part and subsequently milled. It can, however, also be constructed as a cast part. In principle, any surface precision and quality and any transition form is achievable. It is possible, therefore, freely to choose the most economical and best production process.
Moreover, the invention considerably facilitates the series manufacture of automatic weapons with individual cutting to measure. For example, one and the same basic model can easily be designed for different calibers or supplies. For this purpose it is merely necessary to put together suitable combinations of barrel, transition component and supply. The other components of the weapon, however, are no longer affected. This makes possible also an especially economical organization of the production flows.
In a preferred form of execution the transition component is constructed by pressure-casting-, metal-powder injection molding-,fine-casting-, or as a part of sintered metal, or as a plastic part. In this manner retoolings of the transition component become substantially superfluous. This holds also when individual zones or the entire component are complicated in construction. The production of the transition component thus becomes especially economical.
In a further preferred form of execution, the transition component is changeably or removably mounted to the housing. In this manner it also becomes possible subsequently to alter automatic weapons, without disadvantages such has having to accept into the bargain an unsuitable transition form or an offset between transition and supply. In this manner loading obstacles in converted weapons can be effectively avoided. This is advantageous especially in the case of overproductions of individual forms of execution or subsequent wishes of the customer for alterations. It makes possible, however, also the delivery of the weapons as conversion set. Therewith, lastly, the customer himself can arrange the weapon for the type of cartridges which is best suited for his particular requirements. Thus it is possible, for example, to convert a submachine gun at will for the cartridge 9 mm Parabellum or the cartridge .45 ACP, or for cartridges with special projectile forms (truncated missiles). For this it is merely necessary to assemble in each case a suitable barrel, a magazine, a breechblock and a transition component in suitable manner.
Finally, this form of execution makes it possible in case of damages to the transition, to change exclusively this component. Hitherto in such cases it was necessary to retire the barrel or even the whole weapon. The economicalness of repeating weapons is thus considerably improved.
In a further preferred form of execution, the transition component stands in closed-form engagement with the barrel. Preferably there,the closed-form engagement is constructed as a tongue-and-groove system. This makes possible an especially simple fastening of the transition component in the weapon, since only the barrel still has to be fixed. If one chooses for each combination of barrel and transition component a different-type closed form engagement, then, furthermore, confusions can be avoided. Especially in the case of issuing convertible weapons to military personal this can be very advantageous.
In a further preferred form of execution the cartridge supply is constructed as a magazine which is inserted into a reception space. The transition component is seated with its underside on the upper side of the front wall of the magazine. The rear end of the transition component connects, there, to the inner surface of the front wall of the magazine, essentially snugly. In this manner the transition approaches as near as possible to the transfer position. Unevennesses, damages or the like on the guide plate of the magazine can therefore no longer have a negative effect on the transport of the cartridges. The demands for a careful manufacture and treatment of the magazine can thus be lowered without impairing the quality of the weapon. Especially when cartridges of different length or missile form are to be used, this is very advantageous. Frequently, namely, in the magazine of the shorter cartridges in each case relatively thick walls must be domed in order to fit the magazine to the reception opening. Damages such as, say, dents would impair the guidance of the cartridge here especially severely.
In a further preferred form of execution the transition component is not wider than the reception space. A recess accessible through this space is provided for the transition component. The transition component there, in the installation or change is thrust through the receiving space into the recess. This has the advantage that the transition component can be changed especially easily.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is explained in more detail with the aid of examples of execution and of the appended drawing. In the drawing:
FIG. 1 is a partial longitudinal section through a submachine gun according to the invention, which is arranged for the cartridge 9 mm Parabellum;
FIG. 2 a partial longitudinal section through the submachine gun from FIG. 1, which is arranged for the cartridge .45 ACP (Automatic);
FIG. 3 an elevation view of the transition component from FIG. 1; and
FIG. 4 an elevation view of the transition component from FIG. 2.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIG. 1 the submachine gun has, in usual manner a housing 1, in which a barrel 3 is exchangeably arranged and is held by means of a cap nut. This is suited for the cartridge 9 mm Parabellum. The longitudinal axis of the barrel bore there is designated as bore axis 5. The rear end of the bore is constructed as cartridge chamber or carrier 7. At the rear end the barrel has on its outside a collar projecting in the manner of a flange, which is constructed on its underside as a crossbar 9.
In the housing 1 there is formed a magazine shaft 11, which extends about perpendicularly to the bore axis 5 and the central axis (not shown) of which intersects with the bore axis 5. In the magazine shaft 11 there is seated a magazine 15, which has a front wall 13 of relatively thick sheet metal or other material, two side walls and a rear wall. The upper ends of the side walls are extended and constructed as two magazine lips 19 lying opposite one another (only 1 represented).
The cartridges brought up by a follower by action of a magazine spring (not shown) are arranged in two adjacently lying rows offset from one another. The uppermost cartridge 17 is held by the magazine lip 19 allocated to it in its position, and is present in the transfer position which is assigned to its row. Now when the breechblock (no reference number) is moved forward along the bore axis 5, this cartridge 17 is then gripped on its base and introduced into the cartridge chamber or carrier 7. In order to ensure a dependable guidance of the cartridge 17, there is arranged a transition component 25. This is constructed in the example as a feed ramp.
On the feed ramp 25 there is formed a guide surface 23. In the loading process first of all the cartridge tip of the uppermost cartridge 17 runs onto this surface. The cartridge 17 is then introduced into the cartridge chamber or carrier 7. In the process also the circumference of this cartridge 17 runs on beyond the guide surface 23. This is inclined in such manner that it or its imagined extension impinges on the underside of the rear inner circumferential edge of the cartridge chamber or carrier 7.
On the front side the feed ramp 25 has a cross-groove 21 in which the crosspiece 9 engages at the rear outer circumferential end of the barrel 3. When the barrel 3 is arranged in the housing 1 so that it lies firmly in longitudinal direction, then it also holds fast the feed ramp 25. The feed ramp 25 is seated there in a receptacle which is formed in the housing 1. Alternatively, the feed ramp 25 could also be permanently fastened. For example, it would be possible for this purpose to inject it into the housing.
The rear end of the feed ramp 25 extends into the magazine shaft 11 through a distance which corresponds about to the wall thickness of the front wall 13 of the magazine 15. It ends, therefore, at or shortly before the inner surface of the front wall 13.
In conversion of the weapon for another caliber, first of all the breechblock is removed. Then the barrel 3, after releasing of the cap nut together with the feed ramp 25, can be thrust to the rear out of the housing 1, until the latter is present in the magazine shaft 11. By a rotation of the barrel 3 the feed ramp 25 is released from this. It can thereupon be removed from the housing 1. The installation occurs in reverse sequence. It is also possible to remove the feed ramp 25 together with the barrel 3 from the housing 1, and then to unhinge the feed ramp 25 from the barrel 3.
In FIG. 3 the feed ramp 25 is represented as an individual part. Here there is to be seen especially well the complicated shaping of the guide surface 23. This has two transitions in the form of guide grooves which are directed in each case from one of the two transfer positions (in each case beside a magazine lip 19) against the under edge of the cartridge chamber 7. Since therewith the guide surfaces 23 would intersect before the cartridge chamber 7, they bridge the intermediate interval only up to this section line.
In FIG. 2 there is represented the same housing as in FIG. 1. To be sure, there are installed therein a barrel 3' for the cartridge .45 ACP (.45 Automatic), a magazine 15' fitting this and an appertaining feed ramp 25'. The cartridge .45 ACP is longer and thicker than the cartridge 9 mm Parabellum. The magazine 15' must, in order to fit into the shaft 11, have the same dimensions in the cross section as the magazine 15. For this reason the wall thicknesses are less. The feed ramp 25' extends correspondingly less far into the magazine shaft 11. Otherwise the description of FIG. 1 holds correspondingly.
In FIG. 4 the feed ramp 25' is represented as an individual part. The guide surface 23' lies lower than the guide surface 23 of the feed ramp, since the diameter of the cartridge chamber 7' is greater than that of the cartridge chamber 7. The guide grooves are likewise adapted to the greater diameter.
Finally, the crossbar 9' and the cross groove 21' are differently designed than cross bar 9 and cross groove 21, in order to avoid that the possibility that the feed ramp can be inadvertently suspended in a barrel belonging to another caliber.
|
An ammunition transport for use in a repeating weapon includes a transition component that presents a pair of converging sloped surfaces so that cartridges provided in a side-by-side fashion from a cartridge magazine may be transferred to a cartridge chamber of the weapon.
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PRIOR RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application Ser. No. 60/866,699 filed Nov. 21, 2006 entitled “Internal Pipe Slot Tool,” which is incorporated herein by reference in its entirety.
FEDERALLY SPONSORED RESEARCH STATEMENT
[0002] Not applicable.
REFERENCE TO MICROFICHE APPENDIX
[0003] Not applicable.
FIELD OF THE INVENTION
[0004] The invention is a tool for internally cutting vertical slots in plastic pipe and a method of using an internal pipe cutter to improve methane extraction from municipal solid waste facilities (MSWFs). The method uses an internal pipe cutter to slot existing riser pipe and extract additional methane from methane recovery wells at MSWFs. By internally slotting the methane well riser pipes, the volume and rate of methane extraction is enhanced, the amount of methane extracted from a given landfill unit is increased and less methane is emitted into the atmosphere. Increasing methane capture and production while reducing methane emissions assists MSWFs in maintaining regulatory compliance. Additionally, the internal pipe cutter can be used to rehabilitate methane extraction wells where the screen zone has been flooded, clogged or deemed inoperable.
BACKGROUND OF THE INVENTION
[0005] Methane is a primary constituent of landfill gas (LFG) and a potent contributor to greenhouse gasses. MSWFs are the largest source of human-related (anthropogenic) methane emissions in the United States, accounting for about 25 percent of these emissions in 2004. Additionally, these escaping LFG emissions are a lost opportunity to capture and use a significant energy resource. Substantial energy, economic, and environmental benefits are achieved by capturing LFG and reducing greenhouse gasses. LFG recapture projects improve energy independence, produce cost savings, create jobs, and help local economies. LFG is currently extracted from landfills using a series of wells and a vacuum system that consolidates the collected gas for processing. From there, the LFG is used for a variety of purposes including motor vehicle fuel, generator fuel, biodiesel production, natural gas supplement, as well as green power and heating.
[0006] Currently, MSWFs bury waste bodies in layers over time (See FIG. 1 ). The basic structure is a floor and sidewalls (not shown) of compacted clay, covered with a HDPE polymer liner, filled with layers of waste alternated with clay or soil layers. Once a landfill has reached a certain capacity methane recovery wells are installed and gas is extracted from decomposing waste layers, as the waste body increases in height, riser pipe is added to the existing extraction well, once the waste body reaches the design height or capacity it is covered with topsoil, replanted with natural vegetation and left to decompose. LFG is created as solid waste decomposes in a landfill. This gas consists of about 50 percent methane (CH 4 ), the primary component of natural gas, about 40-49% percent carbon dioxide (CO 2 ), and a small amount of non-methane organic compounds. Landfills must be monitored over time to ensure that LFG emissions, groundwater leachate, and waste from the solid waste unit are not being released and impacting the environment. Methane extraction and recovery removes LFG and prevents emission of these air contaminants. Methane is first produced in the oldest, lower decomposing waste bodies. Subsequent layers produce methane at different times and rates. To extract methane from subsequent layers, wells are drilled to a desired depth or elevation and methane extracted. As decomposition continues shallower and shallower wells are required to reach gasses trapped in upper waste bodies. LFG capture and use is a reliable and renewable fuel option that represents a largely untapped and environmentally friendly energy source at thousands of landfills around the world.
[0007] Recaptured LFG can be used to produce electricity with engines, turbines, microturbines, or other technologies, used as an alternative to fossil fuels, or refined and injected into the natural gas pipeline. Capturing and using LFG in these ways can yield substantial energy, economic, environmental, air quality, and public health benefits. Internationally, significant opportunities exist for expanding LFG recovery and use while reducing harmful emissions.
[0008] Extraction of LFG from upper elevations by drilling shallower wells is a capital intensive process. Multiple wells, pipe, equipment and repeated drilling are required to collect and transport the gas to the collection facility. A method of ventilating existing methane wells is required that would not damage the vertical pipe while allowing methane gas to enter the riser from subsequent waste bodies or subsequent elevations within the same well location.
SUMMARY OF THE INVENTION
[0009] The internal slot tool is a cutting tool used to cut vertical slots inside existing methane well riser pipes above the original screen section to allow additional production of gas from upper zones or in wells where LFG production is reduced or completely inoperable. The tool is designed to fulfill the needs of owners and operators at landfill facilities. It provides ventilation to riser pipes initially installed in the waste body and extended with additional riser as waste is added. The amount of riser can reach lengths of approximately 50 feet or more above the original ventilated screen section of the well.
[0010] As used herein “riser pipe” or “vertical pipe” is defined as any length of pipe that is vertical or nearly vertical. Due to shifting waste bodies, imperfections in drilling, and deviation in pipe over time, the pipe may depart from vertical and may even approach horizontal at places within the pipe. Plastic pipe materials include polyvinyl chloride (PVC), chlorinated polyvinyl chloride (CPVC), polyethylene (PE), cross-linked high-density polyethylene (PEX), polybutylene (PB), and acrylonitrile butadiene styrene (ABS), for example. Pipe may also be made from concrete or ceramic.
[0011] The internal slot cutter ( FIG. 2 ) consists of a power supply, body, and cutting apparatus. The power supply may be electric, hydraulic, compressed air, or other non-sparking power supply. The body can be plastic, ceramic or metal. A brass or stainless steel body provides a durable and smooth surface. The motor ( 1 ), ( FIGS. 4 & 5 ) is sealed within the body and may be a sealed electric motor, hydraulic motor, compressed air motor or other non-sparking motor. The cutting apparatus extends from the body of the internal slot cutter. The cutting means ( 34 ) are pushed against the internal walls of the pipe cutting through the pipe and providing ventilation slots allowing LFG to enter the well and increase recovery volume and rate.
[0012] A method of using the internal slot cutter is also described. The cutter is placed within an area of pipe that requires ventilation generally above the original screen zone. The motor ( 1 ) is engaged and the cutting apparatus extended to slot the pipe. The slot is made longer by raising the cutting tool with the motor engaged. Once a desired slot length is reached the motor ( 1 ) is disengaged and the cutting apparatus is retracted. The internal slot cutter is then moved to another area and the process repeated or the tool is removed from the pipe when all slots are finished.
[0013] Sealed electric, pressurized hydraulic, and compressed air power supplies have been developed for a variety of applications. Motors can be selected based on cutting blade size, number of cutting blades, and gear ratio to cut a variety of pipes dependent upon pipe internal diameter and pipe wall thickness. In one embodiment the motor is a pneumatic motor with vented exhaust. In another embodiment the motor is an electric motor.
[0014] The motors may be approximately ¼ horsepower to approximately 10 horsepower, preferably between about ½ horsepower and about 5 horsepower, and most preferably the motor should be approximately 1 horsepower. In another embodiment the motor is about 8 horsepower. A larger or smaller motor may be used dependent upon the size of the pipe, size of the cutter, number of blades, and length of time required to cut through the pipe.
[0015] The tool body or main motor housing ( 11 ) can be plastic, ceramic, metal, carbon steel, cast aluminum, stainless steel, or brass. Cast aluminum, carbon steel, stainless steel and brass bodies provide a smooth, durable surface for the tool. The body may be solid or sectional. In one embodiment the body has a screw-type cap ( 55 ), ( FIG. 5 ) that seals the end of the tool body ( 11 ) as well as providing support for the adapter ( 51 ). Optionally, additional adapters ( 52 ) may also be placed in the end cap ( 55 ) or directly in the tool body ( 11 ).
[0016] The cutting apparatus as depicted on ( FIG. 2 ) can have 2 cutting blades at 180°, 3 cutting blades at 120°, 4 cutting blades at 90°, 5 cutting blades at 72°, 6 cutting blades at 60° apart, or more equally spaced cutting means. Many different cutting blades are known, including circular saws, chain saws, hole saws, and grinding wheels. These can be configured to create slots between 1/10th inch and 1 inch wide. The driving motor worm gear ( 3 ) engages the drive sprocket ( 7 ), rotating chain and cutter sprocket ( 32 ), spinning the cutting blades ( 34 ) at high speeds.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 : Methane Extraction from Municipal Solid Waste Bodies. The methane extraction well consists of a screen zone in a waste body for methane extraction, a riser pipe that carries the methane to the surface header and subsequent gas collection system. A methane extraction well is drilled into a waste body at a specific depth or elevation. Often the screen zone is installed early in the life of the landfill and risers are attached as the waste height is increased. Solid waste bodies are formed in waste-body layers as the landfill matures. To extract gas from waste bodies added above the original screen zone, additional ventilation is required, perforation slots may be added using the internal slot cutter to ventilate additional waste bodies in the existing riser system.
[0018] FIG. 2 : Internal Slot Cutter. An internal slot cutter is described one embodiment is demonstrated. The internal slot cutter (A) uses a power supply that transmits compressed air, hydraulic, or electrical power through hoses or wires ( 58 ) with one or more connectors ( 56 ) that attach to fittings ( 51 ) on the body ( 11 ). The power supply powers the motor ( 1 ) and drive shaft ( 2 ). The drive shaft ( 2 ) rotates the drive arms ( 26 ) thus rotating the saw blades ( 34 ). Two (B), three (C), four (D) or more drive arms ( 26 ) and retractable blades ( 34 ) may be used.
[0019] FIG. 3 : Retractable Blades. The motor ( 1 ) rotates the drive arms ( 26 ) that rotate the retractable saw blades ( 34 ). (A) The retractable saw blades ( 34 ) may be pressed outward by a movable wedge or pusher arms ( 40 ) that presses against the drive arms ( 26 ) and saw blades ( 34 ) against the pipe when pulled toward the motor. (B) The retractable saw blades ( 34 ) may be pulled outward by a rope, chain, or cable ( 63 ) that is attached to the drive arms ( 26 ). Optional eyes ( 62 ) may be fixed along the body to guide the pull cable ( 63 ). (C) The retractable saw blades ( 34 ) may be pressed outward by pushing the motor ( 1 ) and drive arms ( 26 ) against a fixed wedge ( 64 ) thereby forcing the drive arms ( 26 ) and saw blades ( 34 ) outward.
[0020] FIG. 4 : Description of the Internal Slot Cutting Tool and attachment. The figure shows one embodiment of the tool with a diameter of approximately 4.75 inches and a length of approximately 28 inches. The exterior of the tool is shown in Panel A including the arm median (G) and cutter axis (H). Panel B shows a cutaway of the tool demonstrating the motor, worm gears, arms and cutter details. Panel C shows the arm deployment detail and Panel D shows the one embodiment of the cutter detail.
[0021] FIG. 5 : Itemized part detail. Itemized parts are listed in Table 1.
DESCRIPTION OF EMBODIMENTS OF THE INVENTION
[0022] The internal slot cutter is a tool for cutting vertical slots in a plastic pipe. The tool is lowered into a vertical pipe to a target depth and activated. Upon activation, the cutter expands to the internal diameter of the pipe and cuts vertical slots through the pipe casing. The cutting apparatus are positioned on opposing sides of the pipe, either 180° apart for 2 blades, 120° for 3 blades, or 90° for 4 blades. More blades may also be used for larger pipes or where more slots are desired (i.e. 5 blades at 72°, 6 blades at 60°). Wider slots may be generated by increasing the width of the cutting means. Cutting blades can be from 1/10″ to 1 ″ wide, or wider for larger pipes. As the cutting apparatus expands, the blades push equally against opposing sides of the pipe creating vertical slots at each cutting means. Slots may be cut in varying lengths by raising the cutting tool while activated. The size of the slots will depend upon the diameter of the pipe, depth of the pipe, type of pipe, amount of waste body to be ventilated, and the like. In one embodiment the slots are about 1 to about 12 inches long or about 2, 3, 4, 5, 6, 7, 8, 9, 10, 12, 14, 16, 18, 20, 25, to about 30 cm in length; in another embodiment the slots are approximately 6 inches long or 15 cm in length. In another embodiment the slots are several feet or meters long. After the slots are cut to a desired length, the power source is turned off and the cutting apparatus retracted. The tool is lifted and the process repeated until a desired length of pipe is slotted.
[0023] The tool is run in an explosive environment; therefore a non-sparking power source is preferred. In one embodiment air or hydraulic power is used to power the tool. In a preferred embodiment a single pressurized air hose is used to power the tool where the pneumatic motor may optionally be vented to remove the pressurized air from the riser pipe. In another embodiment a hydraulic feed and return line are used to power the tool and recirculate hydraulic fluid. Additionally, a steel cable, rope, or pipe may be attached to the tool.
[0024] In one embodiment, the power source fittings are recessed in the body. The power source fittings may also be coupled, or encased in an end-cap using a variety of connectors known to one of ordinary skill in the art. Connectors include, but are not limited to, screw-type connectors, hydraulic connectors, pressure fittings, and the like.
[0025] The diameter of the tool body must be narrower than the riser pipe. Although ideally the riser pipe would be vertical, the pipe may have bends and obstructions that may intrude into the interior of the pipe. Thus the tool body should be less than about 85%, preferably less than about 80%, more preferably less than about 75%, and most preferably less than about 60% of the pipe's internal diameter. In one embodiment the tool is less than 5 inches in diameter, in a preferred embodiment the tool is between 2 and 6 inches in diameter. The total diameter of the tool body, retracted cutting blades, and all supply lines may be about 2, 2.5. 3. 3.5. 4. 4.5, 5, 5.5, 6, to 6.5 inches, or about 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, to 20 centimeters, or larger diameters.
[0026] The body excluding the cutter should be less than 3 feet long, preferably about 2 feet and most preferably from about 1 foot to about 2 feet in length. The body may be an elongate oval or cylindrical. Body material can be any durable material including plastic, metal, or ceramic. In a preferred embodiment the body is cast aluminum, carbon steel, stainless steel, or brass providing both a durable casing and a weight. The tool may weigh between 2 and 20 pounds. Preferably the tool weighs between 4 and 16 pounds, most preferably about 10 pounds.
[0027] The cutting apparatus needs to expand to the internal diameter of the pipe and cut through the pipe. In one embodiment the internal slot cutter expands about 4 to about 10 inches in diameter (or about 10 mm to about 25 mm). In another embodiment the internal slot cutter expands about 6 to about 8 inches in diameter (or about 15 mm to about 20 mm). In a preferred embodiment the internal slot cutter expands to greater than 8 inches in diameter (greater than 15 mm). The blades must be able to cut about a 0.1 to about 1 inch or about 1 mm to about 3 cm wide slot in the pipe wall. In a preferred embodiment the cutter makes about a ⅛ inch thick slot in the pipe wall. In another embodiment the cutting apparatus makes an approximately ¼ inch slot in the pipe wall. The slots may be about ⅛, 3/16, 7/32, ¼, 9/32, 5/16, ⅓, 11/32, ⅜, ½, ¾, to 1 inch wide, or about 1, 2, 3, 4, 5, 6, 7, 8, 9 to 10 mm wide or approximately 1, 2, 3, to 4 cm wide or greater dependent on the scale of the cutter and the width of the cutting blade. The cutting apparatus can cut a variety of pipe materials including schedule 80 PVC pipe, HDPE, or other plastic pipe materials. Blades may be interchanged dependent upon the material to be cut and thickness of the riser wall.
[0028] An index of parts is shown in Table 1. The parts listed in Table 1 may be substituted with similar parts. For example, a drive sprocket and chain may be replaced with a pulley and belt. A shaft, washer and retaining ring may be replaced with a bolt and nut. A brad may be used to permanently affix two parts instead of screw. A gear box may be substituted for the worm gears. Alternative washers, bushings, bearings, and spacers may be used where appropriate.
[0000]
TABLE 1
Itemized parts list.
ITEM
QTY
DESCRIPTION
Supplier
PART #
1
1
Pneumatic Motor
Atlas Copco
LZB54_3
2
1
Shaft worm gear adaptor
Rush Gears
3
1
Worm gear
Rush Gears
WH12QR
4
3
Machined worm gear
Rush Gears
WB1220QR_Machined
5
3
Worm gear bushing
McMaster-Carr
6391K178
6
3
Drive sprocket spacer
Capital Tool
Spacer_Sprocket_28T
7
3
Drive sprocket
Capital Tool
Sprocket_28T
8
3
Drive sprocket washer
Capital Tool
Spacer_Thrust_Sprocket_28T
9
9
Socket head screw cap
SHCS-English-UNC
10
6
Worm gear bearing
Berg W. M., Inc.
Berg_BR5-2
11
1
Main motor housing
Housing_Working
12
1
Bearing
Stafford Mfg. Corp.
5909K18_ThrustWasher
14
1
Thrust Washer
Stafford Mfg. Corp.
5909K78_Washer_35mm_1mm
15
1
Thrust Washer
Stafford Mfg. Corp.
5909K91_Washer_35mm_3.5mm
16
1
Bearing
Stafford Mfg. Corp.
5909K38_ThrustWasher
18
2
Thrust Washer
Stafford Mfg. Corp.
5909K52_Washer_1.25_.032
19
1
Linear shaft bearing
Berg W. M., Inc.
Linear_Shaft_Bearing
20
1
Linear drive base
Linear_Base
21
1
Linear drive arm support
Arm_Support_2
22
2
Socket head screw cap
SHCS-English-UNC
23
2
Flat washer
Grainger Ind.
ANSI B18.22.1-1965, R1990
24
3
Support arm pusher shaft
Linear_Arm_SetScrew
25
1
Linear drive
Linear_DrivePiece
26
3
Cutter arm
Arm_Sprocket
27
3
Cutter shaft bearing
SKF
4200 ATN9_PART1
31
3
Cutter shaft
Shaft2
32
3
Cutter sprocket
Capital Tool
Sprocket_18T
33
3
Cutter sprocket spacer
Capital Tool
Spacer_Sprocket_18T
34
3
Cutter
3x.25 Cutter
35
3
Cutter thrust washer
Stafford Mfg. Corp.
5906K547_Thrust_Washer
36
3
Retaining ring
Smalley Steel Ring Co.
WSM-37
37
3
Cutter support washer
Stafford Mfg. Corp.
Washer_Cutter
38
3
Screw cap
SHCS-English-UNF ¼-28 × ⅝ lg
39
3
External retaining ring
Smalley Steel Ring Co.
WSM-25, ¼
40
3
Pusher arm
Pusher_Arm
41
3
Pusher sleeve bearing
Berg W. M., Inc.
6338K411_Sleeve_Bearing
42
4
Pusher thrust washer
Stafford Mfg. Corp.
5906K511_ThrustWasher
45
1
Pneumatic drive
Atlas Copco
LZB14R_4
46
1
Linear drive screw
Linear_DriveScrew
47
1
Drive motor housing
BottomHousing_Working
48
3
Worm gear shaft
Rush Gears
WormGearShaft
49
3
Screw cap
SHCS-English-UNC, ¼-20 × 1 lg
50
1
External retaining ring
Smalley Steel Ring Co.
WSM-50, ½
51
2
BSP Adapter
Sanford
38BSP_Adapter
52
1
BSP Adapter
Sanford
12BSP_Adapter
53
1
Motor support sleeve
MotorSleeve
54
1
Spring ring
Smalley Steel Ring Co.
RW-0250-0.144
55
1
End motor cap
MotorLoader
56
2
Fitting Adapter
Chamberlin Rubber Co.
16-12_FTX-S_PRT
57
1
Fitting Adapter
Chamberlin Rubber Co.
20-16_FTX-S_PRT
58
2
Fitting Hose
Chamberlin Rubber Co.
30
59
1
Fitting Hose
Chamberlin Rubber Co.
32
60
1
External retaining ring
Smalley Steel Ring Co.
WSM-125
61
3
Drive housing spacer
Housing Spacer
[0029] All parts are commercially available, but may be manufactured to meet the specifications described herein if custom sizes or materials are desirable. Additionally, the tool may be scaled for larger or smaller pipes thus the part selected may be replaced with an appropriately sized part.
Example I
Pneumatic Cutter Tool
[0030] In one embodiment an airtool was designed to cut ¼″ slots in a 6 to 8 inch diameter pipe. The tool including housing, motor, cutters, pusher motor and housing, is approximately 28″ in overall length and about 4¾ inches in overall diameter. The cutting wheels are shown in their fully deployed position ( FIG. 4 ). The Cutter is held in place on the shaft with a washer and screw. A double row ball bearing is used to support the shaft. The bearing is captured in the arm by an internal shoulder in the arm and a flange on the cutter shaft. The pusher arm is also attached to the shaft to move the cutter out to the pipe ID. Cutter deployment is slowed or stopped when the arm impacts the ID of the tube and cutting begins, the arm is then extended further until a slot is cut through the pipe. A pneumatic motor or electric motor ( 45 ) may be used to deploy the arms ( 26 ). One advantage of a pneumatic motor is that stall does not hurt the motor. With an electric motor, motor current can be monitored to detect stall and control arm deployment.
[0031] The main pneumatic motor ( 1 ) receives compressed air at a flow rate of approximately 37.5 cfm at 100 psi. The supply hoses (forward and reverse) are approximately 1″ outside diameter (OD) or ⅞″ inside diameter (ID), and the discharge hose is approximately 1¼″ OD or 1⅛″ ID. When using a vented exhaust motor, the exhaust hose ( 59 ) must be large enough to prevent back pressure from slowing the motor. Optionally, the end motor cap ( 55 ) houses adapter fittings ( 51 ) that reduce larger supply and exhaust hose fittings ( 58 ) to the motor fittings ( 56 ). Longer hoses may require larger diameter supply and exhaust hoses as the pressure may drop approximately 25 psi over 100 ft of hose length in the supply hoses and 8 psi in the discharge hose.
[0032] In one embodiment, a 0.8 hp motor ( 1 ) is powered by a compressed air supply to rotate at the drive shaft ( 2 ) and worm gear ( 3 ) at approximately 6,700 rpm. At 6,700 rpm the drive shaft worm gear ( 3 ) will rotate the cutter arm worm gear ( 4 ) and drive sprocket ( 7 ), the drive sprocket rotates the chain and cutter sprocket ( 32 ), the cutter sprocket ( 32 ) turns the cutter ( 34 ) at approximately 2100 rpm.
[0033] The cutter ( 34 ) may be a part of the drive chain or may be attached to the cutter sprocket. As shown in FIGS. 4 & 5 , the cutter ( 34 ) is a 3″ diameter by ¼″ thick saw blade. In one embodiment the minimum cutting speed is about 1500 to about 1800 ft/min, preferably about 1600 to about 1700 rpm, and most preferably about 1650 ft/min.
[0034] The cutting arms are deployed by rotating a second motor located inside an “Arm Deployment Motor Housing”. The motor drives the “Drive Screw” as shown in FIG. 4B . The drive screw is threaded into the “Arm Pusher”. The “Arm Pusher” is captured within the “Arm Deployment Pusher”. The “Arm Deployment Pusher” rides on the “Linear Base” (not labeled). The “Linear Base” is square in cross section to prevent rotation. The Linear Drive Mechanism is shown in cross section in FIG. 4B .
[0035] In one embodiment, a M ICRO M O ™ (www.micromo.com) motor provides the power required to drive the pusher arms. The motor about 1″ in diameter and can be selected in a variety of voltages including 6 to 24 V DC motors. The motors are reversible and controllers available from MICROMO™ enhance the ability to manipulate the arms.
[0036] In another embodiment, pressure from the compressed air is used to fill a cylinder driving a push rod. As the push rod extends, the push arms are driven out until the cutter reaches the ID of the riser pipe. Motion can also be achieved with a linear drive pneumatic or hydraulic cylinder.
[0037] Cutter can be of various designs, different widths and diameters. Cutter geometry can be customized to optimize the cutting performance in different materials. A simple cutting blade can be used for PVC and polyethylene. Cement and harder materials may be cut with a diamond-tipped saw. Saw diameter, tooth spacing and material can be optimized for a variety of materials.
Example II
Electric Cutter Tool
[0038] In another embodiment a sealed electric motor is used to power the internal cutter tool. Electric motors can provide drive and torque from a motor with a smaller diameter. The cutting tool can be scaled to very small diameters using electric AC or DC motors. Brushless motors can minimize the danger of spark or flames. Containing the electric motor in a sealed housing may be an added safety measure.
[0039] In one embodiment a ½ horsepower electric motor rotates a drive shaft bevel or miter gear. The drive shaft bevel or miter gear drives a second miter or bevel gear. The second gear drives a cutter arm belt that in turn rotates the cutter shaft. The cutter shaft rotates one or two cutters, thus cutting a slot or pair of slots into the riser pipe. The cutting arms may be pushed out by the main motor when the motor is activated, or may be driven by a second motor or solenoid.
Example III
Tool Operation
[0040] Methane wells may be ventilated when methane production from a given well is reduced due to clogging, flooding, pipe damage, or other factors that may make the well inoperable. A riser may also be slotted as upper waste bodies begin to produce methane, or risers may be vented in an effort to reduce total methane emissions. First, a visual inspection of the vertical pipe ensures the riser is continuous and not damaged. A video camera is run down the pipe to identify obstructions, mark depths and identify any bends in the pipe. Depths of target waste body and desired areas for slotting are then diagrammed and the amount of slotting required for waste body length is calculated. The internal slot tool is dropped or lowered down the vertical pipe (or pushed if a solid pipe, bar, or wire is attached) to the desired depth. Cutting is initiated by powering the tool and expanding the cutting apparatus to the walls of the pipe. The tool is raised a desired length while cutting. Once a length of pipe is slotted the cutting apparatus is retracted and the power is turned off. The tool may be rotated to add additional slots at the same elevation or raised to add slots at a different elevation. The tool is removed when slotting is finished. If required a video camera may be used to verify slot depth and length.
[0041] The methane wells are then monitored and compared to methane production prior to adding ventilation slots. The amount of methane produced may increase from about 5% to over 150% above previous production levels. In another embodiment methane production is increased from about 10% to about 100% above previous production levels. When ventilating new waste bodies within each well location, the amount of methane produced may double or triple depending on the length of riser ventilated.
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An apparatus and method to internally cut vertical slots inside PVC, HDPE, or plastic pipe-riser (blank casing) in existing methane gas recovery wells (extraction wells) that have been installed at Municipal Solid Waste Facilities are described. Vertical slots cut in methane well risers allow methane gas, LFG derived from the decomposition of waste, to enter the existing riser and extraction system. This process saves time and cost associated with drilling additional wells to retrieve methane gas from subsequent layers of the waste body. The process assists in maintaining regulatory compliance by capturing LFG and preventing it from being emitted into the atmosphere.
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This application is filed claiming priority from co-pending Provisional Application No. 60/117,395 filed Jan. 27, 1999.
BACKGROUND OF INVENTION
1. Field of the Invention
This invention relates to the use of diphenylacetanilides which selectively bind to mammalian Neuropeptide receptors. It further relates to the use of these compounds and compositions containing these compounds in treating conditions related to an excess of neuropeptide Y such as feeding disorders and certain cardiovascular diseases.
2. Description of the Related Art
Neuropeptide Y, a peptide first isolated in 1982, is widely distributed in the central and peripheral neurons and is responsible for a multitude of biological effects in the brain and the periphery. Various animal studies have shown that activation of neuropeptide Y1 receptors is related to vasoconstriction, Wahlestedt et al Regul. Peptides, 13: 307-318 (1986), McCauley and Westfall, J. Pharmacol. Exp. Ther. 261:863-868 (1992), and Grundemar et al Br. J. Pharmacol. 105:45-50 (1992); and to stimulation of consummatory behavior, Flood and Morley, Peptides, 10:963-966 (1989), Leibowitz and Alexander, Peptides, 12:1251-1260 (1991), and Stanley et al Peptides,. 13:581-587 (1992).
Grundemar and Hakanson TIPS, May 1994 [Vol. 15], 153-159, state that, in animals, neuropeptide Y is a powerful stimulus of food intake, and an inducer of vasoconstriction leading to hypertension. They further point out that low levels of neuropeptide Y (NPY) are associated with loss of appetite. These reports clearly indicate that compounds that inhibit the activity of this protein will reduce hypertension and appetite in animals.
EP0759441 and U.S. Pat. No. 5,576,337 report that physiological disorders caused by neuropeptide Y include:
disorders or diseases pertaining to the heart, blood vessels or the renal system, such as vasospasm, heart failure, shock, cardiac hypertrophy, increased blood pressure, angina, myocardial infarction, sudden cardiac death, arrhythmia, peripheral vascular disease, and abnormal renal conditions such as impaired flow of fluid, abnormal mass transport, or renal failure; conditions related to increased sympathetic nerve activity for example, during or after coronary artery surgery, and operations and sugery in the gastrointestinal tract;
cerebral diseases and diseases related to the central nervous system, such as cerebral infarction, neurodegeneration, epilepsy, stroke, and conditions related to stroke, cerebral vasospasm and hemmorrhage, depression, anxiety, schizophrenia, and dementia;
conditions related to pain or nociception;
diseases related to abnormal gastrointenstinal motility and secretion, such as different forms of ileus, urinary incontinence, and Crohn's disease;
abnormal drink and food intake disorders, such as anorexia and metabolic disorders;
diseases related to sexual dysfunction and reproductive disorders;
conditions or disorders associated with inflammation;
respiratory diseases, such as asthma and conditions related to asthma and bronchoconstriction; and diseases related to abnormal hormone release, such as leutinizing hormone, growth hormone, insulin, and prolactin.
WO 96/14307 refers to substituted benzylamine derivatives which selectively bind to human neuropeptide Y1 receptors.
SUMMARY OF THE INVENTION
This invention comprises a method of inhibiting or alleviating a pathological condition or physiological disorder in a mammal characterized by or associated with neuropeptide Y which comprises administering to a mammal in need of such treatment a neuropeptide Y inhibiting amount of the compound of the formula:
wherein R is —N(C 2 H 5 ) 2
or a pharmaceutically acceptable salt thereof
In another aspect, this invention comprises a method of inhibiting or alleviating a pathological condition or physiological disorder in a mammal characterized by or associated with an excess of neuropeptide Y which accompanies administering to a mammal in need of such treatment a neuropeptide Y inhibiting amount of the compound of Formula I shown above.
This invention also comprises a method of treating a pathological condition wherein said pathological condition or physiological disorder is a feeding disorder such as obesity or bulimia.
In another aspect, this invention comprises a method of inhibiting or alleviating a pathological condition or physiological disorder in a mammal wherein said pathological condition or physiological disorder is selected from the group consisting of:
disorders or diseases pertaining to the heart, blood vessels or the renal system, such as vasospasm, heart failure, shock, cardiac hypertrophy, increased blood pressure, angina, myocardial infarction, sudden cardiac death, arrhythmia, peripheral vascular disease, and abnormal renal conditions such as impaired flow of fluid, abnormal mass transport, or renal failure;
conditions related to increased sympathetic nerve activity for example, during or after coronary artery surgery, and operations and surgery in the gastrointestinal tract;
cerebral diseases and diseases related to the central nervous system, such as cerebral infarction, neurodegeneration, epilepsy, stroke, and conditions related to stroke, cerebral vasospasm and hemorrhage, depression, anxiety, schizophrenia, and dementia;
conditions related to pain or nociception;
diseases related to abnormal gastrointenstinal motility and secretion, such as different forms of ileus, urinary incontinence, and Crohn's disease;
abnormal drink and food intake disorders, such as anorexia and metabolic disorders;
diseases related to sexual dysfunction and reproductive disorders;
conditions or disorders associated with inflammation;
respiratory diseases, such as asthma and conditions related to asthma and bronchoconstriction; and diseases related to abnormal hormone release, such as leutinizing hormone, growth hormone, insulin, and prolactin.
The compound of formula I when R is —N(C 2 H 5 ) 2 is basic in nature and capable of forming a wide variety of salts with various inorganic and organic acids. The acids that may be used to prepare pharmaceutically acceptable acid addition salts of the compound of formula I are those that form non-toxic acid addition salts, i.e., salts containing pharmacologically acceptable anions, such as the hydrochloride, hydrobromide, hydroiodide, nitrate, sulfate, bisulfate, phosphate, acid phosphate, isonicotinate, acetate, lactate, salicylate, citrate, acid citrate, tartrate, pantothenate, bitartrate, ascorbate, succinate, maleate, fumarate, gluconate, glucaronate, saccharate, formate, benzoate, glutamate, methanesulfonate, ethanesulfonate, benzenesulfonate, and p-toluenesulfonate.
DETAILED DESCRIPTION OF THE INVENTION
The compounds of formula I are known in the chemical literature and may be prepared by the procedures described Muramatsee, et al. Tetrahedron Letters No. 23, pp. 2133-2136 (1973); Stevens and French, J. Am. Chem. Soc. 1953, 75, 657-60; and Hoerhold and Eibish, Tetrahedron 1969, 25, 4277-4286. These references are hereby incorporated by reference.
Briefly, the compound of formula I wherein R is —N(C 2 H 5 ) 2 is prepared by irradiation of molar equivalents of diphenyidiazomethane and p-diethylamino-phenyl isonitrile. The compound of formula I is a colorless solid, mp 145-6° C.
The acid addition salts of this compound are readily prepared by treating the base compound with a substantially equivalent amount of the chosen mineral or organic acid in an aqueous solvent or suitable organic solvent such as methanol or ethanol. Upon evaporation of the solvent, the derived salt is obtained.
The pharmaceutical utility of the compound of Formula I is indicated by the following assays for human NPY1 and NPY5 receptor activity.
NPY1 Assay
The procedure used is similar to that described by Gordon et al. ( J. Neurochem. 55:506-513, 1990). SK-N-MC cells were purchased from ATCC (Rockville, Md.). Cells were maintained at 37° C. and 5% CO 2 in Dulbecco's modified essential media (DMEM) with L-glutamine and 110 mg/L sodium pyruvate, which was supplemented with 10% fetal bovine serum and 25 mM HEPES (pH 7.3). The binding assay was performed in 24-well plates (Falcon) when the cells were confluent. Taking care to not disturb the cells on the bottom of the wells, the media was aspirated, and 0.5 ml of Dulbecco's phosphate buffered saline (DPBS) with calcium and magnesium were added to each well. The DPBS was aspirated and an additional aliquot of DPBS was added and aspirated. To begin the assay, binding buffer consisting of serum-free DMEM containing 0.5% bovine serum albumin, 0.1% bacitracin and 0.1 mM phenylmethylsulfonylfluoride was added to each well. The cells and the binding buffer preincubated for 30 minutes at room temperature, at which point the drug dilution and [ 125 I)]PYY (NEN-DuPont: 50000-75000 cpm ˜50 pM) were added to yield a final volume of 250 ul. Nonspecific binding was defined with 1 mM NPY (porcine or human, Bachem Calif.). After a 3 hour incubation at room temperature, the plates were then put on ice and the wells were aspirated. The cells were washed 4-6 times with 0.5 ml of ice-cold DPBS. A dilute solution of Triton X-100 (1%) was then added to each well. After approximately 1 hour at room temperature, an aliquot from each well was transferred to a 12×75 mm test tube, and the amount of [ 125 I] was quantitated on a gamma counter with an efficiency of 80-85% (Genesys 5000, Laboratory Technologies). IC 50 values were calculated with the non-linear curve fitting program RS/1 (BBN Software Products Corp., Cambridge, Mass.).
Assay for NPY-5 Binding
[ 125 I]PYY Binding at Human NPY Receptors Expressed in Sf9 Cells
Baculovirus-infected Sf9 cells expressing recombinant human NPY 5 receptors are harvested at 48 hours. At the time of harvest, cell pellets are resuspended in lysis buffer (20 mM Tris-HCl, pH 7.4, 5 mM EDTA, 0.5 μg/ml leupeptin, 2 μg/ml Aprotonin and 200 mM PMSF) and homogenized using a Polytron (setting 3, 25-30 seconds). Homogenates are centrifuged at 4° C. for 5 minutes at 200 x g (˜1.5 rpm) to pellet the nuclei. The supernatant is collected into a fresh tube and centrifuged at 48,000 x g for 10 minutes. Pellets are washed once in lysis buffer and centrifuged. The final pellet is resuspended in PBS and stored in aliquots at −80° C. Purified membranes are washed using PBS and resuspended in binding buffer (50 mM Tris(HCl), pH 7.4, 5 mM KCl, 120 mM NaCl, 2 mM CaCl 2 , 1 mM MgCl 2 , 0.1% bovine serum albumin (BSA)). Membranes (20 μg/reaction tube) are added to polypropylene tubes containing 0.035 nM [ 125 I]PYY(porcine), displacers ranging from 10 −12 M to 10 −5 M, and buffer to yield a final volume of 0.5 mL. Nonspecific binding is determined in the presence of 1 μM NPY(human) and accounts for 10% of total binding. Following a 2 hour incubation at room temperature, the reaction is terminated by rapid vacuum filtration. Samples are filtered over presoaked GF/C Whatman filters (1.0% polyethylenemine) and rinsed 2 times with 5 mL cold binding buffer without BSA. A gamma counter is used to count filters with an efficiency of 85%. IC 50 values were calculated with the non-linear curve fitting program RS/1 (SigmaPlot, Jandel).
Compounds of Formula I showed the following binding constants in the NPY5
R
Ki nM
—N(C 2 H 5 ) 2
8
—CH 3
800
14
Functional Assay for NPY Receptors Expressed in Oocytes
Experiments were performed on Xenopus oocytes. Oocytes were prepared and maintained using standard protocols (Dascal and Lotan, in Methods in Molecular Biology; Protocols in Molecular Neurobiology, eds. Longstaff & Revest, Humana, Clifton, N.J., 13:1992). For the present experiments, oocytes were obtained from 6 frogs. Oocytes were recorded from 2-7 days following coinjection of GIRK1 and the H17 NPY-1 or NPY-5 subtype mRNA (25 ng of each, 50 nL total volume).
Two electrode voltage clamp recordings were carried out using a Warner Instruments Oocyte clamp OC 725B. Data were collected on a Macintosh microcomputer and analyzed using Superscope software. Voltage and current electrodes were pulled from glass tubing (1.5 mM O.D.) on a Brown/Flaming micropipet puller (Sutter Instruments, model P-87). Electrodes contained 3M KCl and had resistances of 0.5-2 MOhms. Oocytes were bathed in normal external solution containing; 90 mM NaCl, 1 mM KCl, 1 mM MgCl 2 , 1 mM CaCl 2 , 5 mM HEPES, pH=7.4. Before NPY agonists or antagonists were introduced, a high K + solution containing; 1 mM NaCl, 90 mM KCl, 1 mM MgCl 2 , 1 mM CaCl 2 , 5 mM HEPES was applied to permit recording of the inwardly rectifying K + current. Drugs were applied diluted in the high K + media.
100 μM stocks of NPY, PP or NPY peptide fragments or PYY peptide fragments were prepared in water and frozen until needed.
Oocytes were voltage-clamped at −80 mV with two electrodes. Oocytes were initially superfused with normal external medium (approximate flow rate 4 ml/min.). Before drugs were applied, cells were superfused with high K + solution to permit activation of the inwardly rectifying K + current. In oocytes coinjected with NPY receptor and GIRK1 mRNA, the NPY agonist induced an additional inward current over the resting K + current caused by high K + medium. Because responses desensitized at slow, but varying rates, cumulative dose applications were administered to generate concentration response curves. Two to four doses of agonist were applied to each cell. Agonist dose responses in each cell were normalized against the response to a maximal concentration of human NPY. Dose response curves were fit with a logistic equation using Kaleidagraph software (Abelbeck software, Reading, Pa.).
The compound of formula I or a pharmaceutically acceptable salt thereof (the active compound) may be administered orally, topically, parenterally, by inhalation or spray or rectally in dosage unit formulations containing conventional non-toxic pharmaceutically acceptable carriers, adjuvants and vehicles. The term parenteral as used herein includes subcutaneous injections, intravenous, intramuscular, intrasternal injection or infusion techniques. In addition, there is provided a pharmaceutical formulation comprising a compound of general formula I and a pharmaceutically acceptable carrier. The active compound may be present in association with one or more non-toxic pharmaceutically acceptable carriers and/or diluents and/or adjuvants and if desired other active ingredients. The pharmaceutical compositions containing the active compound may be in a form suitable for oral use, for example, as tablets, troches, lozenges, aqueous or oily suspensions, dispersible powders or granules, emulsion, hard or soft capsules, or syrups or elixirs.
Compositions intended for oral use may be prepared according to any method known to the art for the manufacture of pharmaceutical compositions and such compositions may contain one or more agents selected from the group consisting of sweetening agents, flavoring agents, coloring agents and preserving agents in order to provide pharmaceutically elegant and palatable preparations. Tablets contain the active compound in admixture with non-toxic pharmaceutically acceptable excipients which are suitable for the manufacture of tablets. These excipients may be for example, inert diluents, such as calcium carbonate, sodium carbonate, lactose, calcium phosphate or sodium phosphate; granulating and disintegrating agents, for example, corn starch, or alginic acid; binding agents, for example starch, gelatin or acacia, and lubricating agents, for example magnesium stearate, stearic acid or talc. The tablets may be uncoated or they may be coated by known techniques to delay disintegration and absorption in the gastrointestinal tract and thereby provide a sustained action over a longer period. For example, a time delay material such as glyceryl monostearate or glyceryl distearate may be employed.
Formulations for oral use may also be presented as hard gelatin capsules wherein the active ingredient is mixed with an inert solid diluent, for example, calcium carbonate, calcium phosphate or kaolin, or as soft gelatin capsules wherein the active ingredient is mixed with water or an oil medium, for example peanut oil, liquid paraffin or olive oil.
Aqueous suspensions contain the active material in admixture with excipients suitable for the manufacture of aqueous suspensions. Such excipients are suspending agents, for example sodium carboxymethylcellulose, methylcellulose, hydropropylmethylcellulose, sodium alginate, polyvinylpyrrolidone, gum tragacanth and gum acacia; dispersing or wetting agents may be a naturally-occurring phosphatide, for example, lecithin, or condensation products of an alkylene oxide with fatty acids, for example polyoxyethylene stearate, or condensation products of ethylene oxide with long chain aliphatic alcohols, for example heptadecaethyleneoxycetanol, or condensation products of ethylene oxide with partial esters derived from fatty acids and a hexitol such as polyoxyethylene sorbitol monooleate, or condensation products of ethylene oxide with partial esters derived from fatty acids and hexitol anhydrides, for example polyethylene sorbitan monooleate. The aqueous suspensions may also contain one or more preservatives, for example ethyl, or n-propyl p-hydroxybenzoate, one or more coloring agents, one or more flavoring agents, and one or more sweetening agents, such as sucrose or saccharin.
Oily suspensions may be formulated by suspending the active ingredient in a vegetable oil, for example arachis oil, olive oil, sesame oil or coconut oil, or in a mineral oil such as liquid paraffin. The oily suspensions may contain a thickening agent, for example beeswax, hard paraffin or cetyl alcohol. Sweetening agents such as those set forth above, and flavoring agents may be added to provide palatable oral preparations. These compositions may be preserved by the addition of an anti-oxidant such as ascorbic acid.
Dispersible powders and granules suitable for preparation of an aqueous suspension by the addition of water provide the active ingredient in admixture with a dispersing or wetting agent, suspending agent and one or more preservatives. Suitable dispersing or wetting agents and suspending agents are exemplified by those already mentioned above. Additional excipients, for example sweetening, flavoring and coloring agents, may also be present.
Pharmaceutical compositions of the invention may also be in the form of oil-in-water emulsions. The oily phase may be a vegetable oil, for example olive oil or arachis oil, or a mineral oil, for example liquid paraffin or mixtures of these. Suitable emulsifying agents may be naturally occurring gums, for example gum acacia or gum tragacanth, naturally-occurring phosphatides, for example soy bean, lecithin, and esters or partial esters derived from fatty acids and hexitol, anhydrides, for example sorbitan monoleate, and condensation products of the said partial esters with ethylene oxide, for example sweetening, flavoring and coloring agents, may also be present.
Syrups and elixirs may be formulated with sweetening agents, for example glycerol, propylene glycol, sorbitol or sucrose. Such formulations may also contain a demulcent, a preservative and flavoring and coloring agents. The pharmaceutical compositions may be in the form of a sterile injectable aqueous or oleaginous suspension. This suspension may be formulated according to the known art using those suitable dispersing or wetting agents and suspending agents which have been mentioned above. The sterile injectable preparation may also be sterile injectable solution or suspension in a non-toxic parentally acceptable diluent or solvent, for example as a solution in 1,3butanediol. Among the acceptable vehicles and solvents that may be employed are water, Ringer's solution and isotonic sodium chloride solution. In addition, sterile, fixed oils are conventionally employed as a solvent or suspending medium. For this purpose any bland fixed oil may be employed including synthetic mono- or diglycerides. In addition, fatty acids such as oleic acid find use in the preparation of injectables.
The active compound may also be administered in the form of suppositories for rectal administration of the drug. These compositions can be prepared by mixing the drug with a suitable non-irritating excipient which is solid at ordinary temperatures but liquid at the rectal temperature and will therefore melt in the rectum to release the drug. Such materials are cocoa butter and polyethylene glycols.
The active compound may be administered parenterally in a sterile medium, The drug, depending on the vehicle and concentration used can either be suspended or dissolved in the vehicle. Advantageously, adjuvants such as local anesthetics, preservatives and buffering agents can be dissolved in the vehicle.
Dosage levels of the order of from about 0.1 mg to about 15 mg of active compound per kilogram of body weight per day are useful in the treatment of the above-indicated conditions (about 7 mg to about 1 g per human patient per day). The amount of active compound that may be combined with the carrier materials to produce a single dosage form will vary depending upon the host treated and the particular mode of administration. Dosage unit forms will generally contain between from about 1 mg to about 500 mg of an active compound.
It will be understood, however, that the specific dose level for any particular patient will depend upon a variety of factors including the activity of the specific compound employed, the age, body weight, general health, sex, diet, time of administration, route of administration and rate of excretion, drug combination and the severity of the particular disease undergoing therapy.
As a consequence of its action in treating pathological conditions the compound of the present invention possess utility for treatment of ungulate animals such as swine, cattle, sheep, and goats. The active compound of the invention can additionally be used for the treatment of household pets, for example companion animals such as dogs and cats. The administration of the active compound of formula I can be effected orally or parenterally. An amount of the active compound of formula I is administered such that an effective dose is received, generally a daily dose which, when administered orally to an animal is usually between 0.01 and 20 mg/kg of body weight, preferably between 0.05 and 10 mg/kg of body weight. Conveniently, the medication can be carried in drinking water so that a therapeutic dosage of the agent is ingested with the daily water supply. The agent can be directly metered into drinking water, preferably in the form of a liquid, water-soluble concentrate (such as an aqueous solution of a water soluble salt).
Conveniently, the active compound can also be added directly to the feed, as such, or in the form of an animal feed supplement, also referred to as a premix or concentrate. A premix or concentrate of therapeutic agent in a carrier is more commonly employed for the inclusion of the agent in the feed. Suitable carriers are liquid or solid, as desired, such as water, various meals such as alfalfa meal, soybean meal, cottonseed oil meal, linseed oil meal, corncob meal and corn meal, molasses, urea, bone meal, and mineral mixes such as are commonly employed in poultry feeds. A particularly effective carrier is the respective animal feed itself; that is, a small portion of such feed. The carrier facilitates uniform distribution of the active materials in the finished feed with which the premix is blended. It is important that the compound be thoroughly blended into the premix and, subsequently, the feed. In this respect, the agent may be dispersed or dissolved in a suitable oily vehicle such as soybean oil, corn oil, cottonseed oil, and the like, or in a volatile organic solvent and then blended with the carrier. It will be appreciated that the proportions of active material in the concentrate are capable of wide variation since the amount of agent in the finished feed may be adjusted by blending the appropriate proportion of premix with the feed to obtain a desired level of therapeutic agent.
High potency concentrates may be blended by the feed manufacturer with proteinaceous carrier such as soybean oil meal and other meals, as described above, to produce concentrated supplements which are suitable for direct feeding to animals. In such instances, the animals are permitted to consume the usual diet. Alternatively, such concentrated supplements may be added directly to the feed to produce a nutritionally balanced, finished feed containing a therapeutically effective level of a compound according to the invention. The mixtures are thoroughly blended by standard procedures, such as in a twin shell blender, to ensure homogeneity.
If the supplement is used as a top dressing for the feed, it likewise helps to ensure uniformity of distribution of the active material across the top of the dressed feed.
Drinking water and feed effective for treating domestic animals are generally prepared by mixing the compound of the invention with a sufficient amount of animal feed to provide from about 10 −3 to 500 ppm of the compound in the feed or water.
The preferred medicated swine, cattle, sheep and goat feeds generally contain from 1 to 400 grams of active compound per ton of feed, the optimum amount for these animals usually being about 50 to 300 grams per ton of feed.
The preferred poultry and domestic pet feeds usually contain about 1 to 400 grams and preferably 10 to 400 grams of active compound per ton of feed.
For parenteral administration in animals, the compounds of the present invention may be prepared in the form of a paste or a pellet and administered as an implant, usually under the skin of the head or ear of the animal in which increase in lean meat deposition and improvement in lean meat to fat ratio is sought.
In general, parenteral administration involves injection of a sufficient amount of the compound of the present invention to provide the animal with 0.01 to 20 mg/kg/day of body weight of the active ingredient. The preferred dosage for poultry, swine, cattle, sheep, goats and domestic pets is in the range of from 0.05 to 10 mg/kg/day of body weight of active ingredient.
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The compound
is a neuropeptide Y antagonist and is effective in treating feeding disorders, cardiovascular diseases and other physiological disorders.
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FIELD OF THE INVENTION
[0001] The present invention relates generally to memory cards, and more particularly, to multiple interface memory cards.
BACKGROUND OF THE INVENTION
[0002] Memory cards have found wide application in the electronics and consumer appliance industries. It has been recognized that different electronic applications have different memory access speed requirements. Certain applications such as cameras and PDAs require a high data rate. In contrast, certain other applications are operable with much lower data rates and need a contact-less interface. The present invention is directed to solving this problem of multiple memory access speed requirements.
SUMMARY OF THE INVENTION
[0003] Briefly, the present invention comprises in a preferred embodiment, a memory card, including: a memory mass storage; a first data interface with a contacting interface and a high data transfer rate; and a second data interface ( 40 ) with a contact-less interface.
[0004] In a further aspect of the present invention, a memory card controller is provided for selecting a first data line from said first data interface or a second data line from said second data interface to communicate with said memory mass storage based on a criteria.
[0005] In a further aspect of the present invention, the criteria is a predetermined card select detect signal from said first interface.
[0006] In a yet further aspect of the present invention, the criteria is a detecting an indication of a carrier detect signal from said second data interface.
[0007] In a further aspect of the present invention, the first interface is a contacting interface for one of the following applications: a secure digital application, multimedia card, compact flash, memory stick, or a PCMCIA.
[0008] In a further embodiment of the present invention, a method of operating a memory card is provided comprising the steps of: monitoring for a predetermined signal, and switching an input to a memory mass storage from a cable data interface to a contactless data interface upon detection of the predetermined signal.
[0009] In a further aspect of the present invention, the monitoring and switching steps are performed automatically at power-up.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] [0010]FIG. 1 is a schematic block diagram of a preferred embodiment of the present invention.
[0011] [0011]FIG. 2 is a schematic diagram of a power routing block that may be used to implement a preferred embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0012] Referring now to the FIG. 1, there is shown a preferred embodiment of a memory card 10 in accordance with the present invention. The memory card 10 comprises a memory mass storage 20 , a first data interface block 30 with a high data transfer rate and a contacting interface, and a second data interface block 40 with a contact-less interface.
[0013] The memory mass storage 20 may take a wide variety of implementations, including flash memory, ROM, disk, OTP, or any other memory technology.
[0014] The first data interface 30 may be implemented in a variety of configurations. In a preferred embodiment, the first data interface 20 is implemented with an high data rate interface block. Examples in the market today include the Compact Flash, Secure Digital, MulitMediaCard and Memory Stick interfaces. Standard input lines for such a high data rate interface block are shown. Such lines would include a ground line or lines (Vss/GND), a supply voltage line or lines(Vdd), a clock line (Clock), a command line or lines (Command) and a data line or lines (Data). This type of high speed data rate interface is particularly useful for cameras and PDAs. In order to achieve high data rates, a contacting interface is needed so that the transfer of data between the host device and the memory card can meet the clocking requirements of a high speed interface and not bear the burden of a carrier and encoding that the contact-less interface requires
[0015] The second data interface 40 may take a variety of configurations also. The second data interface may simply comprise an contact-less interface, which, because it is contact-less, has a much slower data transfer rate. However, in a preferred embodiment, a magnetically coupled interface is provided for use with low speed transfers. By way of example but not by way of limitation, this second data interface 40 may be implemented by an RF Powered/Signal Interface Block. This interface would receive signals through magnetic coupled fields, as is well known in the art (such as ISO standard ISO 14443-2).
[0016] A standard power routing block 60 could be connected to both of the first interface 30 and the second interface 40 in order to provide necessary power routing. At the application of power, the power routing block routes the power from the interface block that has been energized to the remainder of the circuitry. FIG. 2 shows this block as a simple diode structure but it could be a more complicated structure.
[0017] In one embodiment of the present invention, the data and commands from the high speed first data interface 30 could be provided directly to the memory card mass storage 20 to a dedicated portion thereof. Likewise, the data and commands from the second data interface 40 could be provided to a different dedicated portion of the memory card mass storage 20 .
[0018] In a preferred embodiment of the present invention, a memory card controller 50 is utilized to route data from one or the other of the first data interface 30 or the second data interface 40 to the memory card mass storage 20 . The memory card controller 50 operates to determine which of the first data interface 30 or the second data interface 40 is active, and then routes the written and read data from the active data interface to the memory card mass storage 20 . In a preferred embodiment, this determination could be performed at power-up. The determination of which interface is active could be accomplished, by way of example, by detecting a card select detect 34 or other signal that the high speed data access interface block asserts when it has been powered up and selected by the host. Alternatively or in addition, the memory card controller 50 could detect the assertion of the carrier detect line 44 from the second data interface 40 . This line is asserted when the carrier signal applied to the card is detected by the RF Powered/Signal Interface Block. Typically, this carrier will be a 13.96 Megahertz carrier, if the ISO 14443-2 standard is utilized. Accordingly, if the assertion of the card select detect signal is detected on line 34 , then data and commands on line 32 are routed from the first data interface 30 through the memory card controller 50 to the memory card mass storage 20 . Alternatively, if a carrier detect signal is detected on line 44 by the memory card controller, then data and/or commands on line 42 from the second data interface 40 are routed through the memory card controller 50 to the memory card mass storage 20 .
[0019] Note that the system could be configured to normally connect one of the data interfaces to the memory mass storage, with a switching occurring to the data line of the other interface only if an appropriate signal or other criteria are met. For example, the memory card controller 50 could be set to normally connect the data line 42 for the wireless interface 40 to the memory card mass storage 20 , but would be switched to connect the data line 32 of the cable interface 30 to the memory mass storage 20 if a criteria is met, such as that a card command is received on line 34 indicating that data is being received at the cable interface 30 .
[0020] Accordingly, it can be seen that a preferred embodiment of the present invention is implemented with a memory mass storage, a cable interface adapted for connection to memory mass storage, and a wireless interface adapted for connection to memory mass storage. If a memory card controller is utilized for selecting either the wireless interface or the cable interface, then the selection may be based on a criteria, such as whether a carrier detect signal is detected or whether predetermined card command signals or other signals are detected.
[0021] Although the present invention has been disclosed in the context of the use of two interfaces for the memory card, each with a different data transfer rate or speed, the present invention may be implemented with more than two interfaces, each with a different data transfer rate or speed.
[0022] Accordingly, it can be seen that a dual or a three or more interface memory card has been disclosed to facilitate the use of a memory card in multiple different applications that require multiple different data transfer speeds. In a preferred embodiment where one of the interfaces is a wireless interface and the other of the interfaces is a cable interface, such a card facilitates use in high data rate applications, as well as providing the ease of convenience of not being required to plug into slots for certain commercial transactions such as e-commerce and banking.
[0023] The foregoing description of a preferred embodiment of the invention has been presented for the purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed, and modifications and variations are possible in light of the above teachings or may be acquired from practice of the invention. The embodiment was chosen and described in order to explain the principles of the invention and its practical application to enable one skilled in the art to utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. It is intended that the scope of the invention be defined by the claims appended hereto, and their equivalents.
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A memory card and a method for operating a memory card, the memory card comprising: a memory mass storage; a first data interface with a contacting interface and a high data transfer rate; a second data interface with a contact-less interface. In a preferred embodiment, a memory card controller is included for selecting a first data line from said first data interface or a second data line from said second data interface to communicate with said memory mass storage based on a criteria.
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This application claims the benefit of U.S. Provisional application No.60/070,518 filed Jan. 6, 1998.
TECHNICAL FIELD
The present invention relates to a lifting apparatus used to portage a boat. More specifically, the present invention relates to a mechanism for vertically lifting a boat out of one body of water, transferring the boat horizontally over a barrier, and then vertically lowering the boat into a second body of water.
BACKGROUND OF THE INVENTION
Known within the prior art are devices for lifting boats out of water for such purposes as making repairs, protecting boats from dock collision caused by tidal action, and preventing damage to a boat's hull from excessive exposure to water. U.S. Pat. No. 5,184,914 describes and shows a boat lift that consists of a frame which cradles and lifts a boat from the water by the means of a hydraulic ram. The device requires a person to enter the water to secure several members of the device around the bottom of the hull. U.S. Pat. No. 5,593,247 describes a programmable boat lift control system that with the push of a button, the lift may either raise or lower the boat to a pre-programmed elevation.
Both of these devices are useful for lifting boats out of water, but are both limited to lifting and lowering the boat in a vertical direction which is indicative of the general state of the art in boat lifting devices. The prior art fails to teach an apparatus that can both, lift and lower a boat in a vertical direction and transfer the boat in a horizontal direction. Applicant has discovered the need to transfer boats over barriers, such as water divider walls. In many areas salt water and fresh water are separated by various types of barriers. Barriers are needed to separate fresh water from salt water due to the various types of organisms, plants and animals which can only survive in either salt or fresh water, but not both. Regardless of the need to isolate salt from fresh water, boats and other types of water vehicles still require access to and from these separate bodies of water.
Therefore, in light of the foregoing deficiencies in the prior art, Applicant's invention is herein presented.
SUMMARY OF THE INVENTION
The present invention relates to a stationary boat lift which raises a boat in a vertical direction to remove it from one body of water, transfers the boat in a horizontal direction over a barrier and then lowers the boat into a second body of water. The preferred embodiment of the present invention is comprised of a housing in which a boat is able to enter and exit with little difficulty. The housing is built over the barrier which the boat is to traverse so that the barrier is centered within the housing. Attached to the top portion of the housing is a hoist capable of movement in a straight path parallel to the length of the housing. The hoist has an outer frame which supports its various components. The hoist includes two motors, one which drives the lifting components and a second which drives the translation components.
After the boat has entered the lift it is positioned over a pair of slings which are placed under the boat. One sling is located near the bow or front portion of the boat while the second sling is located near the stem or rear portion of the boat. The slings are fastened between two support beams which are lowered or raised by cable wires connected to cable spindles which are mounted to the hoist. The spindles and their respective drive shafts rotate in a clockwise or counterclockwise direction depending on whether the boat is to be lowered or raised.
Once the boat is in a fully raised position, the boat lift translates the boat in a horizontal direction over the particular barrier located within the housing. Translation of the hoist is controlled by a second motor which powers a set of flanged wheels to move the hoist back and fourth in a horizontal direction. An operator is able to easily control the functioning of the boat lift through a control panel located either within or outside of the housing. As a result, passengers never need to exit the boat during the lifting process.
It is therefore an object of the present invention to provide a new and improved boat lift capable of lifting a boat in and out of water in both a vertical and horizontal direction.
It is a further object of the present invention to provide a boat lift which can be easily and safely operated by one or more individuals, who are operators of the boat and not require an operator full time for the boat lift.
It is still a further object of the present invention to provide a boat lift which allows a boat to be lifted and carried over various types of barriers.
It is yet another object of the present invention to provide a boat lift in which passengers may remain on board the boat while it is being portaged over a barrier.
These, along with other objects and advantages of the present invention will become more readily apparent from a reading of the detailed description taken in conjunction with the
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front elevational view of the boat lift apparatus of the present invention;
FIG. 2 is a side elevational view of the boat lift apparatus shown in FIG. 1 as a boat initially enters the housing of the boat lift;
FIG. 3 is a side elevational view of the boat lift apparatus shown in FIG. 1 as a boat exits the housing after being portaged over a barrier;
FIG. 4 is a bottom perspective view of the hoist incorporated into the boat lift apparatus;
FIG. 5 is a top plan view of the hoist incorporated into the boat lift apparatus;
FIG. 6 is a front elevational view of the hoist shown in FIG. 5; and
FIG. 7 is a side elevational view of the hoist shown in FIG. 5.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
In the following description of a preferred embodiment of the present invention, reference is made to the accompanying drawings which, in conjunction with this detailed description, illustrate and describe a boat lift capable of hoisting a boat out of one body of water, translating the boat in a horizontal direction over a barrier and then lowering the boat into a second body of water. Referring to FIG. 2, boat lift 10 consists of a frame comprised of a plurality of vertical and horizontal supports, 32 and 40 respectively, which support and maintain roof 42 above the intersection of a first and second body of water, 18 and 20, divided by barrier 16. Many areas having both salt and fresh water bodies must take care not to allow the two bodies of water to mix thereby contaminating the fresh water. Various types of organisms, plants and animals can only survive in either salt water or fresh water. To accomplish this many communities construct barriers separating the two bodies of water. The down side to using barriers is that boats are prevented from freely traveling between the fresh and salt water bodies.
In FIG. 1, boat 12 enters boat lift 10 at either one of two ends via either first body of water 18 or second body of water 20. Channel 14 of boat lift 10 is divided into two sections by barrier 16. Barrier 16 is located between and divides the first and second bodies of water, 18 and 20 respectively, at approximately the middle of the housing effectively creating two isolated bodies of water. The housing of boat lift 10 is constructed over barrier 16 and along channel 14 with a plurality of vertical supports 32 extending from both sides of channel 14. Vertical supports 32 are coupled to a plurality of horizontal supports 40 (shown in FIG. 2) which in turn are coupled to and support roof 42. In the preferred embodiment, both the vertical and horizontal supports, 32 and 40, are steel I-beams which provide the necessary strength and dependability to portage large, heavy boats. Applicant also envisions the present invention being constructed from bricks, strong woods, composites or numerous other materials common in construction so long as the materials provide the requisite strength and durability.
Coupled between horizontal supports 40 is hoist 34 which translates along horizontal supports 40 from one end to the other of boat lift 10. As will be explained in more detail later, power distribution bus 30 provides electrical power to various motors, one of which allows hoist 34 to translate horizontally along the length of boat lift 10. Attached by wire ropes 38 (shown in FIG. 4) and disposed beneath hoist 34 are distribution supports 26 and 28. Due to the enormous stress which boat lift 10 is subjected due to the weight of a typical boat, distribution supports 26 and 28 are comprised of steel I-beams which support and evenly distribute the weight of boat 12. Attached to either end of each distribution support, 26 and 28, are eye hoist hooks 52. To create a cradle for carrying boat 12 over barrier 16, strap-like slings 22 and 24 are coupled between opposing eye hoist hooks 52. Sling 22 is coupled between eye hoist hooks 52 located on a first end of both distribution supports 26 and 28, while sling 24 is coupled between eye hoist hooks 52 located on the second end of both distribution supports 26 and 28. Slings 22 and 24 preferably are fabricated from high strength polyester which is resistant to damage from abrasion and deterioration from exposure to water, particularly salt water. The slings 22 and 24 may also be fabricated materials offering similar damage resistance, such as nylon and the like. It is also possible that the cradle for carrying boat 12 may be comprised of other suitable means, including but not limited to, a heavy gauge net which may be coupled at its extremities to hoist hooks 52. Like the slings, 22 and 24, such net may also be produced from high strength polyester or nylon. In order that the slings 22 and 24, or alternatively a net, will readily submerge rather than float, lead weights are provided with the slings 22 and 24 and the net. In the case of the slings 22 and 24, the lead weights are sewn into packets provided in the slings 22 and 24.
The actual operation of boat lift 10 can be more easily seen by referring to FIGS. 2 and 3. In FIG. 2, boat 12 has entered boat lift 10 via first body of water 18. Once boat 12 is cradled by slings 22 and 24, hoist 34 (not shown) raises boat 12 vertically out of first body of water 18. Electric motors included as part of hoist 34 raise boat 12 with wire ropes 38 and pulleys 36 which are coupled to either end of distribution supports 26 and 28. A user controls the vertical and horizontal direction of hoist 34 through control panel 44 which includes a number of switches and/or control levers as is known in the art. Electrical power is supplied to boat lift 10 and hoist 34 through power distribution panel 46. In FIG. 3, hoist 34 has now traversed the length of boat lift 10 horizontally carrying boat 12 over barrier 16. Once over barrier 16, hoist 34 releases wire ropes 38 in a controlled manner allowing pulleys 36 to lower distribution supports 26 and 28 and their respective slings 22 and 24, thereby vertically lowering boat 12 into second body of water 20. Boat 12 is now free to exit boat lift 10 and proceed from first body of water 18 into second body of water 20. Boat 12 can just as easily travel from second body of water 20 to first body of water 18 by simply entering boat lift 10 from the opposite direction.
Hoist 34 will now be described in more detail with reference to FIGS. 4 through 7. As shown in FIG. 5, hoist 34 is made up of an outer frame portion comprised of two side frame members 100 and two end frame members 102 coupled to one another to create a rectangular frame. Further support is provided by an additional pair of elongated frame members 106 and a plurality of partial frame members 104 coupled within and to frame members 100 and 102. In the preferred embodiment all frame members are comprised of steel I-beams, which again are used for their exceptional strength and durability.
The lifting capability of hoist 34 is provided by motor 148 coupled to drive gear reducer 150, which is permanently positioned on top of mounting base 180 (also shown in FIGS. 6 and 7) located near the center of hoist 34. Mounting base 180 is coupled between elongated frame members 106 by common means such as welding and/or bolting. Extending from mounting base 180 is jack plate 184 which allows additional attachments to be fastened to hoist 34. As the name implies, a jack of some type that for example could be used to remove a boats motor could be coupled from jack plate 184 thereby making hoist 34 more versatile. Drive gear reducer 150 includes a pair of sprockets 152 and 154 coupled to either end of an axle extending from each of its sides. Motor 148 includes conduit box 174 attached toward its rear portion for accepting and interfacing electrical power conductors (not shown) to motor 148.
Coupled between side support members 100 and elongated support members 106, near each of the four comers of the frame of hoist 34, are drive shafts 178 having a spindle 186 attached on one end of each drive shaft 178. On both ends of hoist 34 at a point between both elongated support members 106, opposing drive shafts 178 are coupled together by roller chain couplings 170. Also on both ends of hoist 34, at a position adjacent each roller chain coupling 170 is a sprocket, 162 or 168. Sprockets 162 and 168 are coupled to sprockets 154 and 152 of drive gear reducer 150 by drive chains 164 and 166. Drive gear reducer 150 is configured such that whichever direction sprocket 152 rotates, sprocket 154 rotates in an opposite direction. Through this arrangement spindles 186, located on a first side of hoist 34, rotate in the direction opposite spindles 186 located on a second side of hoist 34, which in turn raises or lowers the distribution supports (26 and 28, not shown) and the slings (22 and 24, not shown). The configuration of drive gear reducer 150 and sprockets 152 and 154 is a significant improvement over hoists used in the prior art in that a single electric motor 148 controls the raising and lowering of both ends and/or sides of boat 12. In the past, boat lifts typically employed two electric motors, one on either end of the hoist. Over time, despite the electric motors being identical, the characteristics of each motor will change slightly due to wear and tear causing them to rotate at slightly different speeds. This difference in rotational speed causes one end and/or side of a boat to raise or lower ahead of the other end and/or side preventing the boat from being maintained in the preferred horizontally level position during transfer from one body of water to another. Because gear drive reducer 150 includes two drive shafts 151, each coupled to one of either sprockets 152 or 154, which rotate in opposite directions and are driven by a single electric motor 148, boat lift 10 raises and lowers boat 12 with fewer components while maintaining boat 12 in the preferred horizontally level position.
As shown more clearly from FIG. 4, a length of wire rope 38 is connected to each spindle 186. As spindles 186 are rotated in a first direction they wind wire rope 38 onto spindle 186 thereby moving distribution supports 26 and 28 (not shown) in an upward direction. When spindles 186 are rotated in a second direction they unwind wire rope 38 from spindle 186 thereby lowering distribution supports 26 and 28 in a downward direction. As slings 22 and 24 are coupled to distribution supports 26 and 28, ultimately a boat being cradled by slings 22 and 24 will move vertically in one direction or the other based on the direction of rotation of spindles 186.
Also shown in FIG. 4, the other end of wire ropes 38 not coupled to spindles 186 are instead coupled through first pulleys 36 then around second pulleys 37, which are connected to partial frame members 104. Couplings 48 are linked to first pulleys 36 through second couplings 50 which are connected at either ends of distribution supports 26 and 28. The free ends of wire ropes 38 are fixedly coupled to partial frame members 108 (shown in FIG. 5).
Once boat 12 has been raised vertically into its upper most position, hoist 34 translates in a horizontal direction thereby moving boat 12 over barrier 16 to the opposite side of boat lift 10. To accomplish horizontal movement, hoist 34 includes a pair of flanged wheels 172 coupled between a pair of axles 182 connected to one another by coupling shaft 188. Attached to the far end of one axle 182 is sprocket 176. Electric motor 156, including sprocket 158 coupled to the drive shaft of motor 156, is permanently attached to the outer portion of one end frame member 102, directly adjacent sprocket 176. Sprocket 176 and sprocket 158 are coupled to one another by a drive chain (not shown) such that when motor 156 rotates, causing sprockets 158 and 176 to rotate, axle 182 rotates as well. Flanged wheels 172 rotate with axle 182 to drive or translate hoist 34 horizontally along horizontal supports 40 which act as a track for flanged wheels 172. Located opposite of flanged wheels 172 and axles 182, are flanged wheels 173 and axles 183. Unlike axles 182, axles 183 are individually coupled between side frame members 100 and elongated frame members 106 so they spin freely as flanged wheels 173, coupled to one end of axles 183, roll across horizontal supports 40 during movement of hoist 34. In the preferred embodiment only the one set of flanged wheels 172 is driven by motor 156, but alternative embodiments are contemplated in which not only flanged wheels 172, but also flanged wheels 173 are powered. In such event a second electric motor 156 may be provided to hoist 34, and axles 183 will be coupled like axles 182 by a second coupling shaft 188.
Referring to FIG. 4, both electric motors 148 and 156 receive power from power distribution bus 30 attached to and spanning the length of one horizontal support 40. Motors 148 and 156 are electrically coupled by a cable to power distribution interface 54 mounted within the framework of hoist 34. Extending downward from power distribution interface 54 are power conductors 56 which are connected to sliding power coupling 58. Power distribution bus 30 acts as a track for power coupling 58 which slides back and forth along power distribution bus 30 while maintaining constant electrical contact. Because power distribution interface 54 is mounted to the frame of hoist 34, as hoist 34 traverses horizontally, power conductors 56 move and drag or slide power coupling 58 along power distribution bus 30. In this manner electricity is supplied to electric motors 148 and 156 without using long conductors and complicated conductor winding mechanisms. As shown in FIG. 4, power distribution bus 30 includes a plurality of grooves in which power coupling 58, which also includes grooves, mates with to maintain constant electrical contact between the two.
FIGS. 6 and 7 further show the arrangement of components which make up hoist 34 and its framework. FIG. 6 shows sprockets 162 and 168 in relation to side frame member 100. Coupled to both side frame members 100, although only shown on one side, on both ends are flange bearings 214. Drive shafts 178, as shown in FIG. 7, are each coupled to individual flange bearings 214 which provide smooth and consistent rotation of the drive shafts. Referring again to FIG. 6, coupled to the underside of hoist 34, shown in ghost lines, is work platform 216 which makes hoist 34 more versatile. Work platform 216 provides an area in which an individual can sit or stand in order to provide maintenance to hoist 34. Platform 216 can also be used to mount further equipment such as additional winches or pulleys that can be used in portaging a boat. Also coupled to either end of side frame members 100 are pillow block bearings 212 which are used to provide fluid rotation to axles 182 and 183 which provide horizontal translation for hoist 34. Axles 182 and 183 (not shown) are coupled to the underside of the frame of hoist 34 by shaft couplings 218.
These and the other advantages and unique characteristics of the boat lift described with reference to the preferred embodiment provides a versatile and reliable apparatus to portage a boat. The foregoing description of preferred embodiment of the invention is merely an example, and the invention is not to be limited to the preferred embodiment, as many variations or modifications would be apparent to those skilled in the art based upon the principals of the invention as set forth herein.
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The present invention relates to a stationary boat lift comprised of a housing in which a boat is able to enter and exit with little difficulty. The boat lift allows a boat to bypass various barriers in a efficient and safe manner by vertically lifting the boat out of one body of water, translating the boat horizontally over a desired barrier, and then vertically lowering the boat into a second body of water.
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BACKGROUND OF THE INVENTION
Field of the Invention
The present invention relates to erosion control and, more particularly, to an erosion control or revetment block which can be used to form an interlocking mat or material of similar blocks to prevent erosion due to water movement.
Description of the Prior Art
Erosion control blocks, so-called revetment blocks, are well known and have been used for years to prevent and or minimize erosion. In general, the revetment blocks are used to minimize erosion caused by the movement of water. The revetment blocks can be used along beaches, bays, lakeshores, waterways, channels, drainage ditches, and the like, so as to be able to revet, depending upon the particular environment, the effects of wave action, water runoff, channeled flow of water, etc.
Examples of revetment blocks can be found in U.S. Pat. Nos. 4,227,829, 4,370,075, 5,556,228, and 8,123,435, all of which are incorporated herein by reference for all purposes.
Revetment blocks currently used in erosion control generally comprise a body having a polygonal shape, e.g., square, which have at least two arms which extend from peripheral side edges of the body and at least one and preferably two sockets which extend into the body from peripheral side edges. It will be understood that depending upon the shape of the block, the number of arms and sockets and their relative position on the block can vary. For example, in one common revetment block which is square, there are two arms extending from respective sides of the block at 90° to one another and two sockets extending into the block from respective side edges, the sockets being disposed at 90° to one another.
It is also common for revetment blocks of the interlocking type as described above to include one or more holes extending through the block, i.e., from the first surface to the second surface. These holes serve the purpose of allowing vegetation to grow from below and through the block and help anchor the block to the surface exposed to the moving water.
SUMMARY OF THE INVENTION
In one aspect the present invention provides a revetment block which can interlock with similarly formed revetment blocks to form a mat or matrix resisting erosion caused by water movement over the mat.
In yet another aspect, the present invention provides a revetment block having a unique shaped hole(s) for vegetation growth.
These and further features and advantages of the present invention will become apparent from the following detailed description, wherein reference is made to the figures in the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top plan view of a revetment block according to one aspect of the present invention.
FIG. 2 is a side, elevational view of the revetment block shown in FIG. 1 .
FIG. 3 is a bottom plan view of the block shown in FIG. 1 .
FIG. 3A is a partial, plan view of another embodiment of the vegetation hole(s) used in the revetment block of the present invention.
FIG. 4 is a view taken along the lines 4 - 4 of FIG. 1 .
FIG. 4A is an elevational view similar to FIG. 4 showing another embodiment of the vegetation hole(s) used in the revetment block of the present invention.
FIG. 5 is a top plan view of a mat made using the revetment blocks of the present invention.
FIG. 6 is an elevational view, partly in section, of a mat made using the revetment blocks of the present invention depicting the ability of the blocks to adapt to uneven or undulating ground contours.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Referring first to FIGS. 1-3 , a revetment block, shown generally as 10 , has a generally square body 12 having, a first, e.g., top surface 16 , and an opposite, second, e.g., bottom surface 18 . Body 12 has a first side edge 20 , a second side edge 22 , a third side edge 24 , and fourth side edge 26 . Extending from side edge 20 is an arm 28 while a second arm 30 extends, at 90° to arm 28 , from side edge 26 . A socket 32 extends into body 12 from side edge 24 while a second socket 34 extends, at 90° to socket 32 , into body 12 from side edge 22 . As can be seen from FIG. 1 , arms 28 and 30 are generally complementary in shape to sockets 32 and 34 for reasons discussed hereafter. Arm 28 has an enlarged head portion 36 distal side edge 20 , head portion 36 being connected to side edge 20 by a narrowed neck portion 38 . In general, arm 28 has a generally dovetail shape when viewed in plan view. Similarly, arm 30 , also having a dovetail shape, has an enlarged head portion 40 which is connected to side edge 26 via narrowed neck portion 42 . Socket 32 has a mouth 44 which opens into an enlarged cavity 46 , socket 32 being generally dovetail shaped when viewed in plan view. Likewise, socket 34 has a mouth 48 which opens into an enlarged cavity 49 , socket 34 having a generally dovetail shape when viewed in plan view.
There are a plurality of holes, shown generally as 50 which extend through a core 52 of block 10 . Core 52 is defined by four imaginary planes passing through lines indicated as A-A, B-B, C-C, and D-D with intersection points, W, X, Y, and Z wherein said planes are normal to said top and second surfaces 16 and 18 , respectively. Thus, as can be seen, basically the core 52 is the portion of the block 10 which is defined by planes passing through the innermost walls 47 and 51 of the sockets 32 and 34 , respectively, and planes passing through the intersection of the arms 28 and 30 with the side edges 20 and 26 , respectively. As seen, holes 50 are generally symmetrically located within the core 52 . However, it is to be understood that the holes need not be symmetrically positioned and can be arranged in various non-symmetrical orientations as desired. However, generally to ensure that the vegetation growth is uniform, symmetrical placement of holes 50 is normally desired. It will also be appreciated that fewer or more holes can be used if desired and their cross-sectional area can vary widely depending on the number of such holes.
With reference to FIG. 4 , it can be seen that holes 50 have a first portion 54 which opens through first surface 16 and a second portion 56 which opens through second surface 18 . As can be best seen with reference to FIGS. 3 and 4 , first portion 54 has a generally cylindrical cross-section forming a circular opening 58 and second portion 56 has a generally rectangular cross-section forming a square opening 60 through second surface 18 of block 10 . As seen in FIG. 4 , portions 54 and 56 intersect at a point generally midway through the thickness of block 10 . However, it is to be understood that this intersection point is somewhat arbitrary, e.g., portion 54 could have a greater depth than portion 56 or vice versa.
At the intersection of portions 54 and 56 , there is formed a ledge 62 which in the embodiment shown in FIG. 3 , extends peripherally around portion 54 . In any event, it will be recognized that where portions 54 and 56 intersect, second portion 56 will have a greater cross-sectional area than the cross-sectional area of first portion 54 at that intersection so as to form a ledge.
Referring now to FIG. 3A , there is shown a variation of a revetment block of the present invention. In all respects, the block 10 A shown in the fragmentary view of FIG. 3A is like block 10 with the exception that the holes 50 A of block 10 A have first and second portions, both of which have circular cross-sections, the first portion opening into the first surface (not shown) defining a circular opening 72 , the second portion opening into second surface 18 A having a circular opening 74 . However, again it will be seen that there is a ledge 76 formed at the intersection of the first and second portions of the holes 50 A. Again, as shown in FIG. 3A , the ledge 76 extends peripherally around the first portion of hole 50 A opening through the first surface of 10 A.
Referring now to FIG. 4A , there is shown yet another embodiment of the revetment block of the present invention. The revetment block 10 B, only a portion of which is shown in FIG. 4A has a first surface 16 B, a second surface 18 B and a hole 80 having a first portion 82 opening through first surface 16 B, and a second portion 84 opening through second surface 18 B. As can be seen from FIG. 4A , first portion 82 and second portion 84 have a frusto-shape in elevation wherein frusto-shape means a volume which can be circular or polygonal in cross-section and which varies in cross-sectional area along its length. A ledge 86 is formed at the intersection of the frusto-shaped portions 82 and 84 , the ledge 86 surrounding frusto-shaped portion 82 . It will thus be appreciated that both first and second portions 82 and 84 , respectively could be frustoconical, the first portion could be frustoconical and second portion frustopyramidal, etc.
It will be apparent that any number of cross-sectional configurations of the holes can be employed, both for the first portion and the second portion, the requirement being that there be a ledge formed at the intersection of the first and second portions. It will also be understood that it is not necessary that the ledge extend in a peripheral fashion around the first portion, i.e., the portion opening through the first surface of the block. Rather, depending on the cross-sectional shape, the ledge could be formed by a series of discontinuous ledges. For example, if the first portion of the hole was circular in cross-section and the second portion of the hole was triangular, the ledge could be formed in three separate portions, it being understood that in such a configuration the triangle defined by the cross-section of the second portion would circumscribe the circle defined by the cross-section of the first portion. Thus, the cross-sectional shapes of the first and second portions can be circular, oval, octagonal, etc.
Referring now to FIG. 5 , there is shown a plan view of a mat formed by interlocked blocks 10 . The mat shown generally as 100 depicts how the arm 30 of one block fits into the socket 34 of an adjacent block and the arm 28 of that same block fits into the socket 46 of an adjacent block. As can be seen, the sockets are slightly larger than the arms to permit some degree of freedom of movement laterally between adjacent blocks. Indeed, it can be seen that the blocks can be spread apart in two dimensions some distance to increase the area for vegetation growth. Although the arms fit loosely in the sockets, when moved apart laterally relative to one another, they do not separate because the heads, e.g. head 40 of arm 30 at its widest dimension is wider than the mouth, e.g. mouth 48 of socket 34 .
Referring now to FIG. 6 , there is shown how the blocks can be vertically adjusted relative to one another to conform to a contoured or undulating ground surface shown generally as G. This ability of the blocks to articulate in a vertical direction relative to one another again is a function of the fact that the arms fit somewhat loosely in the sockets.
While not wanting to be bound by any theory, it is believed that the unique configuration of the vegetation holes through the block, e.g., holes 50 , leads to enhanced vegetation retention of the block. In this regard, since, in one embodiment, the enlarged portion of the vegetation holes is adjacent the surface upon which the blocks are laid, vegetation growing up through the holes is believed to form a larger, more complex root structure in the enlarged area of the second portion of the holes, i.e., the portion that opens to the second surface of the blocks. Thus, it is believed the blocks can resist greater shear forces from moving water.
Although specific embodiments of the invention have been described herein in some detail, this has been done solely for the purposes of explaining the various aspects of the invention, and is not intended to limit the scope of the invention as defined in the claims which follow. Those skilled in the art will understand that the embodiment shown and described is exemplary, and various other substitutions, alterations and modifications, including but not limited to those design alternatives specifically discussed herein, may be made in the practice of the invention without departing from its scope.
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A revetment block comprising a body having a first surface, a second surface and a plurality of peripherally extending side edges. The body has at least two arms extending laterally outwardly from the respective side edges and at least two sockets extending laterally inwardly from the respective side edges. There is at least one hole extending through the body, the hole having a first and a second portion. The first portion of the hole opens through the first surface of the block while the second opens through the second surface of the block. The first and second portions intersect interiorly of the block. The cross-sectional area of the first portion is less than the cross-sectional area of the second portion at the intersection of the first and second portions. Accordingly, the intersection of the first and second portions forms a ledge.
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CROSS-REFERENCE TO RELATED APPLICATION
This is a continuation-in-part of Ser. No. 07/552,073, filed July 13, 1990, abandoned April 30, 1991.
BACKGROUND OF THE INVENTION
Cellulose has previously been recovered from agricultural by-products such as legume hulls by the utilization of a chlorine oxidizing agent as displayed in Thompson U.S. Pat. No. 4,486,459 which is herein incorporated by reference. The utilization of this prior process produces, as a by-product, waste water containing chlorinated phenolic products. The waste water also contains free chlorine that inhibits microbial action and microbial breakdown of the waste in aerated samples, thereby creating a delay for subsequent disposal of the waste. Aeration ponds containing such wastes emanate extreme odors.
It is an object of the instant invention to provide a process for recovering organoleptically improved cellulose from legume hulls by employing chlorine-free oxidizing agents such that no chlorinated phenolic by-products are produced for disposal in the waste water and no free chlorine is present in the waste water to prevent microbial action.
It is a further object of the present invention to provide a process to recover cellulose from legume hulls, said process having reduced process time in comparison to chlorine oxidation techniques.
SUMMARY OF THE INVENTION
The present invention is directed to a process for the recovery of an improved purified short fiber cellulose suitable for human consumption from agricultural by-product materials, especially hulls of edible legumes, preferably soybean hulls. The legume hulls are comminuted into a particulate matter feed which is formed into a water slurry and thereafter oxidized, hydrolyzed and extracted with a caustic oxidizing agent to effect solubilization of the greater portion of non-cellulose material in the feed. A solid cellulose containing material is thereafter removed from the slurry, for example, by filtration or centrifugation. The recovered solid mass is slurried in water and pH adjusted to about 7 by the addition of phosphoric acid. The slurry is preferably agitated and H 2 O 2 is added thereto, and the mixture is heated to promote bleaching and breakdown of the non-cellulose materials. A bleached cellulose-containing residue is recovered, e.g., by filtration or centrifugation. The recovered residue consists primarily of microcrystalline alpha-cellulose fibers which are easily reduced to powder form by milling and classifying, and may be used in food products as an ingredient, in drugs as a diluent and excipient, in talcum powder as a nonallergic component, and in other cellulose-containing or enhanced products contemplated for human consumption or use.
The process of the invention herein comprises the steps of
(a) forming a slurry of particulate legume hulls in water,
(b) adding caustic oxidizing agent to the slurry to raise the pH to about 12,
(c) maintaining a highly alkaline pH in said slurry for 61/2 to 23 hours during which the temperature of the slurry is maintained at 190° F. to 210° F. for at least 30 minutes, to oxidize, hydrolyze and extract the particulate legume hulls, thereby to solubilize the greater portion of the non-cellulose material present therein and form a pulp which consists predominantly of cellulose, in the slurry,
(d) separating the pulp from the slurry,
(e) redispersing the separated pulp in water to form a further slurry,
(f) adjusting the pH of the further slurry to be in the range from about 6.5 to 7.5 by the addition of phosphoric acid,
(g) adding to the pH adjusted slurry resulting from (f) a bleaching effective amount of aqueous hydrogen peroxide solution, and mixing, and heating the resulting admixture to a below boiling temperature to promote breakdown of any non-cellulose material present and bleaching of the pulp, and
(h) separating from the resulting admixture a bleached pulp composition consisting predominantly of short fiber cellulose suitable for human consumption.
DETAILED DESCRIPTION
The raw materials that may be employed in the present process are any relatively non-ligneous agricultural by-products containing a significant alpha-cellulose content. The cellulose content of an agricultural by-product can be estimated approximately by determining the crude fiber content thereof by analytical procedure AOAC 7.050-7.054. This crude assay actually removes 20-60% of the cellulose but leaves significant quantities of hemicellulose and lignins that may be present. As previously indicated, the process herein is very advantageously used with legume hulls.
Examples of raw materials that may be used in the present process and an approximation of their usual analytical character in accordance with AOAC analytical procedure are indicated in the following table calculated to a bone dry basis. The equilibrium moisture present is normally about 5%.
______________________________________ Crude Crude LipidsRaw Material Fiber Ash Protein** (Ether Extract)______________________________________Soybean hull 43% 4.4% 8.9% 2%Pea hull 35% 3.0% 14.4% 1%Corn bran 20% 1.7% 5.5% 2%Beet pulp-dried 23% 4.2% 8.9% 6%Oat hull 30% 4.2% 3.6% 1%______________________________________ **Amine nitrogen 6.25
These by-product materials are readily available in large quantity and at low cost since most of such materials are normally discarded. Other satisfactory raw materials are readily available also and may be employed so long as such materials have a "crude fiber" content of at least 15%, a lignin level under about 7% and possess a relatively high pectin and/or hemicellulose content. Soybean hulls are the preferred raw material, yielding a maximum amount of superior grade cellulose for a given amount of processing and chemical reagent expense. The process of the present invention is not applicable on a practical basis to wood or stalk portions of plants.
The agricultural by-products suitable for use in the present process can be treated as obtained from their source as by-products, but it has been found from an economics standpoint with respect to chemicals and processing time required, that such by-products are desirably first size-reduced to be no finer than through a 20 mesh screen, on a 24 mesh screen, by a hammer milling or an equivalent procedure. The by-products in a coarsely ground granular state permit easier slurrying, faster reactions and shorter processing times. However, finer particles may be used without apparent effect on cellulose yield.
A preferred process herein is described below.
In step (a) of the process described in the Summary of Invention section above, one hundred parts by weight of agricultural by-product, preferably soybean hulls, in a ground state, are admixed with 500 to 1200 parts by weight of water in a suitable reactor tank and stirred into suspension.
In step (b), a suitable amount of a caustic oxidizing agent, such as potassium hydroxide or sodium carbonate, preferably sodium hydroxide (20-30%), is added to initially adjust the pH of the liquid phase to approximately 12, for example, to 12.4 to 12.5.
In step (c), which may be characterized as a peroxide-free alkaline treatment step, a highly alkaline pH of at least 0.5 is maintained in the slurry for 61/2 to 23 hours at temperatures such as to obtain oxidation, hydrolysis and extraction of the legume hulls, thereby to solubilize the greater portion of the non-cellulose material present therein; if the pH should drop below a desired minimum value, normally 0.5, it is readily restored to said value or to exceed said value by addition of a suitable amount of aqueous caustic oxidizing agent solution. Thus, a pH ranging from 10.5 to 12.5 is preferably maintained in step (c). In one embodiment the suspension is maintained at ambient temperature for several hours, i.e., 6-8 hours, and then the temperature is raised to 190° to 210° F., preferably 200° to 210° F., very preferably to 205° F., and this temperature is maintained for 30 minutes to 5 hours, and aqueous caustic oxidizing agent solution is periodically added to restore the pH to about 12, and these conditions are such as to obtain partial breakdown of the raw material agricultural by-product and solubilization of non-cellulosic components by oxidation and alkaline hydrolysis and extraction of gums, lignin, proteins, pectin and other non-cellulosic components. In a different and very preferred embodiment, where the slurry is formed using water initially at a temperature of 120° to 150° F. (e.g., as a result of recovering heat from output from the process), and the pH is initially adjusted to about 12, very preferably to 12.4-12.5, with aqueous caustic oxidizing agent, the temperature is raised to 200° to 210° F., very preferably to 205° F., over a period of 1 to 3 hours, and then a temperature of 200° to 210° F. is maintained for 8 to 12 hours, and the pH is brought up to 10.5 by addition of aqueous caustic oxidizing agent solution, if it drops below that level (normally, the pH would drop below 0.5 near the end of step (c) if it does so at all). In all cases, step (c) is carried out without hydrogen peroxide present. The oxidation in step (c) provides deamination of protein. The hydrolysis in step (c) provides solubilization of coniferyl alcohols and other non-cellulosic components to products which are extractable under the alkaline conditions.
In step (d), the alkaline treated slurry is centrifuged or filtered, and pulp residue consisting predominantly of cellulose is recovered, and the liquid phase is discarded.
In step (e), the pulp residue is suspended in approximately 0.5 to 5 gallons of water per pound of residue. Water at 120° to 150° F., heated from ambient by heat exchange with output streams, is very preferably used.
In step (f), the pH is adjusted with a suitable amount of aqueous acid, e.g., 70 to 85% phosphoric acid, to reduce the pH to be essentially neutral, i.e., to range from 6.5 to 7.5, preferably to a range from 7.0 to 7.5, very preferably to a range from 7.1 to 7.2.
In step (g), the neutralized suspension is agitated and a bleaching effective amount, namely 0.003 to 0.02 parts by weight, e.g., 0.010 to 0.015 parts by weight or 0.004 to 0.008 parts by weight, of aqueous hydrogen peroxide solution per part by weight of the total suspension, preferably 50-70% H 2 O 2 , is added to the neutralized suspension and the resulting admixture is heated to 190° to 210° F., preferably to 206° F. to 210° F., very preferably to 208° F. over a period of 1 to 3 hours and is maintained at this temperature for one to five hours to promote further breakdown of non-cellulosic materials and bleaching of the product. The conditions in step (c) help to maximize the bleaching effect and minimize hydrogen peroxide usage as they cause denaturing of peroxidases and catalases which are present in the by-product feed and which would otherwise degrade bleaching agent hydrogen peroxide. The phosphoric acid usage in step (f) aids in maintaining the pH as the salt resulting from neutralization provides buffering against the lowering of the pH to below 6.5.
In step (h), the peroxide treated suspension is filtered or centrifuged to provide a supernatant and a bleached residue and the bleached residue is recovered. Said bleached residue contains a major portion of microcrystalline alpha-cellulose fibers. Silica and some lipids (including steroids and unsaponifiables) are still present. The residue product may be dried and milled at this point if the lipids that may be present are not found objectionable.
Preferably, agitation is carried out throughout steps (a), (b), (c), (e), (f) and (g).
If it is desired to remove some or all of the lipids, they normally may be removed by extraction, for example, in one of three stages of the processing as described hereinafter. Firstly, lipids may be extracted from the raw starting material. Secondly, lipids may be extracted by treating water moist cellulose cake recovered in step (h). Thirdly, lipids may be extracted by treating dried product. In general, it will be found that lipids can be most easily extracted by treating the water moist cellulose cake obtained from the final separation step above or from dried cellulose cake by treating either with a solvent in which the lipids are selectively soluble. The lipids can be extracted from the raw starting material or from the dried cellulose product by treating either, for example, with mixed hexanes in the same manner as such an extraction is carried out in the preparation of soybean and other seed oils. Extraction of the lipids from water moist cellulose cake can be accomplished best by use of water miscible solvents, such as, for example, isopropyl and ethyl alcohols; this process has the advantage of removing the water from the cake as well as the lipid materials, thus leaving in its place a lower boiling solvent which ultimately can more easily be removed by vacuum stripping same from the cellulose. It is to be clearly understood that other solvents, such as, for example, esters, ketones, other alcohols, and the like, may be used if desired. In any case, only a very limited extraction suffices to remove essentially all lipids after processing, as the lipids are not bound to the purified cellulose.
The resultant material, wet with water or solvent, is readily stripped of this liquid by use of heat, vacuum, or both, to yield a white powder or slightly lumpy material which can readily be reduced to fine particle size by conventional means. The resultant dry powdered cellulose will be found to have a trace of nitrogen compounds present and a small ash content but, in general, the cellulose products are comparable analytically with the conventional wood derived cellulosic materials which are employed for human consumption.
The products made in accordance with the present invention have the important advantage of being naturally fine and the fibers are no doubt shortened by the treatment applied even if they are not appreciably altered chemically. The cellulose products of the present invention can be reduced to the 100-300 mesh size required for food and drug use, for example, by any suitable and well known milling operation. In this respect, the cellulose products of the present invention are quite unlike the long coarse fibers of processed wood or cotton cellulose which are very difficult to grind and size. Having more surface per unit weight, the cellulose produced in accordance with the present invention can carry more water and thus has enhanced functionality in the formulation of low caloric food analogs and approach the utility of microcrystalline cellulose in drug diluent applications at a lesser cost.
The process of the present invention is illustrated by the following specific examples.
EXAMPLE I
Thirteen thousand five hundred pounds of ground soybean hulls were mixed with 13,500 gallons of water and soaked at ambient temperature for six to seven hours. The pH of this solution was raised to 2 by the addition of 170 gallons of 30% caustic soda. The solution was cooked at 200°-210° F. for three hours. An additional 250 gallons of 30% caustic soda solution was added during cooking to maintain the pH at 12. The resulting slurry was centrifuged. The supernatant was discarded, and the residue, approximately 5,100 pounds derived from the soybean hulls, was resuspended in 4,500 gallons of water. The pH of the resulting slurry was lowered to 7 by the addition of 12.5 gallons of 75% phosphoric acid. The suspension was mixed and 27 gallons of 70% hydrogen peroxide was added. The resultant mixture was cooked for five hours at 210° F. The cooked mixture was centrifuged, and the recovered residue yielded a cellulose product of 38% by weight based on the original raw unextracted soybean hulls. The recovered cellulose fiber product displayed characteristics tabulated in Table 1 below and had improved organoleptic properties.
TABLE 1______________________________________COMPOSITIONTotal Dietary Fiber = 93.5%Moisture = 5.1%Ash = 0.8%Protein = 0.4%Fat = 0.2%MICROBIOLOGICAL DATAStandard Plate Count = Less than 10E. Coli = Less than 3Mold = Less than 10Yeast = Less than 10Salmonella = NegativeShigella = NegativePHYSICAL PROPERTIESpH = 6.5-7.0Color = WhiteFlavor = NoneParticle Size = 35 micrometersWater Absorption = 4:1 (4 times its weight)______________________________________
EXAMPLE II
Fifteen thousand gallons of water (at 130°-140° F. due to processing through a heat recovery system) and 13,500 pounds of ground soybean hulls are admixed to form a slurry. Sodium hydroxide (275 gallons of 30% NaOH) is added to the slurry with agitation, to adjust the pH to 12.4-12.5. The temperature of the slurry is raised to 205° F. over a 11/2 hour period and the 205° F. temperature is maintained for 10 hours. Agitation of the slurry is carried out all during the time the temperature is raised to 205° F. and also all during the 10-hour 205° F. cook period thereafter. Following the 10-hour cook period, the slurry is centrifuged and the residue is recovered. The residue (estimated to be approximately 6750 pounds) is admixed in a slurry tank with 140 °-140 ° F. water (temperature obtained by processing ambient temperature water through a heat recovery system). Once the admixture is formed, the pH is in the range of 9.8 to 10.2. The pH is adjusted to 7.1-7.2 by addition, with agitation, of 6.5 gallons of 75% phosphoric acid. Then 80 gallons of 50% hydrogen peroxide is introduced with agitation of the slurry, and the temperature of the slurry is raised to 208° F. over a 11/2 hour period with continued agitation. The temperature is maintained at 208° F. and agitation is continued, for 4 hours. Then the slurry is centrifuged and the residue is recovered and dried to provide the final product. Analysis on the product gives the following: Total Dietary Fiber 92.7%. Alpha-cellulose content, 77.6%. Hemicellulose content, 14.9%. Lignin content, 2.35%.
Variations will be obvious to those skilled in the art. Thus, the scope of the invention is defined by the claims.
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The present invention is directed to a process for the production of an improved purified short fiber cellulose suitable for human consumption from agricultural by-product materials, such as legume hulls, preferably soybean hulls. The legume hulls are comminuted into a particulate feed which is admixed with water to form a slurry. The slurried particulate legume hulls are oxidized, hydrolyzed and extracted with a caustic oxidizing agent utilizing an initial pH of about 12 to effect solubilization of the greater portion of non-cellulose material in the feed. A solid cellulose containing material is thereafter removed from the slurry, for example, by filtration or centrifugation. The recovered solid mass is slurried in water and the resulting slurry if pH adjusted to about 7 by the addition of phosphoric acid. The resulting suspension is agitated and H 2 O 2 is added, and the mixture is heated to promote bleaching and breakdown of the non-cellulose components. The resulting mixture is subjected to a separation operation and a residue is recovered which consists primarily of microcrystalline alpha-cellulose fibers.
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BACKGROUND
Piezoelectric ceramic materials (also referred to as piezoelectric ceramics or piezoceramics) have been widely used in applications such as actuators, transducers, resonators, sensors, and random access memories. For example, piezoelectric devices, such as piezoelectric inkjet printheads or sensors, can be prepared by stacking various piezoelectric materials, other films, and metal, e.g., conductors and/or electrodes, in specific configurations for piezoelectric actuation or piezoelectric sensing. In the case of a piezoelectric printhead, piezoelectric actuation on or in an ink chamber can be used to eject or jet fluids therefrom.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a composition/phase diagram illustrating the range of example lead-free piezoelectric ceramic materials.
FIG. 2 is a graph of polarization hysteresis behavior for an example of a disclosed composition.
FIG. 3 is a graph of Bipolar strain vs. E-field for an example of a disclosed composition.
FIG. 4 is a graph of electromechanical strain under unipolar drive for an example of a disclosed composition.
FIG. 5 is a graph of dielectric spectra for an example of a disclosed composition.
FIG. 6 is a schematic view illustrating a portion of an example inkjet printhead.
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 specific examples. In this regard, directional terminology, such as “top,” “bottom,” “front,” “back,” etc., is used with reference to the orientation of the Figure(s) being described. Because the various components can be positioned in a number of different orientations, the directional terminology is used for purposes of illustration and is in no way limiting. It is to be understood that other versions may be utilized and structural or logical changes may be made without departing from the scope of the present invention. The following detailed description, therefore, is not to be taken in a limiting sense, and the scope of the present invention is defined by the appended claims. It is to be understood that features of the various examples described herein may be combined with each other, unless specifically noted otherwise.
The term polarization hysteresis refers to lead-free piezoelectric ceramic materials that display non-linear polarization characteristics indicative of a polar state.
The term polarization remanence refers to the polarization measured at zero field during a polarization hysteresis measurement. It is a unique characteristic of polar, non-linear dielectrics.
The term electromechanical strain refers to an electric field induced strain and is commonly expressed in terms of one or more piezoelectric coefficients (d 33 and d 31 , for example), where d ij (units pm/V) is the tensor property that relates the strain to the applied electric field (kV/cm). The d 33 coefficient can be measured in many different ways, such a piezoelectric resonance, the direct piezoelectric effect, the indirect piezoelectric effect, and others. In the context of this disclosure, the d 33 coefficient is calculated as the ratio between the maximum electromechanical strain at the maximum applied electric field (d 33 =S max /E max ) Sometimes this is described as the effective piezoelectric coefficient or the normalized strain or d 33 *. An example of its use is given in Y. Hiruma et al., J. Appl. Phys. 103:084121 (2008).
In the context of piezoelectric ceramic materials, the term fatigue refers to the observed loss of polarization and electromechanical strain after the application of a cyclic electric field.
The relative amounts or proportions of the components in a lead-free piezoelectric material are expressed in terms of mole fraction or mole percent (mol %)
Temperature, ratios, concentrations, amounts, and other numerical data may be presented herein in a range format. It is to be understood that such range format is used merely for convenience and brevity, and should be interpreted flexibly to include not only the numerical values explicitly recited as the limits of the range, but also to include all the individual numerical values or sub-ranges encompassed within that range as if each numerical value and sub-range is explicitly recited. For example, a temperature range of about 100° C. to about 500° C. should be interpreted to include not only the explicitly recited limits of 100° C. and 500° C., but also to include every intervening temperature such as 250° C., 300° C., 350° C. and 400° C., and all sub-ranges such as 300° C. to 400° C., and so forth.
The term about when referring to a numerical value or range is intended to include larger or smaller values resulting from experimental error that can occur when taking measurements. Such measurement deviations are usually within plus or minus 10 percent of the stated numerical value.
Piezoelectric materials have been used widely for the applications such as actuators, transducers, resonators, sensors, random access memories, etc. Among these piezoelectric ceramics, lead zirconate titanate (“PZT”), Pb(Zr x Ti 1-x )O 3 and its related solid solutions have been widely used due to their excellent piezoelectric properties and the ease with which modifications by doping can be made during manufacturing.
There are issues limiting use of PZT. One is environmental concern that is caused by the toxicity of lead. Another issue is fatigue behavior associated with PZT. Fatigue is a phenomenon in which the material loses its switchable polarization during electrical cyclic loading. There have been many investigations on the fatigue behavior of PZT under various conditions such as unipolar drive, DC, and bipolar drive with different temperature and frequency effects. In PZT under bipolar fatigue, it is widely believed that the agglomeration of charged point defects from oxygen vacancies, or charge carriers injected from the electrode, inhibits the movement of domain walls and this in turn causes a reduction of the switchable polarization.
The present disclosure provides lead-free piezoelectric materials that include BiCoO 3 (“BC”) as an additive to lead-free piezoelectric systems, such as (Bi 0.5 Na 0.5 )TiO 3 (“BNT”) or (Bi 0.5 K 0.5 )TiO 3 (“BKT”) based systems. BC possesses high polarization and moderate d 33 values. Moreover, the addition of BiCoO 3 to lead-free piezoelectric materials is believed to control the defect equilibrium of the material due to the acceptor nature of Co 3+ . Many device properties such as leakage current and fatigue properties are ultimately tied to point defects.
FIG. 1 is a schematic of the ternary phase diagram for the disclosed compositions. The ternary components are xBiCoO 3 (x≦0.2), yABO 3 and zCDO 3 , where x+y+z=1. ABO 3 and CDO 3 represent common Pb-free piezoelectric perovskite compositions such as BaTiO 3 , NaNbO 3 , KNbO 3 , and compound perovskites such as (Bi 0.5 Na 0.5 )TiO 3 and (Bi 0.5 K 0.5 )TiO 3 .
Examples of disclosed piezoelectric ceramic materials have one of the following general chemical formulas:
xBiCoO 3 -y(Bi 0.5 Na 0.5 )TiO 3 -z(Bi 0.5 K 0.5 )TiO 3 ;
xBiCoO 3 -y(Bi 0.5 Na 0.5 )TiO 3 -zNaNbO 3 ;
xBiCoO 3 -y(Bi 0.5 Na 0.5 )TiO 3 -zKNbO 3 ;
xBiCoO 3 -yBi(Mg 0.5 Ti 0.5 )O 3 -z(Bi 0.5 Na 0.5 )TiO 3 ;
xBiCoO 3 -yBaTiO 3 -z(Bi 0.5 Na 05 )TiO 3 ; or
xBiCoO 3 -yNaNbO 3 -zKNbO 3 ;
wherein x+y+z=1, and x, y, z≠0. For example, 0.01≦x≦0.2 in some implementations. In some examples, the maximum value of x is limited to 0.1 to 0.2 due to the limitations on the solid solubility of BC.
FIG. 2 shows polarization hysteresis behavior for 2BiCoO 3 -98BNT, which is characterized by fully saturated loops and a large remanent polarization of nearly 35 μC/cm 2 . The remanent polarization is expected to be in the range of 25-40 μC/cm 2 for the systems disclosed herein. This level of polarization is comparable to Pb-based piezoelectric materials such as PZT as well as other known Pb-free candidate materials.
FIG. 3 illustrates bipolar strain vs. E-field for 2BiCoO 3 -98BNT. The bipolar strain data shown in FIG. 3 exhibit large negative strains indicative of domain switching and maximum strains near 0.2%. FIG. 4 illustrates electromechanical strain under unipolar drive, with strain values of 0.15%. This corresponds to an effective piezoelectric strain coefficient d 33 * of approximately 180 pm/V. The maximum electromechanical strain value and the piezoelectric strain coefficient d 33 * are expected to be in the range of about 0.1% to 0.3% and 150-500 pm/V, respectively, for the ternary systems disclosed herein.
FIG. 5 illustrates the dielectric spectra which show a dielectric maximum at 300° C. This could indicate that the depolarization temperature of this material is as high as 300° C. which would be well suited for complex device fabrication processes.
Production of Lead-Free Piezoelectric Ceramics
A. Ceramic Discs
The lead-free BC-containing compositions described herein may be produced by any suitable solid-state synthesis method, using Bi 2 O 3 , CoO, Co 2 O 3 , Co 3 O 4 , Na 2 CO 3 , K 2 CO 3 , ZnO, and TiO 2 starting powders of at least 99% purity. The Curie temperature (T C ) of the resulting product is generally between about 100° C. and about 500° C. The T C of a piezoelectric ceramic may be increased or decreased by varying the relative amounts of the starting powders. The relative amounts of the constituents may be adjusted so that the product will have a T C in a specified range. In accordance with conventional solid state synthesis methods for making ceramic materials, the powders are milled, shaped and calcined to produce the desired ceramic product. Milling can be either wet or dry type milling, as is known in the art. High energy vibratory milling may be used, for instance, to mix starting powders and for post-calcination grinding. The powders are mixed with a suitable liquid (e.g., ethanol or water, or a combination of liquids) and wet milled with a suitable high density milling media (e.g., yttria stabilized zirconia (YSZ) beads). The milled powders are calcined, then mixed with a binder, formed into the desired shape (e.g., pellets) and sintered to produce a ceramic product with high sintered density. For testing purposes, prior to electrical measurements the ceramic disc may be polished to a suitable thickness (e.g., 0.9 mm), and a silver paste (e.g., Heraeus C1000) is applied to both sides of the discs. Depending upon the intended end use, a high-density BCBKTBNT ceramic disc or pellet may be polished to a thickness in the range of about 0.5 μm to about 1 μm, suitable for use as a piezoelectric actuator, for example.
B. Ceramic Thin Film
When the intended use of the BC-based ceramic material requires a thin film product, the production method may be modified to include chemical solution deposition using chemical precursors such bismuth nitrate, titanium isopropoxide, etc., or sputtering using solid state sintered or hot-pressed ceramic targets. Any suitable sputtering or chemical deposition method may be used for this purpose. The resulting thin film ceramic may have a thickness in the range of about 50 nm to about 10 μm, in some cases.
C. Piezoelectric Composites
For end uses such as sensors or transducers, which require the use piezoelectric composites, the above-described sintered BC-based ceramic material can be modified for this purpose. The ceramic powder is ground or milled to the desired particle size and loaded into polymer matrix to create a 0-3 piezoelectric composite. The ceramic powder can be formed into sintered rods or fibers using injection molding or similar technique and loaded into a polymer matrix to create a 1-3 piezoelectric composite. The polymer may be piezoelectric, such as PVDF, or non-piezoelectric such as epoxy depending on the final application.
The piezoelectric printhead is an example of an application for the disclosed lead-free piezoelectric material. In the case of a piezoelectric printhead, piezoelectric actuation on or in an ink chamber can be used to eject or jet fluids therefrom. The piezoelectric material can be grown or otherwise applied on the surface of a metal electrode, such as platinum, ruthenium, palladium, and iridium, as well as some conductive and non-conductive oxides, such as IrO 2 , SrRuO 3 , ZrO 2 , etc.
FIG. 6 is a schematic view of a portion of an inkjet printhead 100 . In the illustrated example printhead 100 , a silicon support is fabricated to include multiple ink chambers 112 for receiving and jetting ink therefrom. It is noted that often, ink chambers or other areas where ink may contact the printhead can be coated with any of a number of protective coatings. Those coatings are not shown, but it is understood that such a coating may be used for protective purposes without departing from the scope of the present disclosure. For example, tantalum or tantalum oxide coatings, such as Ta 2 O 5 , are often used for this purpose. Other support material(s) can be used alternatively or in addition to the mentioned silicon support and optional protective coatings. Thus, the term “support” typically includes structures comprising semi-conductive materials such as silicon wafer, either alone or in assemblies comprising other materials applied thereto. Metallic supports can also be used, including metallic materials with an insulating material applied thereto. Certain specific materials that can be used for the support material include silicon, glass, gallium arsenide, silicon on sapphire (SOS), germanium, germanium silicon, diamond, silicon on insulator (SOI) material, selective implantation of oxygen (SIMOX) substrates, or other similar materials. Furthermore, the substrate described herein can actually be the support material, particularly when the support material inherently includes an oxidized surface. However, in many typical examples, a separate membrane of oxidized material is applied to the support and acts as the substrate.
In FIG. 6 , the printhead 100 includes a substrate 114 , a first metal electrode 118 , a piezoelectric layer 120 , a second metal electrode 122 , and a passivation layer 124 . An adhesive layer 116 is provided between the substrate 114 and the piezoelectric layer 120 in some example printheads. Any suitable adhesive could be employed. Some typical printheads could additionally include further layers, including other insulating, semi-conducing, conducting, or protective layers that are not shown. However, one skilled in the art would recognize other layers that could optionally be used, or optionally omitted from the illustrated structure.
In the system shown, the first metal electrode 118 and the second metal electrode 122 are used to generate an electric field with respect to the piezoelectric layer 120 , and as the piezoelectric layer is actuated, the thin film stack bends into an appropriate ink chamber 12 , causing inkjetting to occur. The substrate layer 114 can be the support material with an oxide layer inherently present on its surface, but is typically prepared as an oxide membrane applied to the support material, e.g., SiO 2 , ZrO 2 , HfO 2 , Ta 2 O 5 , Al 2 O 3 , SrTiO 3 , etc. These membranes can be applied as multiple layers, and/or be prepared using multiple materials in a common layer. Thus, the materials are typically applied as one or more layer to the silicon or other support material as described above. When the substrate is in the form of a thin film or membrane, the substrate can be formed at a thickness from 10 Å to 10 μm, for example. In an example piezoelectric actuator device, the thickness of this substrate, e.g., oxidized membrane, can be approximately the same thickness as piezoelectric layer, e.g., at a 1:2 to 2:1 thickness ratio of substrate layer to piezoelectric layer, and both layers can be about 50 nm or greater.
In the printhead 100 illustrated in FIG. 6 , a passivation layer 124 is shown, which can be formed of any suitable material, including, but not limited to wet or dry process silicon dioxide, aluminum oxide (e.g., Al 2 O 3 ), silicon carbide, silicon nitride, tetraethylorthosilicate-based oxides, borophosphosilicate glass, phosphosilicate glass, or borosilicate glass, HfO 2 , ZrO 2 , or the like. Suitable thicknesses for this layer can be from 10 nm to 1 μm, though thicknesses outside of this range can also be used.
The metal electrodes 118 , 122 can be applied at a thickness from about 5 nm to 5 microns, though thicknesses outside this range can also be used. Materials that can be used, particularly for electrodes, typically include noble metals or other metals or alloys, including but not limited to, platinum, copper, gold, ruthenium, iridium, silver, nickel molybdenum, rhodium, and palladium. In other examples, oxides of these or other metals can also be used, such as IrO 2 or SrRuO 3 , if the adhesive properties of the adhesion layers of the present disclosure would be beneficial for use. Platinum is of particular interest as a metal that benefits from the adhesive layers of the present disclosure because its surface does not become readily oxidized. Metal electrodes (or metals applied for another purpose, such as for conductive layers or traces) can be deposited using any technique known in the art, such as sputtering, evaporation, growing the metal on a substrate, plasma deposition, electroplating, etc.
In accordance with the present disclosure, the piezoelectric layer 120 illustrated in FIG. 6 includes a lead-free piezoelectric ceramic material having the general chemical formula
xBiCoO 3 -y(Bi 0.5 Na 3.5 )TiO 3 -z(Bi 0.5 K 0.5 )TiO 3 ;
xBiCoO 3 -y(Bi 0.5 Na 0.5 )TiO 3 -zNaNbO 3 ;
xBiCoO 3 -y(Bi 0.5 Na 0.5 )TiO 3 -zKNbO 3 ;
xBiCoO 3 -yBi(Mg 0.5 Ti 0.5 )O 3 -z(Bi 0.5 Na 3.5 )TiO 3 ;
xBiCoO 3 -yBaTiO 3 -z(Bi 0.5 Na 0.5 )TiO 3 ; or
xBiCoO 3 -yNaNbO 3 -zKNbO 3 ;
wherein x+y+z=1, and x, y, z≠0, as discussed herein above. The piezoelectric layer 120 may have, for example, a thickness in the range of about 50 nm to about 10 μm for a thin-film structure. In other printhead designs, such as those using the disclosed lead-free piezoelectric ceramic materials in bulk, the dimensions and layers configurations would be adjusted accordingly.
Although specific embodiments have been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that a variety of alternate and/or equivalent implementations may be substituted for the specific embodiments shown and described without departing from the scope of the present invention. This application is intended to cover any adaptations or variations of the specific embodiments discussed herein. Therefore, it is intended that this invention be limited only by the claims and the equivalents thereof
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A lead-free piezoelectric ceramic material has the general chemical formula xBiCoO3-y(Bi0.5Na0.5)TiO3-z(Bi0.5K0.5)TiO3, xBiCoO3-y(Bi0.5Na0.5)TiO3-zNaN-bO3, xBiCoO3-y(Bi0.5Na0.5)TiO3-zKNbO3, xBiCoO3-yBi(Mg0.5Ti0.5)O3-z(Bi0.5Na0.5)TiO3, xBiCoO3-yBa-TiO3-z(Bi0.5Na0.5)TiO3, or xBiCoO3-yNaNbO3-zKNbO3; wherein x+y+z=1, and x, y, z≠0.
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This application is a continuation-in-part of application Ser. No. 660,704, filed Oct. 15, 1984 now U.S. Pat. No. 4,537,083 which is a division of Ser. No. 362,896, filed Mar. 29, 1982, now U.S. Pat. No. 4,487,199.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a portable prosthetic device used to treat a human joint by applying "continuous passive motion".
2. Description of the Prior Art
Dr. Robert B. Salter, Professor and Head of Orthopaedic Surgery at the University of Toronto, and Senior Orthopaedic Surgeon at the Hospital for Sick Children in Toronto, first developed the concept and coined the expression "continuous passive motion". Dr. Salter's work is described in the article "Joints Were Meant to Move--And Move Again" by Ohlendorf in "The Graduate", published by The Department of Information Services, University of Toronto, September/October 1980.
Briefly, according to this concept, a human joint, for example, a knee, elbow, or finger joint, is kept under slow continuous constrained motion as distinct from being held motionless or being moved intermittently. Keeping an injured or post operative joint mobile rather than immobilizing it in a cast is beneficial to the cartilage.
Attempts which have been made to provide machines that exercise joints are designed for intermittent operation and do not supply continuous passive motion. Moreover, they are usually too heavy and bulky to be readily portable and thus to be mounted on the body.
A primary aim of the present invention is to provide an apparatus which imparts continuous motion to the joint and which is portable so that it can be mounted on the patient's body.
SUMMARY OF THE INVENTION
Application No. 362,896 covers an apparatus for imparting continuous passive motion to a human joint. It comprises a support and linked thereto first connecting means for connection to a part of the body at one side of a joint to be mobilized, traveller means movable in a linear path relative to the support, provided with second connecting means for connection to a part of the body at the other side of the joint to be mobilized. In this way, the joint forms a movable link which is flexed as the travelling means moves back and forth relative to the support. Motor drive means is provided, for imparting, to the traveller means, substantially continuous slow rhythmic reciprocating movement. And, there is means for reversing the motor drive means at any point in its path to continue the reciprocating movement. More specific structure is also described and claimed.
The present application is directed to a portable continuous passive motion apparatus along these lines, specifically constructed for mobilizing at least one digit, and preferably several digits, of the hand. This apparatus comprises mounting means for firm connection to the forearm. A support is connectable to the mounting means and supports an actuator for producing continuous linear reciprocating movement. An elongating connecting member links the actuator with a distal part of one or more hand digits whereby the joints of the digit are continuously mobilized. In a preferred structure the actuator means includes a motor, an endless train driven thereby through an elongated circuit. The elongating connecting member is connected to the chain to travel therewith throughout its circuit, producing the back and forth movements which are transmitted to the hand digit. For mobilizing several digits at the same time, a structure is provided which has a central connecting rod connected at one end to the travelling means extending from the support to a connection with a manifold block. From the manifold block there extends several connecting rods each connected flexibly to the distal end of a digit. One suitable form of connection is a clevis which is mounted on the end of a connecting rod, with the other end pivotally mounted to a plate held to the distal part of the digit. In a preferred construction, the plate has a flat part resting against the surface of the digit and a lug extending from it for connection to the clevis. An adhesive strip maintains the plate against the surface of the digit and is provided with a slot through which the lug extends to its connection with the clevis.
BRIEF DESCRIPTION OF THE DRAWINGS
Having thus generally described the invention, it will be referred to more specifically by reference to the accompanying drawings which illustrate a preferred embodiment and in which:
FIG. 1 is a perspective view illustrating one form of unit for mobilizing a hand digit joint including a harness mountable on the forearm and hand and a housing mountable on the harness and an actuating rod extending from the housing to the hand digit, in this case the thumb;
FIG. 2 is a perspective view showing the mechanism inside the housing of FIG. 1 with the housing removed and is position shown in dotted lines;
FIG. 3 is a perspective view of an apparatus for mobilzing the joints of several different hand digits at the same time and in which the harness and casing are modified over those shown in FIGS. 1 and 2;
FIG. 4 is an exploded perspective view showing particularly the plate for mounting on the distal part of the hand digit and the adhesive strip used for connecting it;
FIG. 5 is a fragmentary plan view on an enlarged scale showing the several connecting rods leading to the hand digit;
FIG. 6 is an exploded perspective view looking at the top of the harness and showing the interlocking fabric connecting it to the supporting housing; and
FIG. 7 is a side elevation, enlarged in comparison with Figure illustrating particularly the construction of a preferred harness on the arm and its relationship to the drive housing.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring more particularly to the drawings, a drive housing A is carried by a mounting arrangement or harness indicated generally by B, which is supported by the forearm and wrist.
The support housing A is connected to the cuff B and an actuator wire 25 moves back and forth on the housing A through a flexible guide tube 41 to a connection with the thumb.
The connection from the actuator wire 25 to the thumb is through a hinge 43 to a small plate 45 adhesively connected to the thumbnail. Alternatively, the actuator 45 may be connected to any of the fingers or several fingers at the same time.
The mechanism for moving the actuator wire 25 is shown in FIG. 2. The support structure is fashioned from a block of plastic in which recesses have been made to accommodate the various parts. A geared motor 47 drives a sprocket 32 about which there is trained a chain 33 which is also trained about a spaced-apart sprocket 43. The actuator wire 25 is connected at 37 to one of the links of the chain 33. Batteries 46 are accommodated within the block as is an operating switch 51. The motor moves the chain continuously so that the actuator wire 25 moves in one direction along the top run of the chain and then down along the bottom run in the other direction so as to impart substantially continuous reciprocating movement to the wire 25 and consequently to the hand joint.
FIGS. 3 through 7 show an alternative form of device, as compared with that of FIGS. 1 and 2.
The mounting arrangement includes an extensive foam pad 53, which engages the surface of the forearm and wrist. The pad 53 narrows to a neck part 55 which extends over the palm of the hand. For mounting the pad 53 is a saddle 54, of relatively rigid thin plastic, which also narrows to a neck 56 which overlies the neck 55.
Mounted above the saddle 54 is a plate 57, which narrows to a neck 59 which is held to the necks 55 and 56 by a rivet 60.
At its opposite or rear-end, the plate 57 is spaced from the saddle 54 by a prop 80, which in the form shown is a tube having one end screwed to the plate 57 and having the other screwed to the saddle 59.
A fabric anchoring loop 63 is riveted to the margin of the saddle 54 midway along its length and carries a metal eye 65 to receive a belt, for surrounding the forearm, which extends through an adjustable buckle anchored to the other side of the saddle 54.
A belt 69, to surround the hand, is riveted to the assembly of necks 55, 56 and 59. The belt 69 is provided at one end with a buckle 70. The belt 69 encircles the hand just in front of the root of the thumb.
By this arrangement, the plate 57 is supported from the forearm with its forepart strapped relatively firmly to the palm of the hand and its rear part held relatively firmly to the forearm. The plate is thus fully supported from the forearm in a position for mounting the housing A.
To this end, the plate 57 carries a pad 51 of the well known VELCRO (trade mark) fabric having a pile surface made up of a mass of small loops to engage a complementary pad 50 on the undersurface of the drive housing A, having the VELCRO fabric surface made up of a mass of hooks which anchor themselves to the loops of the pad 51. The VELCRO anchorage of the pad 50 to the pad 51 is adequate to hold the housing in place in normal usage. But, the pads 50 and 51 may readily be peeled apart by pulling hard enough, for removal of the housing A from the mounting arrangement B.
In accordance with this form of the invention, an actuator wire extends from reciprocating mechanism inside the housing A (as illustrated in FIG. 2). There is slidably mounted on the actuator wire 25 a cylindrical manifold block or yoke 60, the block 60 having an axial opening through it to accommodate the wire 25. There is a set screw 61 operating in a transverse tapped opening in the block 60 to engage the wire 25 and maintain it in position.
The end of the wire 25 carries a clevis 82 provided with a tapped opening receiving the threaded end of the wire 25. The clevis has a slot 62 dividing its end into fingers 63 through which there extends a pin 64 to engage a connecting pin and finger connector, as will be described.
The connector includes a plate 65a which rests against the surface of the distal part of the finger and is held to it by an adhesive strip surrounding the finger. A perforated lug 67 extends from the plate 65 through an opening 62 in the strip 66 into the slot 62 and is engaged by the pin 64. So with the strip 66 engaging the finger, the clevis is pivotally held to the distal end of the finger.
In a similar manner, the other fingers are connected to the block 60 by respective wires 72 each having a threaded inner end, engaging a tapped opening in the block 60, and a threaded outer end engaging a tapped opening in a clevis similar to the clevis 82 and held to the finger in the same way.
A preferred actuator wire 25 is of 16 gauge solid music wire. Preferred wires 72 are of stranded 16 gauge metal, e.g. steel, wire to give them more flexibility.
The operation of the device is as previously described. The drive mechanism moves the actuator wire 25 back and forth in reciprocal movement which is transmitted to the fingers through the wires 25 and 72 so that the joints of all the fingers connected to the actuator are mobilized at the same time.
Likewise, the thumb may be linked to the manifold 60 by another wire as can the little finger which is shown free in the drawing.
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An apparatus for applying continuous passive motion to the joints of several fingers of the hand at the same time. It includes a support housing for mounting it on the forearm, carrying a motor and a traveller movable by a motor through an elongated path in a reciprocating movement. A connecting rod connects the traveller to a manifold block which, in turn, has elements connected to several fingers whereby their joints are mobilized simultaneously.
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BACKGROUND OF THE INVENTION
The present invention relates to mobile communication system between a mobile station and a base station having a plurality of radio packet channels with different transmission rate with each other.
Conventionally, a mobile communication system for packet communication has a plurality of packet channels each having a single common transmission rate between a mobile station and a base station. In that system, when a free packet channel is selected, a duration for a packet transmission, or a number of frames for continuous transmission, is assigned.
On the other hand, in a future mobile communication system, such as IMT-2000 standard, packet channels having a plurality of transmission rates are possible. In that system, a packet channel having a desired transmission rate must be, first, selected, and then, a duration for a packet transmission can be assigned.
FIG. 1 shows a configuration of a mobile communication system, in which there are a plurality of communication cells each located adjacently, and each cell comprises a base station 2 and a plurality of mobile stations 1 . A base station 2 is controlled by a control station 3 which is installed for a plurality of base stations 2 . An assignment of a packet is controlled either by a base station 2 or a control station 3 .
In a mobile communication system, when distance between a base station and a mobile station is defined, the higher transmission power is requested for the higher transmission rate. On the other hand, when a transmission rate of a packet is defined, the higher transmission power is requested, the longer the distance between a base station and a mobile station is.
Therefore, when the distance between a base station and a mobile station is long, and a transmission rate of a packet is high, the highest transmission power is requested.
However, when the distance between a base station and a mobile station is long, in other words, the mobile station locates close to a border of the cell of the own mobile station and the adjacent cell, the radio wave to/from said mobile station would affect interference to communication of adjacent cells.
SUMMARY OF THE INVENTION
It is an object of the present invention to overcome the disadvantages and limitations of a prior packet assignment system by providing a new and improved packet assignment system in a mobile communication system.
It is also an object of the present invention to provide a packet assignment system in a mobile communication system, so that a radio packet is adaptively assigned so that no interference is affected to adjacent cells.
The above and other objects are attained by a mobile communication system having a plurality of radio packet channels having different transmission rate from each other between a base station and a mobile station; said mobile station comprising; means for measuring a signal quality of a receive signal from a base station, means for assigning packet rate relating to said signal quality thus measured, means for transmitting said packet rate to a base station, and data terminal for transmitting and receiving data to and from the base station with said packet rate.
Preferably, said signal quality is defined by propagation loss which is obtained by transmission power of a pilot signal at a base station and receive power of said pilot signal at a mobile station.
Preferably, said base station comprises; means for receiving packet rate from a mobile station, means for determining number of frames for continuous transmission for each packet rate, and means for transmitting said number of frames thus determined to a mobile station so that communication with said mobile station is carried out with the determined packet rate and the determined number of frames.
Still preferably, a short packet transmission time is assigned when a high transmission rate packet channel is selected, and a long packet transmission time is assigned when a low transmission rate packet channel is selected.
Still preferably, a small number of frames for continuous transmission and a large amount of data in each frame are assigned when a high transmission rate packet channel is selected, and a large number of frames for continuous transmission and a small amount of data in each frame are assigned when a low transmission rate packet channel is selected, so that data amount to be transmitted is uniform irrespective of selected transmission rate of a packet channel.
Preferably a packet channel is set a number of frames of continuous transmission for each transmission rate. Still preferably, said number of frames is adaptively adjusted.
Still preferably, when a high transmission rate packet channel is selected, a short packet transmission time is assigned, and when a low transmission rate packet channel is selected, a long packet transmission time is assigned, so that a mobile station takes a uniform amount of data to be transmitted or received, in spite of location relation of a base station and a mobile station. Preferable, when a high transmission rate packet channel is selected, a number of frames of continuous transmission is small and an amount of data for each frame is large, and when a low transmission packet channel is selected, a number of frames of continuous transmission is large and an amount of data for each frame is small.
Still preferably, a base station, upon finishing transmission or reception of a number of continuous frames to/from a mobile station, begins transmission or reception of a number of continuous frames to/from a next mobile station, so that a mobile station which communicates with a base station is switched recursively.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other objects, features, and attendant advantages of the present invention will be appreciated as the same become better understood by means of the following description, wherein;
FIG. 1 shows a system configuration of a conventional mobile communication system,
FIG. 2 is a system configuration of an embodiment of a mobile communication system according to the present invention,
FIG. 3 is a system configuration of another embodiment of a mobile communication system according to the present invention,
FIG. 4 is a system configuration of still another embodiment of a mobile communication system according to the present invention,
FIG. 5 shows a block diagram of a base station according to the present invention,
FIG. 6 is a block diagram of a mobile station according to the present invention, and
FIG. 7 shows signal sequence between a base station and a mobile station according to the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 5 is a block diagram of a base station according to the present invention, FIG. 6 is a block diagram of a mobile station according to the present invention, and FIG. 7 shows signal sequence between a base station and a mobile station.
It is assumed in the present invention that no transmission power control is carried out in a base station and/or a mobile station, in other words, a base station and/or a mobile station transmits with the maximum power which is allowed to the base station and/or the mobile station, irrespective of transmission rate.
In FIG. 5 , a base station comprises an antenna 10 , an antenna duplexer 11 for common use of a single antenna both for transmission and reception, a receiver 12 for receive process including frequency conversion from radio frequency to baseband frequency and demodulation, a transmitter 13 for transmit process including frequency conversion from baseband frequency to radio frequency and modulation. The numeral 13 A is a means for transmitting a pilot signal and a transmission power of the own base station, and is coupled with the transmitter 13 . The numeral 14 is a transmit/receive process for packeting/unpacketing, multiplexing/demultiplexing, and transmission of a number of continuous frames depending upon a determined communication ratio. The transmit process 14 is coupled with a network 16 through an interface 15 .
The numeral 20 is a packet rate receiver, coupled with the transmit process 14 , for receiving a packet rate which is transmitted by a mobile station. An output of the Packet rate receiver 20 is applied to a frame number decision process 22 which determines a number of frames transmitted continuously depending upon a packet rate. According to the present invention, when a packet rate is high, a number of frames transmitted continuously is small, and when a packet rate is low, said number is large, so that a number of frames in each transmission is almost uniform irrespective of a packet rate. The frame number decision process 22 has a table for determining a number of frames for continuous transmission for each packet rate received from a mobile station.
An output of the frame number decision process 22 is applied to a transmission queue 24 which shows whether there is a transmission queue of another mobile station in the base station or not. If the answer is yes, a mobile station which is waiting for transmission for the longest duration is determined (process 26 ), and a packet is transmitted or received to or from the determined mobile station (process 30 ). If the answer in the process 24 is no, a packet is transmitted or received to or from the mobile station which supplied a packet rate (process 28 ).
An output of the transmit/receive packet process 28 and an output of the transmit/receive packet process 30 are applied to the transmit/receive process 14 , for transmission/reception of a packet through a transmitter 13 or a receiver 12 and an antenna 10 .
A mobile station shown in FIG. 6 comprises an antenna 40 , an antenna duplexer 41 , a receiver 42 for receive process including frequency conversion and demodulation, a transmitter 43 for transmit process including frequency conversion and modulation, a transmit/receive process 44 for packeting/unpacketing, multiplexing/demultiplexing, and reception of a number of frames for continuous transmission.
The transmit/receive process 44 is coupled with a handset 46 for speech and a data terminal 47 through an interface 45 . The data terminal 47 transmits/receives data.
The numeral 50 is a receive signal quality measure which measures a receive signal quality, which may be a propagation loss which is calculated by a receive level of a pilot signal and a transmission power of a base station. In the embodiment of FIG. 6 , the process 52 receives the data of transmission power of a pilot signal by a base station, the process 54 measures receive power of a pilot signal at a mobile station, and the process 56 calculates the propagation loss which is the difference of the transmit power of a pilot signal at a base station and the receive power of a pilot signal at a mobile station.
The numeral 60 is a table search which determines a packet rate according to measured signal quality. When a signal quality is good, a packet rate is determined to be high, and when a signal quality is poor, a packet rate is determined to be low. A plurality packet rates are listed in a table corresponding to each signal quality, and one of the packet rate is selected according to the receive signal quality.
The determined packet rate is applied to a packet rate advice 62 , and is transmitted to a base station.
FIG. 7 shows a signal sequence between a base station and a mobile station for determining a packet rate and a number of continuous frames.
In FIG. 7 , upon establishing a circuit between a base station and a mobile station, a base station transmits a mobile station a transmit power data (process 70 ). Alternatively, said transmit power data may be broadcast by a base station. That transmit power data is received by the mobile station (process 80 ), then the mobile station measures receive power of a pilot signal (process 82 ). The propagation loss (process 84 ) is calculated as the difference between the transmit power of a pilot signal at a base station and the receive power of a pilot signal at a mobile station.
Then, the mobile station searches a table (process 86 ) to determine a packet rate according to a signal quality (propagation loss) thus measured. The mobile station transmits the determined packet rate to the base station (process 88 ).
The base station receives the packet rate (process 74 ), then, determines a number of continuous frames according to the packet rate through a table search (process 76 ). The number of continuous frames thus determined is transmitted to the mobile station (process 78 ).
The mobile station receives the number of continuous frames (process 89 ).
Then, the mobile station and the base station begin the packet communication based upon the determined packet rate and the determined number of continuous frames (process 100 ). Thus, a data terminal 47 ( FIG. 6 ) begins the communication with another mobile station or a network through a base station with the determined packet rate.
Now, some modifications of the present invention will be described. The modifications concern how a signal quality is defined.
FIG. 2 shows an explanatory figure of a channel assignment for a packet according to the present invention, in which a signal quality at a mobile station is defined by a distance between a mobile station and a base station. A distance between a mobile station and a base station is first measured. When the distance is short, a high rate packet channel is assigned, and when the distance is long, a low rate packet channel is assigned. As shown in FIG. 2 , a mobile station A located close to a base station is assigned a high rate packet channel, and a mobile station B located far from a base station is assigned a low rate packet channel. Thus, no interference is affected to an adjacent base station, and further, receive level at a base station of a signal from a mobile station is essentially controlled to be almost uniform.
In another modification, instead of measuring a distance between a base station and a mobile station, a signal quality is defined by a receive level of a signal received by a mobile station. A high receive level implies that a distance between a base station and a mobile station is short, and a low receive level implies the distance is long. Therefore, a base station transmits a pilot signal, and a mobile station measures a receive level S of a pilot signal from the base station. When the receive level S is high, a high rate packet channel is assigned, and when the receive level S is low, a low rate packet channel is assigned, as shown in the table 1.
TABLE 1
S
Packet channel
Comments
Low
low rate packet channel
Mobile station B far
from base station
High
high rate packet channel
Mobile station A near
to base station
In still another modification, a signal quality at a mobile station is defined by a distance between a mobile station and a border of a cell which the mobile station belongs covers. When a distance between a mobile station and a border is long, it means that a distance between a mobile station and a base station is short, and when a distance between a mobile station and a border is short, it means that a distance between a mobile station and a base station is long. Therefore, as shown in FIG. 3 , a mobile station A which locates far from a border is assigned a high rate packet channel, and a mobile station B which locates close to a border is assigned a low rate packet channel.
In still another modification, a signal quality at a mobile station is defined by a receive level of a signal from a base station which the mobile station belongs, and receive levels of signals from adjacent base stations. A first base station which a mobile station belongs, and other base stations adjacent to said first base station transmit a pilot signal. The mobile station measures a receive level S 1 of a pilot signal from the first base station which the mobile station belongs, and receive levels S 2 -S n , of pilot signals from other base stations located adjacent to said first base station. Then, the maximum receive level S max among receive levels S 2 through S n is selected, and the difference ΔS between the first receive level S 1 , and said maximum receive level S max is calculated (ΔS=S 1 -S max ). When ΔS is large, it implies that a distance between a mobile station and a border of a cell from the mobile station is long, and when ΔS is small, it implies that the distance is short. Therefore, when ΔS is large, a high rate packet channel is assigned, and when ΔS is small, a low rate packet channel is assigned, as shown in the table 2.
TABLE 2
ΔS
Packet channel
Comments
Small
low rate packet channel
mobile station B close to
border
Large
high rate packet channel
mobile station A far from
border
In still another modification, a receive signal quality at a mobile station is defined by an interference level I at a mobile station. When an interference level I is high, it means that there exist many other mobile stations near the own station. Therefore, it is essential to decrease transmission power so that interference affects less. On the other hand, when an interference level I is low, it is recognized that there exist less other mobile stations near the own station, and therefore, interference affects less even if transmission power is high.
Therefore, when an interference level I is low, high rate packet channel is assigned, and when interference level I is high, low rate packet channel is assigned. Table 3 shows the relations between an interference level I and packet channel to be assigned.
TABLE 3
I
Packet channel
Comments
Low
High rate packet channel
Less other mobile stations
High
Low rate packet channel
Many other mobile stations
In still another modification, a receive signal quality at a mobile station is defined by receive SIR, or signal to interference ratio at a mobile station. When receive SIR is low, there exist many other mobile stations near own mobile station, and therefore, transmission power must be low so that interference affects less. On the other hand when receive SIR is high, there exist less mobile stations near own mobile station, and therefore, transmission power may be high.
Therefore, when receive SIR is low, low rate packet channel is assigned, and when receive SIR is high, high rate packet channel is assigned. Table 4 shows the relations between receive SIR and packet channel.
TABLE 4
SIR
Packet channel
Comments
High
High rate packet channel
Less mobile stations
Low
Low rate packet channel
Many mobile stations
In still another modification, a receive signal quality at a mobile station is defined as follows. It is assumed the maximum transmission power P max assigned to a packet channel at a base station, transmission loss L measured between a base station and a mobile station, interference power I measured at a mobile station, desired SIR designated for each packet channel, process gain G designated for each packet channel, and compensation factor A for compensating characteristics of an antenna and equipment. Then, the highest rate packet channel is assigned on the condition that the following inequality Is satisfied.
P max >=I−L+SIR−G +A
With the above scheme, the maximum rate packet channel available at the location of the mobile station is assigned. The closer to a base station the higher rate packet channel is assigned, and the farer from a base station, the lower rate packet channel is assigned.
As described above the present invention has the feature that a packet channel depends upon a receive signal quality at a mobile station or location relation of a mobile station and a base station. Therefore, rate of a packet channel to be assigned depends upon location where a mobile station locates.
Next, the present invention further provides a system which assures a predetermined uniform amount of data transmission to all the mobile stations, in spite of transmission rate of a packet channel.
In still another modification, a packet channel may be assigned a number of frames of continuous transmission for each transmission rate. Preferably, said number of frames of continuous transmission may be adaptively adjusted.
In still another modification, when high rate packet channel is assigned, short packet transmission time is assigned, and when low rate packet channel is assigned, long packet transmission time is assigned. Short packet transmission time means that the maximum number N max of frames to be transmitted continuously is small, and long packet transmission time means that the value N max is large.
In still another modification, when high rate packet channel is selected, a number of frames to be transmitted continuously is assigned small and amount of data for each frame is assigned large, and when low rate packet channel is selected, a number of frames to be transmitted continuously is assigned large and amount of data for each frame is assigned small. Amount of data for each frame is called as a frame payload, which is large for high rate packet channel. Table 5 shows an example. Thus, the same amount of data transmission is assured to all the mobile stations, in spite of rate of a packet channel.
TABLE 5
Number of frames
Packet
N max of continuous
Frame
Amount
channel
transmission
Payload
of data
High (1024 Mbps)
1
128 kbytes
1.024 Mbps
(1024 kbits)
Low (16 kbps)
64
2 kbytes
1.024 Mbps
(16 kbit)
In still another modification, when the base station finishes transmission or reception of the maximum continuous number of frames with a certain mobile station, the base station starts transmission or reception of the maximum continuous number of frames with another mobile station, so that a mobile station communicating with the base station is switched recursively.
With the above scheme, amount of data transmission of each mobile station is kept uniform.
Two priority modes in operation of communication control of the whole system are possible as follows.
First priority mode; amount of data of each mobile station is kept constant. Second priority mode; amount of data of a base station is kept constant.
In the above embodiments and modifications, it is assumed that the first priority mode is taken. As for the second priority mode, amount of data of a base station may be the maximum by assigning the value N max of high rate packet channel large and the value N max of low rate packet channel small. Thus, the flexible control of operation of a mobile communication system is possible merely by assigning a value of N max .
As described above, according to the present invention which assigns a radio packet adaptively, a transmission rate and/or transmission time of a packet is assigned adaptively according to location relation of a base station and a mobile station. Therefore, communication between a base station and a mobile station interferes less with adjacent cells of adjacent base stations. Further, a predetermined uniform amount of data transmission is assigned to each mobile station, in spite of location relation of a base station and a mobile station. Further, flexible control is a mobile communication system is possible.
From the foregoing, it will now be apparent that a new and improved mobile communication system which assigns a radio packet channel adaptively has been found. It should be understood of course that the embodiments disclosed are merely illustrative and are not intended to limit the scope of the invention. Reference should be made to the appended claims, therefore, for indicating the scope of the invention.
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In a mobile communication system having a plurality of radio packet channels of different transmission rate with each other between a base station and a mobile station, undesirable interference to adjacent cells of adjacent base stations is decreased. Signal quality of a receive signal at a mobile station is measured, and the better said signal quality is, the higher packet channel is assigned. Thus, although signal quality is poor because of long distance between a base station and a mobile station, no increase of transmission power of a base station is requested. Thus, interference to adjacent cells is decreased. When high rate packet channel is selected, short packet transmission time may be assigned so that amount of data transmission is kept uniform in spite of said signal quality.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a sliver divider on a textile machine, in particular on a drafting arrangement of a spinning machine, for dividing a sliver band into at least two strands that are delivered to a work station for further processing.
2. Description of the Related Art
Prior to the spinning process, the fibers to be processed must be prepared. In cotton, for instance, this is done by opening the bales, removing fibers from the bales, cleaning them and then depositing them as a web on a carder. To increase the cleanness of the fibers, improve their quality, or mix them with other fibers, strands can be produced from this card sliver that are in turn joined with the strands of other card slivers, mixed, and then drawn, in order finally to be deposited as sliver in a can, or wound to make a roving bobbin. So-called sliver dividers can already be used during the step of unraveling the web.
Prior to the spinning process, the sliver, deposited in cans or wound onto roving bobbins, undergoes a further preparation step. This includes paralleling of the fibers and attenuating the so-called feed roving in a drafting arrangement. There may also be sliver dividers within this drafting arrangement, which subdivide the partly drawn sliver still further, for the sake of further doubling or to produce twisted yarns. Drafting arrangements with sliver dividers are therefore especially found in air spinning machines, friction spinning machines and ring spinning machines.
The sliver dividers are disposed stationary in the travel route of the sliver. Usually, the sliver divider is located inside a sliver guide. In drafting arrangements on a spinning machine, the sliver divider is usually located between two devices for drafting the sliver, for instance between two apron-type drafting mechanisms. In other words, as seen in a direction of travel of the sliver, a drafting mechanism is followed by a sliver divider which is again followed by a drafting mechanism. German Published, Non-Prosecuted Patent Application 38 42 120, for instance, discloses a drafting mechanism provided with a so-called sliver parting and guiding apparatus, which comprises a shaft with a rotary element mounted on it and two laterally rotating sliver guides. This sliver parting and guiding apparatus is rotatable at right angles to the plane in which the sliver is transported, but otherwise is disposed in a stationary manner. The sliver is divided as if by a circular saw.
However, if a sliver divider is disposed rigidly, is it possible that the sliver may not be divided uniformly.
Depending on the sliver rotation and compression, the sliver may "creep" within the drafting arrangement. In this case, creep means that, because of nonuniform fiber distribution within the sliver, the sliver may swerve laterally away from its original path. With uneven drafting, the sliver creeps out of its path and no longer arrives at the sliver divider in the intended way. Accordingly, the sliver is no longer divided in the desired manner. In the least favorable case, the sliver divider may lose its function entirely, because the sliver may squeeze into one of the intended division paths, completely missing the sliver divider, therefore no longer being divided.
It is accordingly an object of the invention to provide a sliver divider, which overcomes the above-mentioned disadvantages of the heretofore-known devices of this general type, and which, even in the event of sliver creepage, always adheres to an initially desired division of the sliver.
SUMMARY OF THE INVENTION
With the foregoing and other objects in view there is provided, in accordance with the invention, a sliver dividing device in a textile machine for a sliver travelling in a given direction, comprising a sliver divider for dividing the sliver into at least two strands to be delivered to a work station for further processing, which sliver divider being movable in a direction substantially perpendicular to the given direction.
In contrast to the prior art, the sliver divider of the invention is disposed movably. As a result, it can follow the motions of the sliver and can execute the initially set sliver division properly even if the sliver should creep back and forth. To this end, its direction of motion is set at substantially right angles to the direction of motion of the sliver. Especially with elongated fibers, long, narrow sliver dividers can maintain their initially set position in the sliver even upon creepage of the sliver, as long as it can follow the creeping motion of the sliver or in other words if it is capable of deflecting laterally, or in other words perpendicularly to the direction of motion of the sliver.
Sliver creepage can be reduced substantially, if a sliver guide is provided and the sliver divider is disposed between the walls of a sliver guide.
As a rule, the sliver divider is disposed symmetrically between the walls of a sliver guide. However, depending on the work station following downstream of the sliver dividing and guiding device, a nonuniform division of the sliver may also be provided. In such a case, the sliver divider will be disposed asymmetrically between the walls of the sliver guide. Accordingly, due to the different spacing between, say, one of the guide walls and the sliver divider as compared to the spacing between the other guide wall and the sliver divider, the resulting sliver bands will have different sizes.
In accordance with a further feature of the invention, the sliver divider is displaceably disposed in the sliver guide; the direction of displacement is essentially at right angles to the direction of motion of the sliver. Because of the displaceability of the sliver divider, the sliver divider can advantageously follow all the motions of the sliver.
In accordance with an added, particularly advantageous feature of the invention, the sliver divider is disposed rotatably, with the pivot shaft substantially at right angles to the travel plane in which the sliver moves. The sliver divider is disposed with its axis in the sliver guide, such that its half located downstream the axis, as viewed in the direction of motion of the sliver, is located in a narrowed portion of the sliver guide. If the sliver now creeps because of irregularities, then a larger number of fibers is passed along one side of the sliver divider than on the other. In the narrowed portion of the sliver guide downstream of the pivot shaft, this results in an increased pressure on the sliver divider. The sliver divider deflects from the pressure and rotates about its axis, so that its rear half is rotated into the region where the smaller number of fibers exerts a lesser pressure on its rear half. As a result, the front part of the sliver divider is deflected into the direction of the part of the sliver that includes the increased number of fibers. Because of its oblique position, it divides the sliver in such a way that approximately the same number of fibers is moved past it on either side. The oblique position of the sliver divider will accordingly persist only until such time as the pressure on the side having the increased proportion of fibers is reduced, because of how the fibers are now being divided. Once a balanced proportion of fibers in each strand is attained, the sliver divider returns to its neutral longitudinal direction, in other words the direction in the which the sliver travels. The rotatably disposed sliver divider thus automatically counteracts both creepage of the sliver and uneven fiber distribution within the stands. The sliver divider is adjusted by the sliver itself. Accordingly, no external intervention whatever is needed to restore the intended division of the sliver.
In accordance with an additional feature of the invention, the sliver divider can be adapted optimally to the various fiber parameters. For instance, the sliver divider may be embodied in the shape of a wedge, and the narrow edge of the wedge may be oriented counter to the direction of motion of the sliver. Because of the wedge shape, the sliver is split parted, and a certain amount of compacting takes place at the wide ends of the wedge. In the event of uneven sliver distribution within the sliver, an increased pressure will occur at that point of the wedge-shaped sliver divider, so that the narrow end of the sliver divider will move toward the side of the sliver in which the greater accumulation of fibers is present. The sliver is newly divided, and the distribution of the slivers is effected such that virtually the same number of fibers moves past the sliver divider on the right and on the left. As a result, the same pressure is re-established on both sides of the sliver divider. The sliver is again uniformly divided and returned to its intended path.
In accordance with again another feature of the invention, the narrow edge of the sliver divider and the longitudinal axis of the pivot shaft are located in a common plane. As a result, the two strands are prevented from exerting undesirable torque on the sliver divider.
In accordance with again a further feature of the invention, undesirable torque is avoided by embodying the sliver divider symmetrically with the plane in which the narrow edge of the sliver divider and the pivot shaft are located. Because of the symmetrical design of the sliver divider, the same forces engage the side faces of the sliver divider from both divided strands, if the strands are of the same type.
In accordance with again an additional feature of the invention, the side walls of the sliver divider are provided to have the shape of a plow share. The blade of the plow share divides the sliver, and the curvature of the side walls prevents the fibers from migrating upward at the narrow point in the sliver guide.
In accordance with yet another feature of the invention, the sliver divider may also take the form of an inverted ship's bow, i.e. a ship stood on its deck. Just as the bow of a ship is intended to present particularly little resistance to the water, a thus-shaped sliver divider can effect a particularly favorable, eddy-free passage of the fibers past the sliver divider. The location of the fibers within the sliver is not intended to be disturbed by the sliver divider; that is, it should not have any influence on the drawn position of the fibers in the sliver. Shaping the sliver divider like a bow presents the least possible resistance to the fibers moving past it, and as a result also does not disturb the position of the fibers in the strands.
In certain cases, it may be necessary to provide means at the pivot shaft of the sliver divider for bringing to bear an adjustable counterforce oriented counter to the torque acting on the sliver divider due to the sliver. Particularly in fibers having a high coefficient of friction, even slight fluctuations in the sliver density of the two strands can cause swerving of the sliver divider. Uncontrolled fluttering of the sliver divider is undesirable, that is, uncontrolled swerving to the right and left. For this reason it is advantageous if the motion of the sliver divider is damped, for instance by using an adjustable damping of a known type.
In accordance with a concomitant feature of the invention, the guide walls of the sliver guide may be disposed rotatably and/or slideably. The combination of the two options may also be provided. This makes it possible, without changing the sliver guide, to adjust for various yarn parameters and sliver widths. The walls can also be better adapted to the shape of the sliver divider as a result, if one sliver divider is replaced for one having a different shape. Other features which are considered as characteristic for the invention are set forth in the appended claims.
Although the invention is illustrated and described herein as embodied in sliver divider, it is nevertheless not intended to be limited to the details shown, since various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims.
The construction and method of operation of the invention, however, together with additional objects and advantages thereof will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings, in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic, perspective view of an air spinning machine with a sliver divider according to the invention incorporated in the drafting mechanism;
FIG. 2 is a perspective view of a first embodiment of a sliver guide with a sliver divider disposed displaceably therein;
FIG. 3a is a top plan view of a second embodiment of a sliver divider disposed symmetrically in a sliver guide;
FIG. 3b is a view of the sliver guide of FIG. 3a with the sliver divider deflected by the creepage of the sliver;
FIG. 4 is a top plan view of a third embodiment of a sliver divider disposed asymmetrically in a sliver guide;
FIG. 5a is a front elevational view of a fourth embodiment of a sliver guide with a sliver divider having plowshare-like sidewalls;
FIG. 5b is a top-plan view of the sliver guide of FIG. 5a;
FIG. 5c is a perspective view of the sliver divider of FIGS. 5a and 5b;
FIG. 6a is a front elevational view of a sliver guide with a sliver divider in the shape of a bow of a ship and having adjustable walls;
FIG. 6b is a top-plan view of the sliver guide of FIG. 6a with the side walls moved with respect thereto;
FIG. 6c is a sectional view of the sliver guide along the line C--C of FIG. 6b, seen in the direction of the arrows;
FIG. 7a is a top-plan view of a sixth embodiment of the sliver guide having a sliver divider onto which a counterforce can be applied; and
FIG. 7b is a sectional view along the line B--B of FIG. 7a, as seen in the direction of the arrows.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the figures of the drawings in detail, in which reference numerals are related by their two right-hand digits and in which the left-hand digit corresponds to the number of the respective figure, there is seen, particularly in FIG. 1 thereof, a spinning station in an air spinning machine in a diagrammatical, perspective view. Only the most important equipment, necessary for comprehension of the invention, of this spinning station is shown. The spinning station of an air spinning machine has been selected to represent all other textile machines in which the sliver divider according to the invention can be used.
From a can 1 which is ready at the spinning station, a sliver band or sliver 2 runs over a deflecting rod 3 into a drawing or drafting mechanism A. It is pulled into the drafting mechanism A through a compacter and a sliver guide 4 by a pair of feed rollers 5. The pair of feed rollers 5 is at the same time the back pair of rollers of a first double apron drafting mechanism 6. Here the first drafting of the sliver 2 takes place. The drawn sliver 20 then passes through a first pair of drafting rollers 7, which is the front pair of rollers of the double apron drafting mechanism 6. After that, it passes through the sliver guide 8. The guide walls 9a and 9b are adjustably disposed on a support 10 by means of fastening screws 11a and 11b, which are guided in the respective associated slots 12a and 12b. Disposed between the guide walls 9a and 9b is a sliver divider 13, which divides the already pre-drawn sliver 21 into two strands 21a and 21b. The strands pass through a further, second double apron drafting mechanism 14.
Two sliver band strands 22a and 22b which are ready for spinning leave the drafting mechanism A behind a second pair of drafting rollers 15.
As the work station, two air spinning nozzles 16a and 16b for air spinning of the drawn slivers 22a and 22b are disposed downstream of the drafting mechanism A. The supply of compressed air for the air spinning is effected via the connections 17a and 17b, respectively. A spinning fiber filament 23a leaves the air spinning nozzle 16a, and a spinning fiber filament or textile fiber 23b leaves the air spinning nozzle 16b. On their way to a pair of delivery rollers 18, they are twisted together and they run onto the yarn guide drum 19 in the form of the double end 24. The yarn guide drum deposits them in cross-wound layers into the cross-wound bobbin or cheese 25.
FIG. 2 shows a first exemplary embodiment of a sliver divider according to the invention. The sliver guide 208 comprises two guide walls 209a and 209b, which are mounted on a support 210. This support 210 is not shown in further detail. It is secured inside the drafting arrangement on the machine. The pre-drawn sliver 221 enters the sliver guide 208 in the direction of the arrow. The guide walls 209a and 209b first open in the manner of a funnel at the entry point. The sliver divider 213 according to the invention is displaceably disposed in the middle, between the two guide walls 209a and 209b. The divider 213 is slightly wedge-shaped, with the narrow edge 230 facing counter to the direction of motion of the sliver 221. A narrow edge 230 is oriented vertically with respect to the plane of the sliver, which is defined by the orientation of the top surface of the support 210. The sliver is divided into two strands 221a and 221b by the sliver divider 213.
The sliver divider shown here is particularly suitable for use with long fibers, for instance long, smooth cotton fibers. Once it has been adjusted centrally, the elongated sliver divider seeks to maintain its position within the sliver 221. In the event of lateral creepage of the sliver, it tends to move with the creepage of the sliver.
The sliver divider 213 has two guide cams or cam followers 231a and 231b in succession in its longitudinal direction as seen in the direction of travel of the sliver, from the narrow edge 230 towards the wider back of the sliver divider 213. They are ovally shaped transversely to the longitudinal direction of the sliver divider 213 and are each guided in a respective groove 232a and 232b. The grooves are disposed transversely to the direction of sliver motion in a guide plate 233. The guide plate 233 is screwed with screws 234a and 234b to the guide walls 209a and 209b, respectively. The parallel orientation of the guide grooves 232a and 232b prevents a torsion of the sliver divider.
If the sliver 221 creeps transversely to its direction of motion, the sliver divider 213 is carried with it and displaces laterally. This leads to an increase in pressure against the sliver divider 213 on the side toward which the sliver has crept. The reason is the compression of the sliver on the side toward which the sliver has crept. Because of the length of the fibers and the length of the sliver divider, the sliver divider, due to the increased pressure on the thus compressed side, will return the sliver back to the center of the sliver guide.
In the second embodiment of a sliver divider illustrated in FIGS. 3a and 3b, the sliver guide 308 includes two parallel guide walls 309a and 309b, which open in funnel-like fashion counter to the direction of travel of the pre-drawn sliver 321 and then extend parallel to one another. They are mounted on a support 310 which is not illustrated in detail. The sliver divider 313 is disposed centrally between the two guide walls 309a and 309b. Once again it has the shape of a wedge; the narrow edge or blade 330 of the wedge faces upstream, opposite the direction of travel of the sliver 321. The direction of travel of the sliver 321 is indicated by the arrow just below the numeral 321. The sliver divider 313 is rotatable about a pivot shaft 331. This pivot shaft is vertical to the travel plane 332 of the sliver 321.
If the fiber distribution within the sliver cross section is undisturbed and uniform, the sliver divider will assume a neutral position within the sliver guide 308. As can be seen from the drawing, the narrow edge 330 of the sliver divider and the axis of its pivot shaft 331 are both located in a common plane 333 that is perpendicular to the travel plane 332 of the sliver 321. Furthermore, the sliver divider 313 is construed symmetrically with respect to the plane 333.
Because on the average an equal number of fibers is contained in both strands 321a and 321b, the forces exerted upon the sliver divider 313 by the strands are of equal magnitude, so that the sliver divider 313 assumes a neutral position inside the sliver guide; that is, the plane 333 is parallel to the parallel guide walls 309a and 309b of the sliver guide 308.
The effects of creepage of the sliver are shown in FIG. 3b. From the standpoint of the observer, the sliver 321 has crept toward the right, this causes an increased accumulation of fibers between the sliver divider 313 and the guide wall 309b. Substantially fewer fibers are located between the sliver divider 313 and the guide wall 309a. The result is two nonuniform strands, the thinner strand 321a' and the thicker strand 321b'. The wedge-like shape of the sliver divider 313 creates a narrow point between its rear end, located after the pivot shaft 131, and the guide walls 309a and 309b. The increased accumulation of fibers 334 between the rear, thicker end of the sliver divider 313 and the guide wall 309b leads to an increased pressure on the sliver divider 313 in this narrow point, so that a reaction force 335 acts upon the rear end of the sliver divider 313. The force vector on the sliver divider 313 lies in the direction of the arrow, at right angles to the guide wall 309b. The sliver divider 313 is rotated out of its position of repose, so that its narrow edge moves to the position 330'. The direction of motion of the narrow edge 330 is oriented essentially perpendicular to the direction of motion of the sliver, as indicated by the arrow 336. The reference numeral 333' indicates the axis along which both the narrow edge 330 and the pivot shaft 331 are oriented in the rotated state. The oblique position of the sliver divider 313 in the direction toward the increased accumulation of fibers 334 means that more fibers are diverted from the sliver strand 321b' to the strand 321a' or, in other words, from the right side toward the left side of the sliver divider. Accordingly the sliver divider automatically intervenes in the division of the sliver and makes a corresponding correction in fiber distribution. The changed division of the sliver by the obliquely positioned sliver divider leads to a change in the division in the amount of fiber and thus makes the two strands 321a' and 321b' uniform. Once the increased accumulation of fibers 334 disappears, the reaction force 335 upon the end of the sliver divider 313 disappears as well. The obliquely positioned sliver divider presents increased resistance 337 to the fibers of the strand 321a, and this brings about a reaction force 338 perpendicular to the guide wall 309a, causing it to return toward the left to its original central position.
The above makes it quite clear that the sliver divider 313 automatically equalizes an uneven distribution of the fibers inside the sliver 321. Any departure from uniform distribution of fibers within the sliver leads to a deflection of the sliver divider blade 330 toward the side of the sliver in which the increased number of fibers occurs. As a result, a new division of the sliver is automatically performed such that fibers are diverted to the side having less accumulation. A balance in fiber distribution within the sliver is thus achieved within minimum time, so that the sliver divider can assume its neutral position inside the sliver guide once again, or, in other words, it can resume its orientation parallel to the guide walls. At the same time, the mispositioning of the sliver is also overcome.
Sliver dividers that are rotatably disposed inside the sliver guide are particularly well suited for slivers made up of short fibers. Due to the fact that they are pivotable, sliver dividers of this kind react automatically and virtually without delay to any deviation in fiber distribution within the sliver and perform a speedy equalization thereof.
FIG. 4 shows an asymmetrical disposition of a sliver divider 413 inside a sliver guide 408. The construction of the sliver guide 408 and the sliver divider 413 are similar to those illustrated in the above-described FIGS. 3a and 3b. The sliver divider 413 is asymmetrically disposed on the support 410 between the guide walls 409a and 409b. Its shaft 431 is disposed closer to the guide wall 409a, resulting in two strands 421a and 421b of unequal size. The sliver 421 is divided into a narrower strand 421a and a wider strand 421b. The mode of operation of the sliver divider is the same as that described with reference to FIGS. 3a and 3b.
A further embodiment of the sliver divider according to the invention is shown in FIGS. 5a-5c.
The sliver guide 508 illustrated in FIG. 5a has a sliver divider 513 located centrally between the two side walls 509a and 509b, which are mounted on a support 510. The sliver divider 513, as shown in the top-plan view of FIG. 5b is rotatable about a pivot shaft 531. The pivot shaft 531 is perpendicular to the travel plane 532 of the sliver which is parallel to the support 510. Accordingly, the pivot shaft 531 is also disposed perpendicularly to the support 510. The sliver divider 513 is again wedge-shaped, with its blade or narrow edge 530 vertical and facing upstream opposite the direction of travel of the sliver 521. The narrow edge 530 and the pivot shaft 531 are both located in a plane 533, as can be seen from FIG. 5b. This plane is at right angles to the travel plane 532, or in other words perpendicular to the support 510. In the entry region of the sliver, the side walls 509a and 509b of the sliver guide are slightly rounded. The side walls of the sliver divider 513, that is, the walls 538a on the left and 538b on the right, have a plowshare-like curvature.
FIG. 5b, in combination with FIG. 5a, shows that both side walls 538a and 538b of the sliver divider 513 are curved three-dimensionally toward the top and back, as viewed in the direction of sliver travel, which is indicated by the arrow 521.
The perspective view of the sliver divider in FIG. 5c, illustrates the construction of the side walls, in this case the side wall 538b, particularly clearly.
As a result of the concave curvature of the side walls of the sliver divider 513, the sliver is compacted in the narrowing of the sliver canal at the end of the sliver guide between the side walls. With the aid of the plowshare-like side walls of the sliver divider, deflection of the fibers upward, out of the sliver guide, can be prevented.
Regardless of the construction of the side faces of the sliver divider, the side walls of the sliver guide may also be embodied as concave or convex; this construction will depend on certain fiber parameters, which are clearly within the knowledge of the ordinary person skilled in the art.
The fifth embodiment of the sliver divider 613 according to the invention, as illustrated in FIGS. 6a to 6c, has a sliver guide 608 with adjustable side walls 609a and 609b. Longitudinal slots 612a and 612b have been milled into the side walls 609a and 609b, respectively, at right angles to the direction 621 of sliver travel. Bolts 611a and 611b, respectively, extend through the slots 612a and 612b and with them the side walls are firmly screwed to the support 610. Once these screws are loosened, the side walls can be displaced and rotated in the oblong slots. This makes it possible to perform special sliver divisions. The division of the sliver can be performed asymmetrically as well, with a stationary sliver divider 613, in order to divide the sliver into different sliver widths.
In the exemplary embodiment, the sliver divider 613 is disposed symmetrically between the two side walls 609a and 609b. The sliver divider 613 has a shape that is similar to a bow of an inverted ship, standing on its head. The blade or narrow edge 630 extends in the manner of the keel of a ship's bow. The sliver divider 613 is rotatable about a pivot shaft 631, which is perpendicular to the travel plane 632 of the sliver. Accordingly, it is also perpendicular to the support 610. The side walls 609a and 609b have a concave curvature, adapted to the bow-like shape of the sliver divider 613.
As can be seen in FIGS. 6a and 6b, the construction of the sliver divider 613 is symmetric with respect to a plane 633, which passes through the pivot shaft 631 and the narrow edge 630. The bow faces upstream, against the direction 621 of sliver travel. The side walls 609a and 609b have a funnel-like widening, to enable smooth entry of the sliver into the sliver guide.
As seen in all of the preceding exemplary embodiments, the narrow points in the sliver guide are located downstream of the pivot shaft 631 of the sliver divider 613, as viewed in the direction of sliver transport 621.
The section line C--C in FIG. 6b indicates the cross-section of the sliver divider and sliver guide in FIG. 6c. There, the bow shape of the sliver divider is particularly clearly visible.
Both the sliver divider and the side walls of the sliver guide should be constructed taking the fiber parameters into account. Short and smooth fibers behave differently during sliver division than long fibers, which have a tendency to kink. The sliver divider should part the sliver as gently as possible, and due to its shape displace the two separate strands laterally, as much as possible without disturbing the course of the fibers. The lateral displacement should be far enough so that separate processing of the strands becomes possible.
As a rule, the sliver divider should be easily movable about its vertical pivot shaft, so that it can rapidly follow fluctuations in the fiber content within the sliver and can bring about a suitable change or adjustment in the distribution ratio. With short, rough fibers, however, this could cause erratic behavior of the sliver divider. Accordingly, a sixth embodiment is therefore shown in FIGS. 7a and 7b in which a sliver divider can be protected against fluttering in such cases.
The sliver guide of FIGS. 7a and 7b is similar to the one shown in FIGS. 3 and 4. The sliver guide 708 comprises two guide walls 709a and 709b, which are disposed parallel and which widen in funnel-like fashion facing upstream toward the direction from which the sliver 721 is delivered. The sliver divider 713 is disposed symmetrically between the two guide walls. It is wedge-shaped and its narrow edge or blade 730 points counter to the direction 721 of sliver travel. Its direction of rotation about the axis 731 is perpendicular to the travel plane 732 of the sliver. The narrow edge 730 and the pivot shaft 731 are both located in a plane 733 that is perpendicular to the travel plane 732 and thus is perpendicular to the support 710 on which the guide walls 709a and 709b are disposed. A damping device 740, the contours of which are suggested in dashed lines, is disposed underneath the support 710.
The cross-section along the line B--B in FIG. 7a, which is illustrated in FIG. 7b, shows the damping device 740 in a side view. The action of the damping device 740 is adjustable. In the present exemplary embodiment, the damping device comprises a cylindrical cup 741 mounted underneath the support 710. The shaft 731 of the sliver divider 713 protrudes into this cup and has a vane 742, which completely fills one half of the cup cross section. In the same plane of the vane, directly behind it in the position of repose, the cup is divided in its other half by a fixed partition 743. The cup may be filled with air or with a damping fluid. The cup is divided into two halves by the vane 742 and the partition 743. If the sliver divider 713 is deflected to one side, the fluid or air is forced against the fixed partition 743 by the vane 742. Motion of the vane would be more or less prevented, if the partition 743 did not have an opening 744 through which the medium in the cup could flow into the other half. The size of the opening determines the quantity that can flow to the other half per unit of time and thus the damping action of the damping device 740 as well. For this reason, the opening 744 is closable to a variable extent by a slide 745. The damping action can thus be adjusted in an infinitely graduated manner.
The damping device illustrated in FIG. 7b is merely one exemplary embodiment of the damping devices known in the prior art. A person skilled in the art would be able to decide which type of damping device should be used with the invention according to the above specification in order to achieve the desired results.
The foregoing is a description corresponding in substance to German Application P 39 33 218.7, dated Oct. 5, 1989, the International priority of which is being claimed for the instant application under 35 U.S.C 119, and which is hereby made part of this application. Any material discrepancies between the foregoing specification and the aforementioned corresponding German application are to be resolved in favor of the latter.
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A sliver dividing device in a textile machine for a sliver travelling in a given direction comprises a sliver divider for dividing the sliver into at least two strands to be delivered to a work station for further processing. The sliver divider is movable in a direction substantially perpendicular to the given direction. In a preferred embodiment, the device includes guide walls for guiding the sliver with the sliver divider being disposed between the guide walls. In another preferred embodiment, the sliver divider is further rotateable about a pivot shaft and the guide walls are moveable and/or rotatable.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to water well operations and, more specifically, to a Shot Perforator Device and Method for Water Well Bore Decommissioning.
2. Description of Related Art
At the end of the life of a water well, it is generally not desirable to simply leave the well as an abandoned hole. The fear is that fall hazards, source contamination, or terrain collapses may occur and so it is not uncommon to be required to decommission the well by some means.
In the past, wells have been decommissioned through a variety of unsafe and/or ineffective methods. These methods have included attempts to fill the well casing with sand or gravel or even with concrete or cement. The problem with filling the casing is that only the inside of the casing is being filled as a result of these approaches and the surrounding area around the outside of the well casing remains a void that can cause future safety issues.
A more recent example of a method for well decommissioning is shown in Turley, et al., U.S. Patent Publication No. 2008/0128133. While Turley seeks to safeguard the abandoned well, it essentially uses a plug to do so. Although this approach will safeguard the top of the well for the purposes of falling hazards, it will not prevent cross contamination and future erosion of the terrain surrounding the well. What is needed is a system and method that will decommission a well and leave it in a condition that is safe from hydraulic cross contamination, erosion issues and fall hazards.
SUMMARY OF THE INVENTION
In light of the aforementioned problems associated with the prior systems and methods, it is an object of the present invention to provide a Shot Perforator Device and Method for Water Well Bore Decommissioning. Application of the method and device to a water well should permanently seal the well casing in order to prevent cross-contamination with other water wells in the area. The method should employ a string of explosive modules in spaced relation along the depth of a well's blank casing. This weighted string of explosive modules should be lowered into non-perforated sections of the well casing, wet concrete should then be introduced into the casing, after which the explosive elements should be detonated sequentially, starting at the top of the well. Detonation of the elements in such a manner should force the wet concrete or cement out through the newly-created well casing perforations, so that the well casing will be entirely encapsulated within the cured concrete. The individual explosive elements should be made from detonating cord and metallic ball bearings wrapped into bundles, and then the bundles should be wrapped up in suitable adhesive tape.
BRIEF DESCRIPTION OF THE DRAWINGS
The objects and features of the present invention, which are believed to be novel, are set forth with particularity in the appended claims. The present invention, both as to its organization and manner of operation, together with further objects and advantages, may best be understood by reference to the following description, taken in connection with the accompanying drawings, of which:
FIG. 1 is a partial side view of a preferred embodiment of a perforation element of the system of the present invention;
FIG. 2 is a shot perforation module utilizing three of the elements of FIG. 1 ;
FIG. 3 is a partial cutaway side view of a seal cap used in the module of FIG. 2 ;
FIG. 4 is a side view of a shot perforation assembly of the present invention using the modules and elements of FIGS. 1 and 2 ;
FIG. 5 is a cutaway side view of a well casing where the method of the present invention is being executed; and
FIGS. 6A and 6B are a flow chart depicting the steps of a preferred embodiment of the well decommissioning method by catastrophic perforation of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The following description is provided to enable any person skilled in the art to make and use the invention and sets forth the best modes contemplated by the inventor of carrying out his invention. Various modifications, however, will remain readily apparent to those skilled in the art, since the generic principles of the present invention have been defined herein specifically to provide a Shot Perforator Device and Method for Water Well Bore Decommissioning.
The device of the present invention and the method to use it involves the use of a custom-built, liner-shaped explosive device that will catastrophically destroy and decommission an abandoned water well bore. The objective of the device and method is to perforate and/or breach the well's casing while simultaneously injecting liquid cement or concrete just outside the well's casing (through the holes in the well casing). This process will prevent any hydraulic cross contamination from the well being decommissioned with any surrounding active or future well sites.
The present invention can best be understood by initial consideration of FIG. 1 . FIG. 1 is a partial side view of a preferred embodiment of a perforation element of the system of the present invention. The discrete item used to make up the decommissioning system is a perforation element 10 . A perforation element is a bundle of custom detonating cord wrapped in an explosive bundle along with several carbon steel ball bearings that will essentially create an explosive device that will shoot these ball bearings into the walls of the casing thereby creating perforations through which liquid concrete or cement can pass to the outside of the well casing.
The perforation element 10 comprises an explosive bundle made of a number of wraps 14 in a detonating cord 12 . The detonating cord preferably has a double layer PVC jacket that provides a water-tight environment and additional protection to the explosive material on the inside of the cord 12 . Since it is not uncommon for the system to be left sitting in water and/or liquid concrete or cement for ten hours or more in the course of the decommissioning process, the number of wraps 14 is guided by the size and condition of the well itself. For example, a perforation element 10 may have five to seven wraps 14 for well casings having a four- to six-inch diameter. In another example, 21 to 23 wraps 14 are used for a diameter of 20 to 22 inches. While the wraps 14 are created, a plurality of ball bearings 16 are being added along the way. These ball bearings 16 are preferably ⅜-inch diameter of carbon steel material; however, other size and composition bearings may be suitable. Once the wraps are complete for the element 10 , the element 10 will be bound with tape 8 such as conventional electrical tape. The binding tape 18 serves to increase the load factor of the explosives so that less explosives will create a more severe detonation and damage to the well casing. As shown here, the detonating cord 12 extends both upwardly and downwardly to the next element in the string.
If we now turn to FIG. 2 , we can examine how these elements are interrelated. FIG. 2 is a shot perforation module utilizing three of the elements of FIG. 1 . It should be understood that this is merely an example of how a series of elements 10 are interconnected to create each module 20 . Each module 20 is generally forty-six (46) feet in length, with the spacing 11 between elements 10 being between two and three feet (per element).
In this depiction, the first shot perforation module 20 is shown. This module 20 would be the top module in a string of modules making up the entire assembly as will be shown in more detail below in connection with FIG. 4 . The detonating cord 12 interconnects three shot perforation elements 10 as depicted above in FIG. 2 . The elements 10 are spaced by element spacing 11 . This spacing 11 will change depending on the diameter and condition of the well casing. For example, it is typical to have two-foot spacing for well casings having diameters of less than 12 inches while three-foot spacing would be used for those well casings equal to or greater than 12 inches in diameter. At the top end of the first shot perforation module 20 , the detonating cord terminates in a seal cap 22 which will be discussed below in connection with FIG. 3 . A detonator 24 is attached to the seal cap 22 and this detonator 24 will control the detonation of the entire first shot perforation module 20 . The other modules discussed below in FIG. 4 each have their own detonator. A lead line 26 extends from the first detonator to a safe area away from the well casing. The lead line 26 is an electrical cable that's used to detonate the detonators 24 . At the bottom end of the module 20 , a second seal cap 22 isolates the detonating cord 12 of the first shot perforation module 20 from the rest of the modules making up the system.
FIG. 3 discusses the structure of the seal cap. FIG. 3 is a partial cutaway side view of a seal cap used in the module of FIG. 2 . As shown here, the detonating cord 12 terminates in an end 13 which could be just a blank end as shown here or it could be an end where a detonator would be located. The seal cap 22 is a metal cap slid over the end 13 and then maintained in place permanently by a series of crimps 24 . The seal cap 22 prevents liquid from penetrating into the detonating cord and interfering with the explosive capability of the cord 12 .
FIG. 4 shows the overall shot perforation assembly. FIG. 4 is a side view of a shot perforation assembly of the present invention using the modules and elements of FIGS. 1 and 2 . As shown here, a series of modules 20 , 32 , 34 are interconnected and spaced out along the length of the well casing. At the bottom end, a weight 36 is hung from a long piece of wire, such as piano wire, that runs the entire length of the assembly 30 . The wire (not shown) supports all of the elements of the modules 20 , 32 , 34 , and is tied off at its end at the weight 36 . The wire relieves the stress of the hanging weight from the detonating cord interconnecting the modules and elements.
The weight 36 , hanging from the assembly 30 below the third module 34 serves to prevent the shot perforation assembly 30 from floating upward from its desired pre-detonation position when the wet cement or concrete is introduced into the well casing. The weight 36 is at least ten pounds in weight and has a length that is greater than the casing diameter. These aspects will also aid in preventing the assembly 30 from floating away from its placement position. As discussed above, the lead line 26 terminates at the detonator 24 and seal cap 22 which comprised the top end of the first perforation module 20 . The second perforation module 32 terminates in a seal cap at its top end and a seal cap 22 and detonator 24 at its bottom end. Similar to the first module 20 , the third module 34 has a seal cap 22 and detonator 24 at its top end and terminates in a seal cap 22 at its bottom end. Generally the upper seal cap 22 and detonator 24 for the complete assembly 30 is placed approximately 6 to 10 feet below the surface of the wet cement or concrete and can extend as deep as 100 or 150 feet. A typical module length is approximately 46 feet, with a elements spaced at approximately 2 to 3 feet. The lead line 26 is generally fifteen (15) feet long, with its conductive end fitting being connected to a Shooting Panel (device outside of the well area that controls the detonation).
FIG. 5 depicts the initial steps of the perforation process. FIG. 5 is a cutaway side view of a well casing where the method of the present invention is being executed. In FIG. 5 we see prior to detonation of the assembly 30 . A trim pipe 38 has been inserted into the well casing 40 so that liquid concrete or cement can be introduced to the well casing 40 all the way at the bottom of the well casing 40 without damage to the assembly 30 . A concrete pumper would be hooked up to the top end of the trim pipe 38 in order to introduce the concrete. The perforation assembly 30 is dropped into the well casing 40 and the lead line 26 is threaded out through a protective sleeve 42 . The protective sleeve 42 is typically going to be made from a plastic material that is hard to prevent crushing yet flexible to allow for adjustment due to terrain or orientation of the other elements in the system. Once the concrete has been completely introduced into the well casing, the trim pipe is removed and the cover plate 44 is laid atop the protective sleeve 42 and then chained to the ground.
As discussed above, the lead line 26 extends approximately ten (10) feet down into the well casing 40 , leaving approximately five (5) feet of lead line 26 outside of the well casing 40 , connected to the shooting panel (not shown).
The flow chart of FIGS. 6 a and 6 b provide additional detail regarding this new method. FIGS. 6 a and 6 b are a flow chart depicting the steps of a preferred embodiment of the well decommissioning method by catastrophic perforation of the present invention. The well decommissioning method by catastrophic perforation 46 commences by lowering the trim pipe into the well 100 as shown above in FIG. 5 ; however, in order to create the perforation assembly, the well casing must first be inspected by camera in order to derive the placement and number of wraps on the perforation elements of binding tape as well as the spacing of the perforation elements which is a function of the diameter, age and condition of the well casing. The only way to truly ascertain these conditions is through visual inspection. Once the trim pipe has been lowered into the well 100 the shot perforation assembly is lowed into the well casing beside the trim pipe 102 . At this point, liquid concrete or cement is injected into the well until the well casing is full 104 . The trim pipe is then removed 106 and the well is covered with a cover plate that is then attached to the ground with chains 108 . Generally a safety weight is placed atop the cover plate 110 such as a 300-pound dead weight that can be easily lifted by a forklift or crane. Once the safety weight is in place, the shot perforation modules are detonated 112 . What is unique here is that the elements are not detonated simultaneously, but rather are detonated sequentially. The top module is detonated first 112 a after which the middle module is detonated 112 b and then the bottom module is finally detonated 112 c . The modules are detonated at approximately one-and-a-half second intervals. The result is to utilize the weight and viscosity of the cement or concrete and to sequentially cause the concrete to compress down into the well and push out through the perforations formed in the wall of the well casing. This creates a continuous squeezing effect, forcing wet concrete or cement to be pushed down and out through the perforations into the surrounding area around the well casing. Once the detonations have occurred, the cover plate is removed 114 and a mechanical depth sounding is performed in order to confirm that the liquid concrete or cement level has dropped adequately. It is common for that liquid level to drop one-third the overall length of the shot perforation assembly 30 . The well is then refilled with cement or concrete 118 to within five feet of the top of the well. Approximately 24 hours later after the initial cure is complete, the area around the well casing is excavated to a depth of approximately ten feet, the top of the well casing is cut off and removed, a cement or concrete “mushroom cap” is poured over the casing, and, finally, the hole is refilled with the dirt that was initially removed 120 which then completes the method 122 .
Those skilled in the art will appreciate that various adaptations and modifications of the just-described preferred embodiment can be configured without departing from the scope and spirit of the invention. Therefore, it is to be understood that, within the scope of the appended claims, the invention may be practiced other than as specifically described herein.
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Application of the method and device to a water well will permanently seal the well casing in order to prevent hydraulic cross-contamination with other water wells in the area. The method employs a string to explosive modules in spaced relation along the depth of a well casing. This weighted string of explosive modules is lowered into the well casing, wet concrete should then be introduced into the casing, after which the explosive elements are detonated sequentially, starting at the top of the well. Detonation of the elements in such a manner should force the wet concrete or cement out through the well casing perforations, so that the well casing will be entirely captured within the cured concrete. The individual explosive elements are made from detonating cord and metallic ball bearings wrapped into bundles, and then the bundles are bound in suitable adhesive tape.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of Korean Patent Application No. 10-2013-0009665 filed on Jan. 29, 2013, which is hereby incorporated by reference in its entirety into this application.
BACKGROUND OF THE INVENTION
[0002] 1. Technical Field
[0003] The present invention relates generally to a building energy management apparatus and method. More particularly, the present invention relates to technology for extracting and managing objects of a building related to the energy of the building based on a Building Information Model (BIM) required to manage the life cycle of the building (design, construction, start-up, maintenance, etc.), thus efficiently managing building energy.
[0004] 2. Description of the Related Art
[0005] Recently, due to a remarkable rise in oil prices and an exponential increase in power consumption, the need for energy management has increased. In order to manage the energy of buildings, it is required to manage both a part for supplying energy to each building and a part for consuming the energy of the building. Building energy includes electricity, gas, water, etc., and methods for supplying such energy include methods based on electric equipment and heat source equipment. Gas is converted into thermal energy and supplied to buildings for air-conditioning. The part of the building consuming supplied energy includes, for example, lighting equipment, electric heating equipment, and heat source equipment in the case of electricity, air-conditioning spaces in the case of thermal energy, and restrooms and shower rooms in the case of water supply.
[0006] Generally, a system for managing the facilities of each building is called a Building Automation System (BAS), and mainly denotes a system for managing pieces of heat source equipment. A BAS is in charge of the state management and control of pieces of heat source equipment in a building. For example, the inlet and outlet temperatures of cold water of a chiller/heater, the inlet and outlet temperatures of coolant, the operations of various types of pumps, and the operations of various types of air-conditioning fans are monitored and controlled. In conventional technology disclosed in Korean Patent Application Publication No. 10-2010-0075040 or the like, when a BAS is installed, a list of facilities, sensors, and meters installed in each building and locations thereof are taken into consideration, and the facilities, sensors and meters are mapped to and set in a computer system via manual operations in most cases, thus enabling various types of information to be converted into and managed as digital information.
[0007] However, such an installation method is disadvantageous in that the number of manual operations that must be conducted by persons can be increased and work time can be lengthened, and in that, when the scale of each building is increased, a workload and work time show a tendency to increase in proportion to the scale of the building. Therefore, there is required a scheme for reducing the need for manual operations by a person and automatically converting building energy objects into digital information.
SUMMARY OF THE INVENTION
[0008] Accordingly, the present invention has been made keeping in mind the above problems occurring in the prior art, and an object of the present invention is to provide a method of reducing the number of manual operations conducted by persons and automatically extracting as many building energy objects as possible, thus enabling the implementation of digital information.
[0009] Another object of the present invention is to provide an apparatus and method that extract building energy objects from BIM data by utilizing a BIM used as a standard in the fields of buildings and convert the building energy objects into digital information in the form of a database (DB), and that connect the building energy object DB to sensors, meters, heat source equipment, lighting equipment, etc. in an actual building, thus monitoring the states of the building and managing building energy based on the building energy object DB.
[0010] In accordance with an aspect of the present invention to accomplish the above objects, there is provided a building energy management apparatus including a Building Information Model (BIM) analysis unit for receiving and parsing BIM data and then analyzing BIM objects; a building energy object extraction unit for extracting building energy objects related to building energy from the BIM objects; a building energy object database (DB) for storing a building energy object data into a DB by arranging the building energy objects; and a building energy management unit for managing energy of a building based on the building energy object data.
[0011] Preferably, the building energy management apparatus may further include a building energy object management unit for managing the building energy object DB.
[0012] Preferably, the BIM analysis unit may parse the BIM data through an Industry Foundation Classes (IFC) browser.
[0013] Preferably, the building energy object extraction unit may include a mapping table for indicating relationships between the BIM objects and the building energy objects; and a control unit for transferring objects corresponding to the mapping table, among the BIM objects, to the building energy object DB, wherein the mapping table can be revised by a manager.
[0014] Preferably, the building energy object DB may include an interface operating in conjunction with a sensor or a meter present in the building.
[0015] Preferably, the building energy object DB may periodically store data about building energy-related actual objects, such as a sensor, a meter or a Building Automation System (BAS) present in the building.
[0016] Preferably, the building energy object management unit may add, remove or replace object data of the building energy object DB as a sensor, a meter or a BAS of the building is added, removed or replaced.
[0017] Preferably, the building energy management unit may sense a condition of energy supply and manage the supply of energy to the building, or sense a condition of energy consumption and manage energy consumption of the building.
[0018] In accordance with another aspect of the present invention to accomplish the above objects, there is provided a building energy management method including receiving and parsing Building Information Model (BIM) data and then analyzing BIM objects; extracting building energy objects related to building energy from the BIM objects; storing a building energy object data into a DB by arranging the building energy objects; and managing energy of a building based on the building energy object data.
[0019] Preferably, the building energy management method may further include managing the building energy object DB.
[0020] Preferably, analyzing the BIM objects may be configured to parse the BIM data through an Industry Foundation Classes (IFC) browser.
[0021] Preferably, extracting the building energy objects may be configured such that objects corresponding to a mapping table, among the BIM objects, are stored in the building energy object DB, the mapping table indicates relationships between the BIM objects and the building energy objects, and the mapping table can be revised by a manager.
[0022] Preferably, the building energy object DB may include an interface operating in conjunction with a sensor or a meter present in the building.
[0023] Preferably, the building energy object DB may periodically store data about building energy-related actual objects, such as a sensor, a meter or a Building Automation System (BAS) present in the building.
[0024] Preferably, managing the building energy objects may be configured to add, remove or replace object data of the building energy object DB as a sensor, a meter or a BAS of the building is added, removed or replaced.
[0025] Preferably, managing the building energy objects may be configured to sense a condition of energy supply and manage the supply of energy to the building, or to sense a condition of energy consumption and manage energy consumption of the building.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] The above and other objects, features and advantages of the present invention will be more clearly understood from the following detailed description taken in conjunction with the accompanying drawings, in which:
[0027] FIG. 1 is a block diagram showing a building energy management apparatus according to the present invention;
[0028] FIG. 2 is a diagram showing the configuration of a building energy object extraction unit; and
[0029] FIG. 3 is a flowchart showing a building energy management method according to the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0030] The present invention will be described in detail below with reference to the accompanying drawings. In the following description, redundant descriptions and detailed descriptions of known functions and elements that may unnecessarily make the gist of the present invention obscure will be omitted. Embodiments of the present invention are provided to fully describe the present invention to those having ordinary knowledge in the art to which the present invention pertains. Accordingly, in the drawings, the shapes and sizes of elements may be exaggerated for the sake of clearer description.
[0031] A building energy management apparatus according to the present invention includes a Building Information Model (BIM) analysis unit for analyzing data about all elements of each building included in a BIM, a building energy object extraction unit for extracting building energy objects from analyzed BIM data, a building energy object database (DB) for storing the extracted building energy objects in a DB, a building energy object management unit for adding, removing or revising stored building energy objects, and a building energy management unit for performing the management of building energy based on the data stored in the building energy object DB.
[0032] Hereinafter, the operation of the building energy management apparatus according to the present invention will be described in detail.
[0033] FIG. 1 is a block diagram showing a building energy management apparatus according to the present invention.
[0034] Referring to FIG. 1 , a building energy management apparatus 100 includes a BIM analysis unit 110 , a building energy object extraction unit 120 , a building energy object DB 130 , a building energy management unit 140 , and a building energy object management unit 150 .
[0035] The BIM analysis unit 110 performs tasks for loading a BIM data file 10 , parsing all information of a building included in the input file according to the format of a standardized Industry Foundation Classes (IFC) file, and discriminating shapes, attributes, and elements recorded in IFC data. Generally, for efficient and systematic management during the life cycle of the building, a BIM is widely used. Currently, a BIM is frequently required by an orderer even when a building is constructed. “BIM” designates a digital model for providing a reliable basis for making a decision during the life cycle of facilities depending on the physical or functional characteristics of facility objects in all construction fields including construction, engineering works, and plants, and also designates task procedures for creating the digital model. BIM includes BIM objects required to design, construct, and maintain a building, such as the shape information, structure information, and internal material information of the building. IFC denotes a certified international standard specification used to implement an open BIM in such a way that various software elements openly share or exchange model information, and has been used as a BIM data exchange standard. IFC can be mainly classified into product, process, resource, actor, control, and group. Further, detailed information models are defined for respective groups. A modeling language used for definition is EXPRESS, and relationships between individual objects are defined in detail in an object-oriented manner depending on the features of the EXPRESS language. Here, “object” denotes a house, a wall, a pillar, a window, etc., and “relationship” means that inclusion, aggregation, dependence, etc. are present between objects.
[0036] The BIM analysis unit 110 may use an IFC browser as a tool for utilizing the BIM, and function to parse the IFC data of the BIM, render the parsed data in a 3D form, and show various types of construction information through the IFC browser. The BIM analysis unit of the present invention functions to identify space-based objects and attribute information by parsing the IFC data.
[0037] The building energy object extraction unit 120 functions to extract information to be managed from the standpoint of building energy, based on the results of analyzing the IFC data by the BIM analysis unit 110 . For example, objects for supplying energy in a building include a freezer, a boiler, a heat charging pump, a cooling pump, a cooling fan, an air-conditioning fan, a damper, a fan coil unit, etc. Cases where energy is consumed in a building include a case where heating/cooling is activated in an indoor space, a case where electric heating power used by office products or the like is consumed, a case where lighting power is consumed, etc. In particular, in the case of heating/cooling, energy may be wasted due to doors, windows or blinds of an indoor space, and energy may also be wasted even when lighting equipment and electric heating equipment are excessively used. Building objects of the indoor space related to waste may be building energy objects. The building energy object extraction unit 120 functions to extract the above objects, together with the attributes of the objects, as energy objects, from the results of the analysis by the BIM analysis unit 110 .
[0038] The building energy object DB 130 is a DB for storing data about objects for the energy management of the building. The building energy object DB 130 is storage for storing building energy objects extracted by the building energy object extraction unit 120 . The building energy object DB 130 accumulates time-series data by continuously incorporating time-varying values of the objects occurring in the building into the stored building energy object data and storing resulting values. The stored data may be data of sensors or meters installed in the building, and may generally be data received from a system called a Building Automation System (BAS). The data of sensors or meters denotes data, such as a temperature, humidity, motion (presence of a person in an indoor space), illuminance, a flow rate, air volume, a pressure, and a water temperature. The data of the BAS generally denotes information obtained from a system called a Central Control Monitoring System (CCMS), and refers to information, such as a freezer, a boiler, a pump, an air-conditioning fan, a damper, a water pressure, air volume, a flow rate, and hot and cold water temperatures. The data of the BAS may also include information such as lighting and electric heating. Further, the data of the BAS may include other types of information related to the building.
[0039] Moreover, the building energy object DB 130 is implemented in the form of a DB table as an easily managed form from the standpoint of energy of the building, and has columns in which monitored values of actual objects can be recorded. The building energy object DB 130 has an interface operating in conjunction with sensors or meters actually present in the building, and periodically records actually measured sensor values or meter values. Further, the building energy object DB 130 has an interface operating in conjunction with the BAS, and periodically records monitored values of the BAS. Therefore, the building energy object DB continuously accumulates and records the state information of the sensors, meters, and BAS, which are generated with time in the building. Such accumulated information is utilized as basic data for the management of building energy. In this case, the building energy object DB is composed of a plurality of tables, wherein the number of tables is variable without being limited, depending on the scale and characteristics of a building or the number and characteristics of objects.
[0040] The building energy management unit 140 functions to manage a waste of energy in the building based on the data of the time-varying building energy objects accumulated in the building energy object DB 130 , and induce optimal energy consumption if possible. For example, the building energy management unit 140 performs the operation of turning off lighting when no one is present in an indoor space, or turning off an air-conditioning fan or a fan coil unit in a situation in which air-conditioning is unnecessary. Alternatively, in a space, such as a conference room, which is variably used, energy is managed according to a reservation scheduling in such a way that when a reservation is not made, air-conditioning is not performed or lighting power is turned off. That is, the building energy management unit 140 functions to sense the operating states of energy supply parts of a building, for example, a freezer, a boiler, an air-conditioning fan, a pump, and a cooling fan, based on the building object data accumulated in the building energy object DB, and optimize the supply of energy, thus managing building energy. Further, the building energy management unit 140 performs the management function of sensing elements consuming the energy of the building based on the building object data stored in the building energy object DB, recognizing the condition of a waste of energy, and then reducing the consumption of building energy. In this way, the building energy management unit 140 enables optimal energy consumption to be performed in consideration of the condition of the waste of energy in relation to the states of energy objects of the building using various methods.
[0041] The building energy object management unit 150 functions to add, remove or revise the object data of the building energy object DB when a sensor, a meter, or a BAS is added to or removed from the building or is replaced with another one in the building. By means of this function, the connection interface between the individual objects of the building energy object DB 130 and existing sensors, meters, and BAS is changed depending on the degree of a change. Further, the building energy object management unit 150 is also used to map the objects of sensors and meters of the building and the objects of the BAS to the building energy object DB 130 .
[0042] Hereinafter, the configuration of the building energy object extraction unit according to the present invention will be described.
[0043] FIG. 2 is a diagram showing the configuration of the building energy object extraction unit.
[0044] Referring to FIG. 2 , the building energy object extraction unit 120 includes a control unit 121 and a mapping table 122 . The building energy object extraction unit 120 may include the mapping table 122 including rules for mapping between BIM objects obtained from BIM data through the BIM analysis unit 110 and objects of the building energy object DB 130 . Then, the building energy object extraction unit 120 may include the function of selecting objects obtained from the BIM analysis unit 110 and transferring the selected objects to the building energy object DB 130 . The mapping table 122 may be revised by a manager depending on the change in the structure, shape, sensors, meters, and the BAS of the building.
[0045] Referring to back FIG. 2 , the control unit 121 is configured to compare a BIM object received from the BIM analysis unit 110 with the mapping rules stored in the mapping table 122 , and if the received BIM object is present in the mapping table 122 , add a building energy object to the building energy object DB 130 depending on the rules of the mapping table 122 . In this case, the control unit 121 functions to extract the building energy object stored in the mapping table 122 from all pieces of data received from the BIM analysis unit 110 .
[0046] Hereinafter, a building energy management method according to the present invention will be described in detail.
[0047] FIG. 3 is a flowchart showing a building energy management method according to the present invention.
[0048] Referring to FIG. 3 , the building energy management method is performed in the sequence of steps S 110 to S 140 . At step S 110 , BIM data is received and parsed, and then BIM objects are analyzed. At step S 120 , building energy objects related to building energy are extracted from the BIM objects. At step S 130 , the building energy objects are arranged into a DB, and then data about building energy objects is stored in the building energy object DB. At step S 140 , the energy of the building is managed based on the building energy data. If the respective steps are performed, a building energy management system may be easily implemented from the BIM data. Here, the building energy management method according to the present invention may be performed to further include the step of managing the building energy object DB.
[0049] Step S 110 denotes the step of parsing the BIM data based on the standard format of a BIM, and analyzing pieces of information including individual objects and the attributes of the objects.
[0050] Step S 120 denotes the step of extracting objects required for the management of building energy from the BIM objects obtained at step S 110 .
[0051] Step S 130 denotes the step of storing the building energy objects obtained at step S 120 in a DB.
[0052] Step S 140 denotes the step of managing the energy of the building based on the building energy objects stored at step S 130 and actual data stored in correspondence with the building energy objects.
[0053] As described above, the present invention is advantageous in that, in order to solve the disadvantages of the above-described conventional technology, the number of manual operations conducted by persons is reduced and as many building energy objects as possible are automatically extracted, thus enabling the implementation of digital information.
[0054] Further, the present invention is advantageous in that it extracts building energy objects from BIM data by utilizing a BIM used as a standard in the fields of buildings and converts the building energy objects into digital information in the form of a DB, and it connects the building energy object DB to sensors, meters, heat source equipment, lighting equipment, etc. in an actual building, thus monitoring the states of the building and managing building energy based on the building energy object DB.
[0055] As described above, in the building energy management apparatus and method according to the present invention, the configurations and schemes in the above-described embodiments are not limitedly applied, and some or all of the above embodiments can be selectively combined and configured so that various modifications are possible.
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Disclosed herein is a building energy management apparatus and method. The building energy management apparatus includes a Building Information Model (BIM) analysis unit for receiving and parsing BIM data and then analyzing BIM objects. A building energy object extraction unit extracts building energy objects related to building energy from the BIM objects. A building energy object database (DB) stores a building energy object data into a DB by arranging the building energy objects. A building energy management unit manages energy of a building based on the building energy object data. Accordingly, the present invention provides technology for extracting and managing objects of a building related to the energy of the building based on a BIM, thus efficiently managing building energy.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to synthetically derived high density liquid hydrocarbon fuels.
2. Description of the Prior Art
High density liquid hydrocarbon fuels are characterized in having a net volumetric heat of combustion in excess of about 140,000 BTU per gallon. A high density or high energy fuel is essentially required for fueling turbojet and ramjet propelled limited volume missile systems. Beyond the need for a high energy content in order to maximize range performance of the missile, there are other requirements in the forefront depending, in the main, on the manner in which the missile is to be deployed. For instance, in the air-borne deployment of a missile where the latter is carried exteriorly of the aircraft, the fuel must exhibit the combination of a very low freeze point, high volatility and be reasonably fluid at the low temperatures encountered.
A high density fuel of the foregoing type does not occur in nature rather must be chemically synthesized. Essentially all of the current generation of such fuels commonly feature a norbornane moiety having an additional cyclic hydrocarbon appendage. A noteworthy fuel of the foregoing type is represented by the exo-stereo isomer of tetrahydrodicyclopentadiene which in commerce is generally referred to as JP-10. The latter is prepared by first hydrogenating dicyclopentadiene yielding the solid endo-isomer of the hydrogenated derivative. The endo structure is then isomerized in the presence of a catalyst to produce the exo-isomer almost quantitatively in a relatively pure form. Since JP-10 is derived from abundantly available raw materials coupled with the fact that the isomerization procedure is highly developed, such are the main factors why the product is regarded as a prime fuel.
Neat JP-10, however, fails as a universal fuel because of its flash point. The flash point of JP-10 is too low, although only marginally so, for ship or submarine launching operations; whereas, it is considerably higher than that required in air-borne deployment of the missile system. The object of this invention, accordingly, is that of modifying JP-10 in a manner whereby the flash point is substantially reduced without significantly diluting the high heat content associated with the fuel itself.
SUMMARY OF THE INVENTION
In accordance with the present invention, a high density fuel composition is provided which is essentially completely composed of JP-10. The contemplated compositions further contain from 0.1-weight percent of a C 3 -C 7 and more preferably a C 3 -C 5 cyclic or acyclic alkane as a flash point depressant. Neat JP-10 exhibits a flash point of 131±1° F. and a volumetric heat content of 141,880 BTU per gallon. Depending on the selection of the indicated depressants and the amount thereof utilized, the flash point of a fuel composition in accordance with this invention can be extensively varied ranging to 35° F. or lower while maintaining an overall heat value of at least. 140,000 BTU per gallon.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
As indicated previously, JP-10 is a commercially available product. However, for a more complete understanding of the best mode contemplated for carrying out the present invention, it will be desirable to comment briefly on the process applicable for producing this fuel. Further details regarding this process can be found in U.S. Pat. No. 3,381,046. The first step involved is that of completely hydrogenating dicyclopentadiene to provide the endo-stereo isomer of the tetrahydro derivative. Generally hydrogenation is carried out in two stages. In the first stage the 8,9 positions of the dimer are hydrogenated at a temperature generally in the order of about 120° C. The dihydro derivative is relatively thermally stable, thus permitting the use of a substantially higher temperature in the second stage, viz., in the order of about 215° C. Hydrogenation is carried out in the second stage to the extent whereby the resultant tetrahydro derivative exhibits a melting point of at least about 70° C. Hydrogenation pressure conditions range from about 5-15 atmospheres.
In the second step of the process the endo isomer of the tetrahydro derivative is isomerized to the exo form. The crude hydrogenation product or an appropriate distilled fraction thereof, rich in the exo-isomer content, can alternatively be subject to isomerization in accordance with the prior art. In the context of the present invention, however, it is advantageous to utilize the total crude hydrogenation product in the isomerization reaction. The isomerization is carried out in the presence of a variety of acidic catalysts such as the Bronsted or Lewis acids. The Lewis acids and specifically, aluminum chloride, are preferred from the standpoint of inducing a rapid reaction rate. On the other hand, aluminum chloride has a tendency to cause the isomerization to proceed beyond the exo isomer thereby resulting in the objectionable formation of substantial amounts of transdecalin and adamantane. Accordingly, due care must be exercised in the utilization of this catalyst.
The extent of conversion to the exo isomer can be conveniently monitored by vapor liquid gas chromatography. Upon attaining substantially complete conversion; i.e., 98+%, the reaction mixture is cooled to about 80° C. to provide, upon settling, a two-phase system thereby permitting recovery of the fuel from the sludge by decantation. The product is then fractionally distilled to provide a heartcut which consists essentially of the exo isomers. If the crude hydrogenation product is employed in effecting the isomerization reaction, a forecut of the isomerization reaction product will be essentially composed of isomeric pentanes with the major portion thereof, i.e., about 70 percent, being cyclopentane. This forecut represents an effective flash point depressant in accordance with this invention and is especially suited for this purpose. Other alkanes applicable for use in the practice of this invention include cyclopropane, butane and mixtures thereof.
EXAMPLE
This example is illustrative of the manner of modifying commercial JP-10 in accordance with this invention to achieve a lower Seta flash point without significantly diluting the net heat content thereof. The flash point depressants utilized were cyclopropane, butane and an isomeric mixture of pentanes. The results obtained are set forth in the following tables.
TABLE 1.______________________________________PENTANES* IN JP-10 Net Heat ofSample Wt. % Wt. % Flash CombustionNumber Pentanes* JP-10 Point (°F.) BTU/gallon______________________________________1 0.53 99.47 120 141,7702 1.07 98.93 105 141,5903 1.76 98.24 87 141,4504 1.95 98.05 70 141,2805 2.45 97.55 64 141,1406 2.76 97.24 53 141,1007 0.00 100.00 131 141,880______________________________________ *Mixture of 10.5% Isopentane, 18.0% nPentane, and 71.5% Cyclopentane
TABLE 2.______________________________________BUTANE IN JP-10 Net Heat ofSample Wt. % Wt. % Flash CombustionNumber Butane JP-10 Point (°F.) BTU/gallon______________________________________1 0.16 99.84 120 141,8102 0.35 99.65 84 141,7403 0.53 99.47 69 141,6604 0.91 99.09 31 141,5105 0.00 100.00 132 141,880______________________________________
TABLE 3.______________________________________CYCLOPROPANE IN JP-10 Net Heat ofSample Wt. % Wt. % Flash CombustionNumber Cyclopropane JP-10 Point (°F.) BTU/gallon______________________________________1 0.66 99.34 <35 141,7902 0.45 99.55 45 141,8203 0.28 99.72 76 141,8404 0.06 99.94 120 141,8705 0.00 100.00 132 141,880______________________________________
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A high density fuel composition having low temperature operational capability for propelling turbo-jet, limited volume missile systems consisting essentially of at least 95 weight percent exo-tetrahydrodicyclopentadiene (JP-10) and a correspondingly minor amount of a C 3 -C 7 saturated hydrocarbon.
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BACKGROUND OF THE INVENTION
The invention disclosed herein relates to toy objects equipped with a radiating (wave) energy (e.g., light) projector, a radiated energy detector, or both, which may be configured as action figures (including dolls), robots, vehicles, etc., and which are manipulatable by a human player, or by remote control, to play a shooting game in which the toy objects are the participants.
Toys for playing a shooting game in which human players are the participants are currently available, for example, from Toymax Inc. of Plainview, N.Y. under the trademark "Laser Challenge". The following U.S. patent applications, the disclosures of all of which are incorporated herein by reference, relate to toy light projecting and/or detecting guns and targets marketed by Toymax Inc.: 08/795,895, filed Feb. 5, 1997, titled "Interactive Light-Operated Toy Shooting Game"; Ser. No. 08/871,248, filed Jun. 9, 1997, titled "Interactive Toy Shooting Game Having A Feelable Output"; Ser. No. 09/15,863, filed Jan. 29, 1998, titled "Player Programmable, Interactive Toy For A Shooting Game"; and Ser. No. 09/19,747, filed Feb. 6, 1998, titled "Computer Programmable, Interactive Toy For A Shooting Game". These applications are referred to below as "the cited patent applications".
U.S. Pat. Nos. 5,375,847 and 4,844,474 discloses toys which detect light fired from a gun operated by a human player. In the '847 patent, the toy is a toy soldier which topples when hit. In the '474 patent, the toy is a vehicle which mechanically explodes when hit.
The patent applications and patents identified above disclose apparatus used by at least one player as a direct participant in a shooting game, whereas the invention herein relates to toy objects in the form of toy action figures, robots, vehicles, etc., which are the game participants and are provided with shooting and detecting apparatus. Of course, children have long used passive toy objects as participants in shooting games simulated entirely by imagination, i.e., a child manipulates the toy object, provides sound effects and determines in his or her imagination whether the toy object hit the intended target. As disclosed for example in U.S. Pat. No. 5,073,140, the disclosure of which is incorporated herein by reference, sound effects and speech may be provided to such otherwise passive toy objects. However, there is no interactivity between these passive toy pieces.
U.S. Pat. Nos. 4,840,602 and 4,857,030 disclose toy dolls which each generate voice messages to which the other apparently responds. Though there is apparent interactivity between the dolls, a child is more of an observer than a participant in that interactivity.
In today's hi tech environment, where electronic toys are ubiquitous, and electronic and computer games are being played by younger and younger children, non-interactive and purely mechanical toys have little play value for use in a shooting game. More realism with less imagination is needed to attract and hold the attention of modern children. At the same time, electronics and high tech in toys are frequently accompanied by high cost.
U.S. Pat. No. 4,938,483 discloses a multi-vehicle interactive toy system comprising military tanks controlled wirelessly with a joystick that shoot and detect infrared ("IR") light. The toy objects disclosed in the '483 patent are required to perform interactive tasks under remote control, and likely are relatively expensive and may be difficult for younger children to operate. See also U.S. Pat. No. 5,127,658.
U.S. Pat. No. 5,029,872 discloses a spaceship toy also controlled by a joystick (though not wirelessly) that fires light at targets embedded in a screen. The targets disclosed in the '872 patent do not move, and do not shoot back. Also, the space ship does not include a detector for detecting light shot at the space ship. Although the toy disclosed in the '872 patent is interactive, i.e., the targets on the screen detect light shot at them and indicate hits, a game played with a stationary screen is not very realistic or interactive, especially after playing a few games.
OBJECTS AND SUMMARY OF THE INVENTION
There is a need for a simple, low cost toy which provides high tech, interactive toy objects which participate in a shooting game under control of one or more human players.
It is an object of the invention disclosed herein to provide such a toy.
It is another object of the invention to provide toy objects which radiate energy, and can be simply controlled, e.g., moved, aimed and fired by a player, and/or which detect radiated energy and can be simply moved to avoid being hit.
It is another object of the invention to embody the toy objects described herein as various objects with which children have traditionally played, such as human, space, animal or creature action figures, military and space vehicles, etc.
It is another object of the invention to provide toy parts removably or non-removably attached to, or forming a part of, toy objects which incorporate an energy emitter, or sensor, or indicating device, or circuit, or combinations thereof.
It is another object of the invention to provide such toy figures in greatly reduced scales as compared to the height of the actual or imagined object, e.g., ranging down to a few inches in height.
The invention provides interactive toy objects which project (emit) and/or detect radiated energy , and which are manually controlled by one or more players. Though manually controlled, these toy objects are high tech in that they project and/or detect radiated energy. (Radiation, radiated and wave energy are meant in a broad sense to encompass visible and IR light energy, electromagnetic energy, electrostatic energy, sound energy, etc.) Complex and expensive electronics are not needed, but the high tech effect of a radiated energy shooting game, for example, a laser-type shooting game, is nonetheless realized. Thus, the invention can provide the play value of a high tech toy at low cost.
The invention also provides a toy part, e.g., an accessory, for a toy object to which are mounted or coupled some or all of the components used to project and detect radiated energy, and the combination of the accessory and the toy object. Such a toy part can facilitate manufacture of a toy which includes a radiation emitter and sensor (detector), particularly in the case of small toys such as action figures (including dolls) and miniature vehicles. (Radiation sensor and radiation detector are meant in a broad sense and sometimes are used interchangeably herein. A radiation sensor and a radiation detector typically provide an output in response to received radiation. A detector may include processing circuitry. Use of each term may encompass the other, unless the context indicates otherwise.)
When made removable, such a toy part provides play value in addition to the play value resulting from the high tech nature of a radiated energy shooting game. For example, toy parts can be made interchangeable and provided with different features, capabilities, configurations, visual appearances, etc. Children can collect an inventory of toy parts, and choose depending upon the particular shooting game or set of conditions. Play value is provided in collecting such toy parts, choosing the appropriate toy part, and the ability to use different toy parts, which also reduces the possibility that the child will become bored with the same, unchangeable toy.
The invention toy part may be an accessory such as a backpack for an action figure, or a removable emitter, e.g., one that can be plugged into and unplugged from the toy object or the toy part therefor, or a part of a vehicle such as a tank turret. The emitter preferably is associated with a weapon or a feature of the toy object.
The invention provides numerous inventive embodiments and configurations of the toy objects and the accessory.
As discussed above, remote control of toys imparts play value to the toys, as does use of removable parts including accessories and emitters for the toy objects disclosed herein. It is within the contemplation of the invention to provide toy objects with removable parts that are also remote controlled, i.e., the toy object, the toy part may be remote controlled. Such remote control may be achieved conventionally using radio transmission or infrared light transmission.
In one configuration, the invention provides a toy which includes a plurality of toy objects which are compatible (e.g., with respect to operability, theme (e.g., military, police, space, etc.), size, visual appearance, configuration, etc. ) for playing a shooting game in which the objects, as manually controlled by one or more human players, are game participants. The toy comprises a first toy object including a first energy source that radiates (emits) energy and a first circuit coupled to the energy source to cause the energy source to selectively radiate energy. The first toy object is manually movable during play by a human player to direct radiated energy from the first energy source in a selectable direction.
The toy comprises a second toy object including a first energy sensor responsive to energy radiated (emitted) by the energy source of the first toy object and a second circuit coupled to the sensor which makes a determination that a hit has occurred when energy received by the sensor is compatible with energy emitted by the energy source of the first toy object. The second toy object is manually movable during play by a human player to face the first energy sensor in a selectable direction. The toy also comprises at least one hit indicator device coupled to the second circuit which is responsive to the second circuit to provide an audible or visual output when the second circuit determines a hit has occurred.
The first and second circuits may be located with the respective first and second toy objects, or elsewhere, e.g., together and coupled to the respect toy object.
In various embodiments:
the first toy object is provided with a toy weapon to which the energy source is mounted to radiate energy therefrom; the second toy object includes a second energy source that selectively radiates energy, is coupled to a circuit which causes the second energy source to selectively radiate energy, and is manually movable during play by a human player to direct radiated energy from the second energy source in a selectable direction;
the first toy object includes a second radiated energy sensor coupled to a circuit which makes a determination that a hit has occurred when energy received by the second sensor is compatible with energy emitted by the second energy source of the second toy object, and is manually movable during play by a human player to face the second energy sensor in a selectable direction;
the toy comprises at least one other hit indicator device coupled to the circuit to which the second sensor is coupled responsive thereto to provide an audible or visual output when that circuit determines a hit has occurred;
the second toy object has a toy weapon and the second energy source is mounted to radiate wave energy from that weapon;
the emitters may be removably mounted and interchangeable with other toy objects;
one or both toy objects are toy action figures.
In another configuration, the invention provides a toy part such as an accessory for a toy object for playing a shooting game in which the object is a participant in the shooting game. The accessory is configured to be compatible with the toy object and is removably attached to, or non-removably attached to or forming part of, the toy object. The accessory includes a circuit having an input and an output, and is responsive to the input to cause an energy source coupled thereto to selectively radiate energy and is responsive to a radiated energy sensor coupled to the output which is responsive to energy radiated by another wave energy source to make a determination that a hit has occurred when energy received by the sensor is compatible with energy emitted by the other energy source. The circuit is responsive to a determination of a hit causing a hit indicator device coupled to the circuit to provide an audible or visual output.
In various embodiments:
the toy part includes the emitter, the sensor and the hit indicator device;
the emitter, the sensor and/or the hit indicator are electrically coupled to the circuit and are adapted to be attached to and supported by the toy object;
the emitter may be removably attached to, or non-removably attached to, or form part of the toy part or the toy object;
the input comprises a manually actuatable switch;
the accessory is a backpack for an action figure toy object;
the toy part may be a base to which is mounted the toy object.
A backpack accessory may be removably or non-removably attached to the action figure. In a removable embodiment, the backpack includes means for removably attaching it to the action figure. In this embodiment, the emitter is mounted to a member which is non-removably coupled to the backpack. However, the emitter may be removably attached to the backpack, and interchangeable with other emitters which can selectively be attached to different backpack accessories.
The invention also provides combinations of toy parts and incorporating an emitter and toy objects, including combinations of toy parts, backpack accessories, weapons and action figures. The toy parts, accessories, weapons and toy objects may be removably coupled so that various different combinations and effects may be obtained by interchanging toy parts, accessories, weapons and objects.
As mentioned above, embodiments which removably attach an emitter or toy part may add play value over toy objects with non-removable emitters or toy parts which are remote controlled, and such embodiments are within the contemplation of the invention.
In another configuration, the invention provides a toy object configured to represent a mobile object for playing a shooting game in which the object is a participant. The toy object comprises an energy sensor, a circuit and a hit indicator device as described above, but not an energy emitter. In play, this toy figure may represent an unarmed toy object, such as a miliary transport vehicle, or a satellite, etc. A game may be played in which the players manipulate toy objects with emitters to hit the unarmed target before it reaches its intended destination or before it performs an intended task, etc.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is illustrated in the figures of the accompanying drawings which are meant to be exemplary and not limiting, in which like numerals in the different figures refer to like or corresponding parts, and in which:
FIG. 1 is a side view of a two toy action figures embodying the invention armed with light emitters engaged in a shooting game;
FIG. 2 is a front view of a removable backpack embodying the invention worn by the action figures depicted in FIG. 1;
FIG. 3 is a rear view of the backpack, with the torso of the action figure represented in broken lines;
FIG. 4 is a side view of the backpack, shown in exploded fashion with respect to the action figure which is represented in broken lines;
FIG. 5 is a side view of a weapon incorporating an emitter which can be removably plugged into part of a backpack accessory;
FIG. 6 is an electrical block diagram of the circuitry within or coupled to the backpack; and
FIG. 7 is a side view of representations of an unarmed military transport vehicle and an armed military tank which embody the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 illustrates a shooting game played with two toy action FIGS. 10 which each are armed with a radiated energy emitter 12, and each have a radiated energy sensor 14 (FIG. 2) compatible with the wave energy emitters 12. Each action FIG. 10 also includes a circuit 16 (FIG. 6) coupled to the respective emitter 12 and sensor 14 to control the respective component, and one or more hit indicators 18 coupled to the respective circuit 16 which audibly or visually indicate a hit whenever the circuit 16 determines that a hit has occurred. As shown in FIG. 1, the hit indicator 18 is a light (lamp or LED) which is illuminated to indicate a hit. An input device in the form of a push button switch 20 is provided on each action FIG. 10 for activating the respective emitter 12. Other suitable input devices may be used, such as touch switches, motion switches, proximity switches, etc.
In the embodiment of FIGS. 1-4, the emitter 12, the sensor 14, the circuit 16, the hit indicator 18 and the push button switch 20 are mounted or coupled to a toy part, specifically a backpack accessory 22, removably attached to an action FIG. 10. However, the backpack 22 (or other toy part) may be non-removably attached to the action figure, or may form part of the action figure, i.e., be formed as part of or be integral with the action figure. The emitter 12 is coupled to the backpack 22 and is mounted in a weapon 24 is removably attached to the action FIG. 10. In other embodiments, not shown, the backpack may be permanently attached to the action figure, or some or all of the components 12, 14, 16, 18 and 20 may be mounted to the action figure. In still other embodiments, not shown, some or all of those components may be mounted to another accessory attached or coupled to an action figure, such as a larger weapon (e.g., a hand-held missile launcher, anti-tank weapon or bazooka, etc.), or a weapon attached to or coupled to a vehicle, etc. In other words, it is within the contemplation of the invention that the components described above be mounted in any appropriate toy part such as an accessory or weapon, or in any appropriate part of an action figure, e.g., the turret of a tank.
Coupling or mounting the components to the backpack (or other toy part or accessory) provides advantages and enhances the play value of the game. For example, mounting and/or coupling the components to the backpack can simplify manufacture and reduce cost, particularly in the case of smaller action figures less than about ten inches in height (e.g., 33/4 inch and 57/8 inch action figures). Also, where the backpack is made removable, regardless of the size of the action figure, different backpacks can be provided with different shooting game features, as disclosed in cited patent applications, or with different visual features and different configurations, or different weapons may be coupled to them, etc.
For example, backpacks can be provided with single shot operation, or with automatic and semi-automatic shot operation. Also, backpacks may have different shot capabilities before requiring reloading, or different reloading options, or with no reloading possible for a given game or time period. The radiated energy shots fired by different backpacks may also be weighted (e.g., by codes) with different hit values, i.e., a hit from a given backpack may score a given number of points on the backpack that detects the hit. Further, certain backpacks may be configured to transfer functions and features to other backpacks, e.g., in codes carried by the radiated energy. Children may select what they believe to be an appropriate backpack for a given situation. This adds play value prior to the game, involved with the initial selection, and during the game as the player finds out how appropriate the selection was. If a game permits backpacks to be changed during the game, still more play value is provided associated with making and implementing the in-game choices. This of course applies not only to removable backpacks, but also to other removable parts and accessories.
These features may be programmed into the circuit 16 as described in the cited patent applications. The circuit 16 and the components may be mounted to the action figure, and the features may be provided by programming the action figure as described in the cited patent applications.
The backpack 22 includes a rear section 30 and a front section 31 hinged thereto. Mounted in the rear section are most of the components represented in the electrical schematic diagram shown in FIG. 6, including batteries (not shown). All or some of those components may be mounted on a printed circuit board (not shown). The components including the batteries, a speaker and the printed circuit board may be mounted in any suitable manner. For example, the batteries may be mounted in the lower part of the rear section 30 positioned in a stack extending laterally (horizontally) across the rear section. The sensor 14 is mounted to the front section 31 of the backpack 22. Wires (not shown) couple the sensor 14 to the rest of the circuit 16 in the backpack rear section 30. In the embodiment depicted in FIGS. 1-5, as mentioned above, the hit indicator 18 is a light (lamp or LED) mounted to the backpack front section 31, which is coupled to the rest of circuit 16 by wires (not shown). The wires may be run internally of the shoulder harness elements 39 (FIG. 2) from the components mounted in the backpack front section 31 to the rear section 30. As shown in FIG. 6, a speaker 18a may also be provided as a hit indicator, which is mounted in the backpack rear section 30. U.S. Pat. No. 5,147,237, the disclosure of which is incorporated herein by reference, discloses an example of the mounting of circuit components, a speaker and button batteries in a small enclosure.
The weapon 24 may be attached or coupled to the action FIG. 10 in any suitable manner, either removably or non-removably, and may be either movable relative to the action figure or non-movable. In the embodiment depicted in FIGS. 1-4, the weapon 24 is removably attached to the action FIG. 10 and is non-removably coupled to the backpack 22, and is movable with respect to the torso of the action FIG. 10. Referring to FIGS. 1-4, weapon 22 is connected to an arm 40 coupled to the backpack 22 by a frictional pivot joint 42 (FIG. 2) which keeps the pivoted position of the arm 40. A clasp 44 extends from the weapon 24 sized to engage the fore arm of the action FIG. 10. The prongs 45 of the clasp flex outwardly as the weapon 24 is pressed onto the forearm of the action FIG. 10, and then return inwardly to their unstressed state to engage the respective action figure.
The emitter 12 is mounted to the weapon 24 coupled to the rest of the circuit 16 in the backpack rear section 30 by wires (not shown). The wires may be run internally of the arm 40 from the emitter 12 to the rear section 30.
Referring to FIGS. 1 and 4, the arms 47 of the action FIG. 10 are pivoted at the shoulder and at the elbow by a simple frictional pivot or by a frictional ball joint, which keep the position to which the arm and forearm are moved, and which permit the arm and forearm to be moved into numerous positions. Thus, the weapon 24 may be aimed by suitably positioning the arm 47 to which the weapon is coupled, as well as by positioning or manipulating the action figure itself.
The emitter 12 is suitably mounted to the weapon 24 to emit energy therefrom for a desired range. In the case of a light emitter 12, it is set back within the weapon 24 spaced from a light-transmitting aperture 35 through which light is emitted from the weapon 24. The space between the light emitter 12 and the aperture 35 is tubular in shape and sized to provide a desired range for the light emitter 12. For example, the space and aperture, and the light source are selected to provide a beam of from approximately two to four inches in diameter at distances of from approximately six to 12 feet. Of course, use of an optical system which includes a lens, as disclosed for example in applications Ser. Nos. 08/795,895 and 09/15,863 cited above, would extend the effective playing range. The emitter 12 may be a light source that emits IR or visible light.
The backpack 22 may be mounted to an action FIG. 10 in any suitable manner. In the embodiment of FIGS. 1-4, the front section 31 is hinged to the rear section 30 by a pivot 50 (FIG. 4), preferably a frictional pivot that keeps its pivoted position, and the backpack front section 31 includes a flexible clasp 26 sized to fit around the waist of the action figure. The backpack rear section 30 has spaced projections 52 extending from the inside of the backpack rear section 30 which are snap-fitted into holes 53 in the back of the action FIG. 10. With the backpack front section 31 pivoted to its open position shown in FIG. 4, the backpack 22 is pressed onto the action FIG. 10 to seat the backpack projections 52 in the action figure holes 53. As the front section is pivoted to its closed position shown in FIG. 1, the prongs 27 of the clasp 26 flex outwardly, and then return inwardly to their unstressed state to engage the action figure. The backpack 22 may be mounted to the action figure in other ways, for example as disclosed in U.S. Pat. Nos. 5,073,140 and 5,147,237.
In other embodiments, the backpack 22 and the weapon 24 may be permanently attached to the action FIG. 10 in any suitable way, and the weapon 24 may be movable or stationary with respect to the action figure. For example, referring to FIG. 5, the weapon 24a has an electrical connector part 48 and the arm 40a (pivotally connected to the backpack 22 as shown in FIGS. 1-4) has a mating electrical connector part 49 into which the connector part 48 is plugged and unplugged to make electrical connection of the emitter 12 with the circuit 16 via conductors (not shown) extending from the connector part 49 to the circuit 16. The connector parts 48 and 49 may be mating telephone connectors, or any other suitable connectors. The weapon 24a may be supported by the connectors 48, 49 and/or by the clasp 44 (not shown in FIG. 5).
A shooting game is played by the action FIGS. 10 as manipulated by a child or two children (or more with more action figures) to fire (radiate) energy at the sensor 14 of an opposing action figure. Prior to the game, each player selects a backpack for each action figure, if a supply of backpacks is available. During play, each player grasps an action FIG. 10, or a single player grasps two action FIGS. 10, and tries to score a hit on the opposing action figure. The children manually pose the figures, manually position the arms (and the weapons) and manually move the figures to fire in a selected direction and/or to avoid being hit from the fire of another action FIG. 10. Thus, young children can play the shooting game without difficulty, and a relatively low cost but high tech toy is provided for children to play an interactive shooting game.
The backpacks 22 may be provided with any of the features described in the cited patent applications, in addition to simply determining and indicating hits. The backpacks may also be provided with sound effects and voice messages, as described in U.S. Pat. Nos. 5,073,140 and 5,147,237, all cited above. Game play is altered to the extent appropriate to use these features and functions. To provide even more play value, the emitter, the sensor and the circuit components can be mounted to a gun and a vest (instead of a backpack) which resemble the gun and vest of the "Laser Challenge Pro" toy (available from Toymax Inc.) worn by human players as direct participants in a shooting game.
FIG. 6 depicts a block diagram of an embodiment of a circuit 16 for implementing an IR emitting and detecting action FIG. 10. Circuit 16 includes a controller 60, an IR sensor 14, the push button switch 20, an IR LED 12, a modulator (or oscillator) 66 for modulating the input of the IR LED 12, the hit light 18 (in the form of a lamp) and a speaker 18a. The microcontroller 60 receives and processes the output of the IR sensor 14, and in response thereto controls the hit light 18 and the speaker 18a, via appropriate drivers 70, 71. The controller 60 also receives the output of the push button switch 20 and in response thereto provides signals to the modulator 66 for the IR LED 12.
The width of a burst of light emitted by the IR LED 12 may fixed or variable. If the shooting game provides only for the shooting and detection of light, and for no functions which would require the emitted light to carry information, then the modulator 66 may provide for a single fixed burst width. If the light emitted by the IR LED 12 is to carry information for providing game features and functions as discussed below and described more fully in the cited patent applications, then modulator 66 may provide for light bursts of different width. The modulator 66 may be similar to the one disclosed in Application ser. No. 08/795,895, which can modulate the input to the IR LED 12 in a single fixed width or in different widths, as controlled by the controller 60. Although the modulation circuit 66 and the controller 60 are represented by separate blocks in FIG. 6, they can be implemented in the same integrated circuit as well as by separate circuits.
Controller 60 includes a speech synthesizer, and is capable of providing signals to the driver 71 for the speaker 18a for realistic sound effects and speech. The controller 60 may be as described in Application Ser. No. 08/795,895, e.g., a 528 Series microcontroller available from Winbond Electronics Corp. Alternatively, controller 60 may be an SN67003 microcontroller available from Sonix Technology Co., Ltd. Other suitable controllers may be used, which may include a modulating circuit therein, in which case the modulator 66 may be eliminated or replaced by a drive transistor, or the like. The IR sensor 14 may be a 12043 Series infrared receiver available from Kodenshi Corp. The 12043 Series receiver detects infrared light radiated at a carrier frequency of 37.9 KHz., and provides a logic level change output in response to detection.
If the action figures are configured to perform any of the functions disclosed in the cited patent applications, in addition to simply determining and indicating hits, then as discussed above the controller 60 and the modulator 66 provide a plurality of codes for the light emitted by the LED 64 (e.g., represented by the width of the emitted light burst). Correspondingly, the controller 60 is effective to determine and control the function represented by the codes in the emitted light. Input controls, circuitry and/or a computer may be provided to program the backpacks (or the action figure to which the circuit 16 is mounted), and upload and download programming, features, functions and use information, etc. Where the toy objects are small in size, such as smaller action figures, vehicles, etc., a connector (e.g., a standard telephone connector 48 as shown in FIG. 5) may be provided for removably connecting input devices such as a keypad or computer, etc.
The electrical circuitry described above implements the emission and detection of IR light. However, visible light could be emitted instead of IR light, and suitable sources and circuitry for effecting the transmission and detection of visible light are known to those of skill in the art.
If desired the circuit 16 may also control a motor 75 via a driver 76 in response to determination of a hit. The motor may move a part of the action figure to indicate a hit, such as tilting the head, toppling the figure, bending the torso, etc. The motor may also provide a feelable output which a player can feel, such as vibrations, ejection of a liquid, etc.
The circuit 16 also includes a speech synthesizer, as mentioned above, which may be incorporated in the controller 60. This adds play value in that the action figures or other toy objects may not only sound a sound effect when a hit is determined or when firing, but also various sound effects associated with other functions such as reloading, rapid fire, out of shots, etc. Moreover, the controller may store speech phrases coordinated with the particular action figure or functions performed by the action figure or other toy object. The speech and sound effects can be sounded automatically according to the controller program, or in response to switch activation or sensor activation (e.g., loading a new backpack on an action figure).
The accessory contemplated by the invention may be embodied in a base which supports a toy figure, particularly a miniature figure as small as 1 to 2 inches. The base may serve the function of mechanically supporting the figure, as well as housing electrical components, as described for the backpack accessory. The base may include a receptacle for snap fitting the feet of the figure therein, or the base and the figure may include a projection and mating receptacle of any suitable shape, e.g., tutbular or rectangular, etc., or a bayonet type connection. The base may have attached thereto the sensor 14 and the hit indicator 18, while the emitter 12 could be mounted to a weapon removably attached to the figure. Alternatively, the sensor 12 and the hit indicator 18 may be mounted to a vest which is removably attached to the figure.
If desired, the removable backpacks 22 (or other removable toy part) may be equipped with a receiver for remote control of one or more features or functions implemented by the backpacks. Remote control may be in addition or in lieu of the push button switch 20. Such a receiver and a remote control are known to those of skill in the art. This provides a limited remote control feature which can be implemented at low cost.
Toy objects may be implemented with energy sensors and detection circuitry only, i.e., they may not be provided with an energy emitter and thus are "unarmed" and can not shoot at other toy objects. FIG. 7 depicts a representation of an unarmed military transport vehicle 80 including at least one sensor 14 being fired at by a military tank 82. Preferably, either the one sensor 12 is omni-directional, or multiple sensors are provided (e.g., connected in a logical OR configuration) to receive compatible energy over 360 degrees. The vehicle 80 is also provided with a hit light 18 and a speaker (not shown). The vehicle 80 may include the same circuit 16 as provided in the backpack 22, except that the IR LED 12 and the modulating circuitry 66 are omitted. The tank 82 may include all of the circuitry in or coupled to the backpack 22.
In a game played with one or more action FIGS. 10 (or other objects having an energy emitter), a player may try to move the vehicle 80 to its destination without the vehicle being hit by the tank 82, or by an action figure carrying an anti-tank type weapon. The vehicle may be provided with storage space, which may, for example, hold additional backpacks that may be used if the vehicle reaches its destination.
While the invention has been described and illustrated in connection with preferred embodiments, many variations and modifications, as will be evident to those skilled in the art, some of which are described or mentioned herein, may be made without departing from the spirit and scope of the invention. For example, as discussed above, features and functions disclosed in the cited patent applications may be implemented in the action figures, backpacks, accessories, toy parts, etc., described or mentioned herein using the components described in those applications. Also, features and functions other than those described herein, and variations of the features and functions described herein are possible. Further, the invention may be embodied in objects other than those shown in the drawings, for example, in military vehicles such as planes, ships, in space craft, in dolls, robots, spacemen, creatures and animals, etc. Still further, certain parts may be removable and some embodiments which incorporate removable parts may include remote control of one or more features. The invention as set forth in the appended claims is thus not limited to the precise details of construction set forth above as such variations and modifications are intended to be included within the spirit and scope of the invention as defined in the appended claims.
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The invention disclosed herein provides toy objects such as action figures, robots, vehicles, creatures, etc., with apparatus for playing a shooting game controlled by one or more human players. Each toy object includes either a energy emitter, a energy sensor, or both. The toy objects are manipulatable by the players to face the emitters and the sensors in directions to hit other objects with radiated energy or avoid being hit with radiated energy from other objects. In the preferred embodiment, the emitter radiates infrared light and the sensor detects infrared light, and are operated from a backpack movably attached to an action figure. Control of radiating and detecting infrared light is similar to the control in a currently popular "laser" shooting games available from Toymax Inc. under the trademark "Laser Challenge".
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CLAIM OF PRIORITY
This application claims priority under 35 USC §119(e) to U.S. Patent Application Ser. No. 61/055,038, filed on May 21, 2008, the entire contents of which are hereby incorporated by reference.
TECHNICAL FIELD
This invention relates to Micro Electro Mechanical Systems (MEMS), and more particularly to a three dimensional (3D) MEMS arm and system.
BACKGROUND
Micro ElectroMechanical Systems (MEMS) integrate mechanical elements, sensors, actuators, and/or electronics on a common silicon substrate through micro fabrication technology. The electronics are often fabricated using integrated circuit (IC) process sequences. The micromechanical components are often fabricated using compatible micromachining processes that selectively etch away parts of the silicon wafer or add new structural layers to form the mechanical and electromechanical devices.
MEMS devices generally range in size from a micrometer (a millionth of a meter) to a millimeter (thousandth of a meter). Common applications include: inkjet printers that use piezoelectrics or bubble ejection to deposit ink on paper, accelerometers in cars for airbag deployment in collisions, gyroscopes in cars to detect yaw and deploy a roll over bar or trigger dynamic stability control, pressure sensors for car tire pressure, disposable blood pressure sensors, displays based on digital light processing (DLP) technology that has on a chip surface several hundred thousand micro mirrors and optical switching technology for data communications.
SUMMARY
A micro assembly have a substrate and an operating plane coupled to the substrate. The operating arm is movable from an in-plane position to an out-of-plane position. One or more electric connections provide electric power from the substrate to the operating plane in the out-of-plane position. A tool is coupled to the operating plane. The tool is operable to receive electric power from the operating plane to perform work.
The tool may be, for example, pliers, cutting tool. extension device, hot knife, magnetic bead implanter gun, and biopsy tool. Thus, the micro assembly may perform specific functions in three dimensions, such as reaching above and beyond the plane of the chip in order to do work or to obtain and retrieve tangible objects for analysis.
The details of one or more embodiments of the invention are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the invention will be apparent from the description and drawings, and from the claims.
DESCRIPTION OF DRAWINGS
FIG. 1 illustrates one embodiment of a MEMS device in accordance with the present disclosure;
FIGS. 2A-F illustrate force information for the MEMS device;
FIG. 3 illustrates one embodiment of an electrical wire in the MEMS device;
FIG. 4 illustrates one embodiment of rotation geometry;
FIG. 5 illustrates further details of the bond pads in accordance with one embodiment;
FIGS. 6A-C illustrate one embodiment of the shark-jaws;
FIGS. 7A-C illustrate one embodiment of a magnetic bead implanter gun and cell breaking points;
FIG. 8 illustrates one embodiment of micropliers;
FIG. 9 illustrates one embodiment of a cutting tool;
FIG. 10 illustrates one embodiment of a biopsy tool;
FIGS. 11A-D illustrate a cauterizing tool; and
FIGS. 12-49 illustrate further details of the MEMS device, including various tools and applications, and fabrication of the device.
DETAILED DESCRIPTION
FIG. 1 illustrates one embodiment of 3D MEMS device that operates at significant elevation levels (greater than 1 mm) and performs activities. The device contains an arm that raises into a position orthogonal to the chip, allowing one of several different tools to come into contact with the space above the chip. Potential tools operated by the device could include one of any number of different mechanical devices: measuring tools, tools suitable for medical applications such as biopsies, etc.
The device has three major components. First, using on-chip actuation, this design automatically rotates a structure with sizable length (e.g., mm) to a vertical position that is orthogonal to the plane of the chip. Second, the device is designed to provide electrical power (insulated hot and ground leads) to the top of the vertical structure once it is upright. Third, at the top of the vertical structure which rises significantly above the substrate, it provides real estate space for micro-tools that move and perform work. The micro-tool has a telescopic accordion-like arm with the ability to reach up and grab something over 300 μm above the top of the elevated structure which is about 1.5 mm above the substrate of the chip. In summary, the device is the realization of several features including, for example, automatic 90 degrees rotation of released MEMS structures into vertical orientations, electrical power supplied up through the elevated structure, and micro-tool work and movement at the top of the elevated structure. Applications include nanotechnology, biomedical, micro-manufacturing, micro-fluidics, and micro-sensors. Applications include reaching up above chip to perform tasks, reaching out off chip to perform tasks and providing power and/or power leads out of plane. Other applications include medical applications including: micro-surgery, cut or grab a micro-hunk of tissue, micro-surgical tool, monitoring of bodily functions from inside the body on the micro scale, collecting data or samples on the micro scale, fertilized egg turner. Micro-tooling applications include micro-sensing, measuring micro distances, using MEMS robot to construct other micro-structures, and using MEMS robot to repair objects on the micro scale grabber, extension arm, micro cutter and micro activator.
The device contains an arm that raises into a position orthogonal to the chip, allowing one of several different tools to come into contact with the space above the chip. Electrical contacts may extend between the out-of-plane platforms and the in-plane platform. The different tools allow the device to become one of any number of different mechanical devices: a measuring tool, a cutter, a grabber, a manipulator, or a specialized tool designed to complete a specific task.
The geometry of MEMS devices creates a product that is, in effect, a two and half dimensional object. Therefore, having the ability to raise part of the device and interact in the third dimension will give MEMS devices new and progressive 3-D abilities. There are numerous potential applications, including interaction with a second chip in a flip-chip or other system or allowing the raised chip to interact on a new level within its working environment. While structure can be raised up manually (e.g., probe tip actuation), the device, using on-chip actuation, will erect itself into a vertical orientation using its own means. In addition, electrical power will run up the vertical structure in order to run the micro-tools at the end of the operating plane. The 3-D micro-robot may perform micro-tasks in the 1 mm to 2 mm range distances above the surface of the chip. The 3-D micro-robot may perform micro-tasks in the 1 mm to 2 mm range distances off the edge of the chip. The 3-D micro-robot may perform micro-tasks using electrical energy in the 3 to 50 volts range with current less than 1.0 milliamp. Designs may fit within the standard 2820μ×6340μ module chip size.
Referring to FIG. 1 , the device includes ground lead 1 , provides a ground for the tools on the top of the operating plane. Hot lead 2 includes three hot leads. One hot lead is provided for every thermal actuator required to do a function (i.e. extend the arm, close the grabber, etc.). These leads connect into the encased oxide (garage) portions of the operating plane. Thermal actuators with jacking system 3 uses teeth to incrementally move the jacking system forward. Pin and cross system 4 uses a set of angled cross bars that when drawn forward, apply a force on a set of pins orthogonally attached to the axle of the operating place. This results in a torque on the axle which causes the operating plane to rate 90°. There are three cross members on each side of the rotating axle with 15° between the two cross members. Thermal actuators and latches 5 keep the operating plane secure while it is not being elevated. Operating plane 6 is the main body that is being elevated. The circles are the pores in the operating place. They allow etching trough to the substrate layer which will release the operating plane 6 from the surface of the chip. In operating plane 6 contains a series of structures of encased oxide (garages) that will allow P3 to be insulated and serve as the hot lead for the tool 9 . Tool connection 7 connects to the tool 9 to provide rigidity, and this is also where the thermal actuator connects for its ground. Thermal actuator for tool 8 may be a smaller thermal actuator than the others, so it can fit on the top of the operating plane. It contains a jacking system to allow the tool to reach its full extension. Tool 9 may be the scissor action extension arm or other tool option.
In regard to the thermally actuated jack lift system 3 , the operating plane 6 is to be raised 90 degrees by the thermally actuated jacking system 3 . The jack itself is simply a thermal actuator with a ratcheting centerpiece designed to incrementally drive a series of cross member components. Each actuation motion travels about 10 μm, and the ratchet teeth are each separated by 4 μm. This means that each actuation pushes the cross members two teeth, or 8 μm.
The cross member components are designed to translate the force provided by the thermal actuators in order to put a torque on the operating plane pivot axle. Pins that are fixed perpendicularly to the axle are guided by the cross members along a path that is 15 degrees off of the axis. This allows the torque to incrementally raise the operating plane 6 to a position orthogonal to the MEMS chip. The total distance that the cross member components need to travel is 18 μm. This means that 2.25 actuations are required to reach 90 degrees. There are a total of 6 cross member components; a larger number of cross members reduces the force required for the thermal actuators to achieve plane rotation. Mathematical proofs of FIG. 2 illustrate the key force information for the MEMS system.
In regard to the operating plane latch system 5 , during the release phase of the SUMMiT V fabrication process, there are turbulent forces that can potentially damage a design if the device is not properly secured to the chip. To minimize the potential for damage, a set of thermally actuated latches will he utilized to safeguard the device. Located on either side of the operating plane (i.e. the plane to be raised), the latches will secure the plane to the chip face until it is time to raise the plane. At such time, the latches will be released by activating the thermal actuators, which in turn will free the operating plane from the face of the chip.
In regard to the operating plane 6 , the operating plane provides stability, electrical current, and be the proper size to give height off the face of the chip. To do this a 1.4795×0.8 mm plane designed that is electrically charged and fastened at its base to a torsional lift axle. The plane may have the capacity for up to 6 separate circuits, though the main design requires only 2. The interior of the operating plane 6 is perforated by release pores, to ensure separation of the 3 structural polysilicon layers from the substrate material of the chip. Also on the interior are the ‘hot’ sides of the electrical tool circuits. To do this, polysilicon layer 3 is encapsulated in segmented shafts that run the length of the plane. The shafts are long shells constructed using polysilicon layers 1 , 2 , 3 , and 4 (also referred to as P1, polyl, etc.). Layers 1 and 2 serve as the bottom faces of the shell, layer 4 serves as the top face, and layer 3 serves as the side rails. A single strand of polysilicon layer 3 is separated from the shell by the encased oxide and will run the length of the shaft. In effect, electrical ‘wires’ have been created that enable current to be carried to the tool mounted at the top of the operating plane. See FIG. 3 . Along the side edges of the operating plane 6 run segments that act as grounds for the electrical circuits.
In regard to leads 1 and 2 , the purpose of the leads is to bring power to the plate when it is raised to 90 degrees. To accomplish this, 3 hot leads and three ground leads are provided that, when the plate is in place, will connect to the leads which run through the core of the plate. Before the plate can be raised these leads need to be pulled out of the way to clear the path of motion. The geometry for this rotation is illustrated in FIG. 4 . Electrostatic forces are used to accomplish this. By running a lead along the base plate that is next to, but not directly beneath, the main leads, a conductor can be used on top of each beam to pull it down without letting it touch the conductor. This prevents a short circuit that would cause the beam to release back to its original position. During the raising of the plate both the ground and hot leads will be bent out of the way to allow the plate to pass. Once the plate passes, the leads will be released and allowed to contact the bottom of the elevated plan thus completing the circuit. This is will provide power to the top of the plate. To ensure this component will work properly it is necessary to calculate the force developed by the charge field below the beam, so that the proper voltage is passed through the conducting plate. These calculations allow the actual tip displacement of the beam to be estimated using beam theory. From the calculation for one beam, the force needed to lower the beam a distance of 2 μm is 2.241 μN. To generate this force it is necessary to have a charge difference of approximately 35 volts between the plates. This voltage must be somewhat higher in practice due to the number of arms to be lowered and because it is not an ideal situation. After examining the geometry of the plate bottom and its rotation, the minimum amount the leads can be lowered to allow for clearance is 1.89 μm. In order to allow for the plate to shift it is advisable to lower it as far as possible, which will be 2 μm.
One major area of concern in the original design of the lifting mechanism for the plate was running power up to the top. In fact this was one of our main design objectives. One of the challenges facing the design team was to be able to raise the plate and then connect the power in such a way that the power lines did not interfere with the plate on its way up. To accomplish this the leads were designed as cantilever beams that could be stressed out of the way and allowed to snap back in to position after the plate was raised to its full height. For this application the team chose to use an electrostatic pull down effect on the beams to bend them low enough to gain the clearance required. Using the formulas for beam bending and electromagnetic attraction force between parallel plates, the team was able to derive a method to not only determine the voltage required to “snap down” our current design, but how a redesign could be done to reduce the voltage required and to prevent arcing between the charged plate and the beam being pulled.
Part of the design takes into account the possibility of a short circuit; this involved placing the actual beam having the electrostatic force applied in the layer above the beam that needed to be cleared of the plate. Thus, the team assured that the beam would not touch any layers. This change in design had major effects on the math model for the electrostatic snap down, because the force that was being applied over an area was being transferred to a non-central non-end point on a different beam. This required the use of the parallel plate force equation and the non-central point beam deflection equation, each using the size and shape of the respective beam. Basic assumption could be made: the beam would act linearly in bending, the cross section would remain uniform, and the electromagnetic field produced by the base charging plate would be uniform. For simplicity sake the force on the beam due to gravitational acceleration was ignored as well. With these assumptions in place the entire equation became a simple algebraic expression with either data values that the design team could set or change as needed, or material constants. From this simple equation the team was able to derive an expression for the voltage required to move the beam a certain maximum distance. Once the maximum distance that the beam can moved has been obtained, work can go into determining the actual distance it would have to travel to clear the rotation of the operating plane. Then those beams could snap back in to place and link up for the required.
In regards to the scissor action extension gripper or other tool 9 , the scissor action extension gripper is located at the end of the operating plane and provides the ability to extend a tool beyond the plane surface. Two gripping jaws, named shark jaws, are attached to the end of the extension system, allowing the device to grasp three-dimensional objects as the system extends. There are a multitude of micro tools 9 that can be affixed to the gripper system (wrenches, sensors, cutters, etc.).
The scissor action extension gripper is powered by a single thermal actuator, which is connected to a bearing on the jack system 3 . As the thermal actuator is charged and displacement occurs, the bearing is pulled by the thermal actuator. The bearing is connected to a stationary bearing on the jacking system 3 through a series of bearings and beams. The stationary bearing has two functions as the pivot point for the jacking system 3 and as the connection for the struts that hold the jack system 3 in place. To the right of the stationary bearing lies the device that performs the action of extension. It is essentially 3 rows of 5 bearings per row, each connected by a simple beam. As the thermal actuator pulls on the bearing, the angles of the beams decrease, thus causing the beams to extend in the opposite direction of the thermal actuator's pull. The decreasing angle of the beams thus causes the shark jaws to clasp towards each other.
The shark jaws have serrated edges in order to minimize the surface contact between the jaws and the object to be grasped. As the contact area between the two surfaces is decreased, the magnitude of Van der Waal's and stictional forces is decreased, facilitating the release of the object.
Regarding the bond pads, FIG. 5 provides details of the bond pads and their applications.
The device, in the SUMMiTV application, relies on being able to use the interaction of the cross-members in P1, P2, and P4 with the bar in P3 to create rotational movement. Additionally the gripper system uses P1, P2, and P4 to make two separate bars with hinge pins that are comprised of P1, P2, P3 and P4, allowing the bars to rotate and the scissor-jack to expand and contract.
The Sandia Ultra-planar, Multi-level MEMS Technology 5 (SUMMiT V™) Fabrication Process is a five-layer polycrystalline silicon surface micromachining process (one ground plane/electrical interconnect layer and four mechanical layers). It is a batch fabrication process using conventional IC processing tools. Using this technology, high volume, low-cost production can be achieved. The processing challenges, including topography and film stress, are overcome using methods similar to those used in the SUMMiT V™ Process: topography issues are mitigated by using Chemical-Mechanical Polishing (CMP) to achieve planarization, and stress is maintain at low levels using a propriety process.
MEMS are also produced in the SUMMiT V™ Fabrication Process by alternately depositing a film, photolithographically patterning the film, and then performing chemical etching. By repeating this process with layers of silicon dioxide and polycrystalline silicon, extremely complex, inter-connected three-dimensional shapes can be formed. The photolithographic patterning is achieved with a series of two-dimensional “masks” that define the patterns to be etched. The SUMMiT V™ process uses 14 individual masks in the process.
The functionality of the micro-robotic arm lies in its ability to accommodate a wide assortment of tools for a variety of purposes. The tools 9 are detailed below.
FIG. 6A illustrates the scissor action extension gripper 20 . It is located at the end of the operating plane and provides the ability to extend a tool beyond the plane surface. Two gripping jaws, named shark jaws, are attached to the end of the extension system, allowing the device to grasp three-dimensional objects as the system extends. There are a multitude of micro tools that can be affixed to the gripper system (wrenches, sensors, cutters, etc.).
The scissor action extension gripper is powered by a single thermal actuator, which is connected to a bearing on the jack system. As the thermal actuator is charged and displacement occurs, the bearing is pulled by the thermal actuator. The bearing is connected to a stationary bearing on the jacking system through a series of bearings and beams. The stationary bearing has two functions as the pivot point for the jacking system and as the connection for the struts that hold the jack system in place. To the right of the stationary bearing lies the device that performs the action of extension. It is essentially 3 rows of 5 bearings per row, each connected by a simple beam. As the thermal actuator pulls on the bearing, the angles of the beams decrease, thus causing the beams to extend in the opposite direction of the thermal actuator's pull. The decreasing angle of the beams thus causes the shark jaws to clasp towards each other.
The shark jaws have serrated edges in order to minimize the surface contact between the jaws and the object to be grasped. As the contact area between the two surfaces is decreased, the magnitude of Van der Waal's and stictional forces is decreased, facilitating the release of the object.
The extension distance of the gripper is a function of the thermal actuator's displacement. A maximum thermal actuator displacement of 15 μm results in a reach distance of 319.41 μm. There is a linear relationship between the displacement of the thermal actuator and how far the gripper reaches into space (see FIG. 6B ). The relationship can be expressed as:
Extension=(δ TA )*21.214
Where: δ TA —Displacement of the thermal actuator
The force exerted by the teeth of the shark jaws is dependent on two parameters: the displacement of the thermal actuator, and the location of the contact point between the jaws and the object to be grasped. An object near the end of the shark jaws' grasp will not receive as much force as an object near the joint, or pivot point, of the jaws. This force is dependent on the moment at the pivot point for the jaws.
M
=
(
F
TA
2
)
δ
v
Where: δ v —Vertical displacement of the bearings attached to the thermal actuator F TA —Force exerted by the thermal actuator, which is 612.5 μN
The linear relationship between the displacement of the thermal actuator (δ TA ), and δ v can be expressed as: δ v =−0.1963δ TA +59.611 (see FIG. 3 ). Using this relationship, the force exerted at the contact point on the jaws can be expressed as:
F
(
x
0
,
δ
TA
)
=
M
x
0
=
F
TA
δ
v
2
x
0
=
F
TA
(
(
-
0.1963
)
(
δ
TA
)
+
59.611
)
2
x
0
Where: x 0 —Distance from the joint of the jaws to the contact point
FIGS. 7A and 7B illustrates a magnetic bead implanter gun 30 . The problem with current magnetic bead technologies is the failure to specifically target an individual cell for sorting purposed. In order to affix magnetic beads to a certain type of cell, the beads are put into solution with the cells and then randomly attract to one another. This can be problematic If the researcher only wants to collect a unique cell out of a group. The magnetic bead implanter gun (MBIG) solves this problem by shooting a single bead into an individual cell, breaking the membrane and becoming Immersed m the cell's cytoplasmic fluid.
The magnetic bead is fit into the two circular holes at the end of the MBIG. The holes serve the purpose of holding the magnetic bead in place because the magnetic bead's diameter is much greater than the holes' diameter.
Cold finger technology is used in the MBIG to secure the magnetic bead while the operating plane rotates into an orthogonal position. The P2 and P4 layers actually hold onto the magnetic bead while the P3 layer provides the thermal expansion necessary for the MBIG's deformation. The P3 layer is attached to the P4 layer via a small square of Sac-Ox near the end of the gun, and as a current is applied to the P3 layer it expands and consequentially raises the P4 layer a distance of several microns. Once expanded, a magnetic bead can be placed between the layers.
The bead is shot from the MBIG via a ramming rod that is connected to a thermal actuator. When the thermal actuator is activated and physically displaced, this drives the ramming rod into the bead. The ramming rod is in P3, so it is necessary for the P3 layer attached to the body of the gun to thermally expand and rise out of the way so the layers will not collide upon impact.
The MBIG is designed so that a bead can successfully puncture a cell's exterior membrane. FIG. 7C shows several varieties of single celled organisms and their corresponding pressures needed to break the cell membrane. The salmonella cell has the largest measured breaking pressure with 10.13 MPa, so the MBIG should deliver a bead at a relatively higher pressure. The pressure exerted on the bead can be calculated by dividing the thermal actuator's exerted force by the area of the ramming rod that impacts the bead, or:
P
=
F
A
=
612.5
µN
14
µm
×
2.25
µm
=
19.44
MPa
Thus, the MBIG delivers an appropriate pressure to break the membrane of a cell. It should also be noted that the cell will not be permanently damaged by this process. Due to the elastic properties of cells, they will actually expand in order to accommodate the newly acquired magnetic bead. Once the magnetic bead is inside the cell, it will be manipulated with an electromagnetic field in order to maneuver the cell-bead pair to a desired location.
FIG. 8 illustrates micropliers 40 . Due to an enlarged contact surface area, the micropliers are an ideal tool for holding onto large objects. The pliers are driven by a thermal actuator that pulls on a bearing that is connected to a stationary bearing through a series of beams. The stationary bearing serves as the pivot point for the pliers and as the connection for the struts.
FIG. 9 illustrates cutting tool 50 . The cutting tool was designed to cut an object with its sharp edges. Driven by the same mechanism as the micropliers, the two heads of the tool pull together and pinch a very small contact area. The elongated beams of the cutting tool allow for a greater moment to occur at the pivot point, resulting in a higher force exerted at the contact point.
FIG. 10 illustrates biopsy tool 60 . The tool was based on the shark jaws tool and thus is very similar in shape and operation. Calculations for extension are the same as those for the shark-jaws tool because it uses an identical scissor jack, thus the maximum thermal actuator displacement of 15 μm results in a reach distance of 319 μm. Although the scissor jack system is the same, the end of the tool operates differently. The basic shape is similar to the shark jaws in order to best fit the compacted scissor jack shape. However instead of a curved meeting of teeth, the biopsy tool 60 features straight edges that come together at one time, instead of rotating through each other. The plates that make up the head of the tool are replaced by a similarly shaped retaining device. This tool head is made by constructing a half-garage for each side of the head, using P2, P3, P4, and the Sac-Ox layers for the walls on three sides, but leaving out the P3 layer on the interior side so that material can enter into the space between the P2 and P4 layers as the two half-garages come together. This material can then be retrieved and examined.
FIGS. 11A-11D illustrate the cauterizing tool 70 . There are many aspects of medicine that can benefit from micro scale tools and procedures, for the simple reason that the area of interest is almost always crowded by other sensitive organs and tissue. In order to cause the least amount of damage while affecting repairs it would seem prudent to have the least invasive tool that is capable of doing the job. Preventative care is a particular case that a tool should be able to address. The heart is the center of everything that keeps the human body functioning, and excess protein in the body can and will build up not only In veins and arteries but also on the valves of the heart. Like any well running machine these foreign inclusions will cause wear and tear. These build ups on the heart valves lead to the most frequent cause of strokes to date, the fat on the valves can break off and get pumped through that heart at a high rate of speed then jam itself up in a capillary. The back up pressure caused by this blockage can lead to a stroke. Current procedures to remove the blockages are messy, invasive, and not very reliable. Open heart surgeries, and valve replacement, are the best solutions to remove these fatty deposits. Any procedure that involves cutting the heart open and replacing a piece of it with something artificial is going to be traumatizing, and there is also a fear of the body rejecting the new part. To avoid this type of complication new methods must be developed to battle the unwanted deposits in both the arteries and veins of the body.
The MEMS micro torch is one such device that addresses the aforementioned problems. For most current high precision cutting operations doctors have used lasers. The applications of lasers in the field of medicine have aided the doctors to no end in performing precise surgical cuts and operations, but they still do not address how one reaches inside the heart without resulting in damage. With a MEMS device this could change drastically. Because of its small size and power requirements, a MEMS device would be ideal for mounting onto the front an arthroscope to give surgeons a means of interacting with and manipulating an object in teal time. Aside from the obvious advantage of causing less damage to the patient, this tool would allow for surgery to be performed in areas that are dangerous to reach. For this to be useful a precision device that could reach out above itself and do work is necessary. The same device should also be able to retract and reapproach, giving it the ability to make multiple passes and do many tasks. Because the device is small and batch fabricated, sterilization would not be necessary, simply replacing the tip of the arthroscope with a clean one is sufficient.
A tool that makes precise, measured cuts is needed for the aforementioned MEMS application. Cuts are normally made with surgical knives, but more recently the cuts are being made by either lasers or heated cutters. Heating something on this scale has proven to be both simple and reliable as evidenced by the thermal actuators. The ability to heat a rod or beam coupled with the ability to reach above the plane results in the building blocks for a micro scale precision cutting torch, but the design needs a way to retract.
To retract the jacking mechanism once it is elevated a few things must be done. First the teeth that enable the jacking system to work must be released. To accomplish this, an interlinked system involving a thermal actuator and mechanical linkages have been designed. This apparatus did require that the interim of the jacking system in both the actuator and the stationary ratcheting device be redesigned to allow for release of the teeth. Once the redesign was complete the teeth could be pulled back with a single power source, in essence giving the thermally actuated jacking system a reset button. Enabling the system to retract was the first hurdle of the design. To add reliability to the retraction and make it uniform, a spring is attached to the rear of the rod that is being extended, which will apply a spring force and retract the rod more rapidly than simply releasing the ratcheting mechanism. This was added because the device is expected to act not only in a fluid medium, but in any direction necessary, and gravity could not be relied upon to retract the rod.
For the issue of bring heat to the target area, the decision was made to utilize the same system as the beams in the thermal actuators. Since the desire is for simple heat and not a forced translation, only two side beams are truly needed. But a problem arose in the area of powering these beams. They would be moving out and back many times in even the most rudimentary surgery, and the beams themselves would be stressed constantly. To avoid excess stress on the jacking system and the beams possibly snapping under the cycling stress, the design was modified so that the beams were curved. The curved shapes acts much the same as pre-stressing on a spring, it affords the rod more length to extend without having to actually stretch the beams that are built across it. This will also reduce the required amount of force to extend the base rod in comparison to if the side beams were originally straight.
FIGS. 12-49 illustrate further information for the MEMS device.
A number of embodiments of the invention have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the invention. Accordingly, other embodiments are within the scope of the following claims.
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A micro assembly having a substrate and an operating plane coupled to the substrate. The operating plane is movable from an in-plane position to an out-of-plane position. One or more electric connections provide electric power from the substrate to the operating plane in the out-of-plane position. A tool is coupled to the operating plane. The tool is operable to receive electric power from the operating plane to perform work.
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This is a continuation of application Ser. No. 09/449,345 filed Nov. 24, 1999. The entire disclosure of the prior application(s) is hereby incorporated by reference herein in its entirety.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to image forming systems that incorporate light sensitive photoreceptors.
2. Description of Related Art
Generally, electrophotographically forming an image includes charging a photoconductive member to a substantially uniform potential. This sensitizes the surface of the photoconductive member. The charged portion of the photoconductive surface is then exposed to a light image from either a modulated light source or from light reflected from an original document being reproduced. This creates an electrostatic latent image on the photoconductive surface. After the electrostatic latent image is created on the photoconductive surface, the latent image is developed. During development, toner particles are electrostatically attracted to the latent image recorded on the photoconductive surface. The toner particles form a developed image on the photoconductive surface. The developed image is then transferred to a copy sheet. Subsequently, the toner particles in the developed image are heated to permanently fuse the toner particles to the copy sheet.
SUMMARY OF THE INVENTION
Ambient room light is made of various wavelengths of light. Thus, when a photoconductive member is exposed to room light, for example, when the image forming system is serviced, random areas on the surface of the photoconductive member become light-shocked by the ambient room light. As a result, these light-shocked areas of the photoconductive member become more sensitive to the light used to form the latent image. Thus, the non-uniform room light causes non-uniform exposure voltages to accrue on imaging areas of the photoconductive member. Non-uniform exposure voltages across the imaging areas of the photoconductive member cause distortions in the electrostatic latent image developed on the imaging areas of the photoconductive member. Thus, the developed image on the photoconductive member includes image density variations, or distortions. As a result, when the developed image is subsequently transferred to a recording medium, the resulting image is distorted. These image distortions create images that would be objectionable to a customer.
Additionally, photoreceptors are relatively expensive. Unfortunately, during servicing, photoreceptors are often exposed to ambient room light. Thus, many photoreceptors are needlessly discarded by service personnel during servicing because of expected poor performance after these photoreceptors are exposed to ambient room light.
This invention provides apparatuses, systems and methods to maintain a photoreceptor in a uniformly light-shocked condition.
This invention separately provides apparatuses, systems and methods to supply a light source within a photocopy machine that will shine light on the photoreceptor.
This invention separately provides apparatuses, systems and methods to supply a light source within a photocopy machine that will shine high level, wide band fluorescent light on the photoreceptor.
This invention separately provides apparatuses, systems and methods that reduce the photoreceptor's sensitivity to ambient room light.
This invention separately provides apparatuses, systems and methods that limit a level of light shock to reduce the non-uniform voltages within the print area of the photoreceptor.
This invention separately provides apparatuses, systems and methods that limit a level of light shock to reduce defects in resulting images.
This invention separately provides apparatuses, systems and methods that limit a level of light shock to reduce adverse effects on the life of the photoreceptor.
This invention separately provides apparatuses, systems and methods that limit a level of light shock to reduce adverse effects on the performance of the photoreceptor
This invention separately provides apparatuses, systems and methods for more effectively removing undeveloped toner particles from the surface of a photoreceptor.
In accordance with the apparatuses, systems and methods of this invention, various exemplary embodiments of the light exposure systems according to this invention use a light that constantly shines on the photoreceptor during normal printing. In various exemplary embodiments, the light includes a wide band fluorescent light.
Other exemplary embodiments of this invention include systems and methods that turn on a fluorescent light only during specific time periods. In various exemplary embodiments, the specific time periods include times during which special diagnostic routines are being performed. This allows a user or service personnel to operate the wide band fluorescent light if print quality appears to be poor, or after, or as part of, a servicing routine. In various exemplary embodiments, the specific time periods include time periods when the image forming system is not printing. The time periods when the image forming system is not printing could include, for example, time periods when the image forming system is in a warm-up or a shut-down cycle. In various exemplary embodiments, the specific time periods include time periods when a fault diagnostic system determines that the image forming system is in a condition requiring analysis or problem solving, such as, for example, any time that the doors of the image forming system are open.
Other exemplary embodiments of this invention include systems and methods that use a bank of lights that constantly shine light on the photoreceptor.
Other exemplary embodiments of this invention include systems and methods that use a bank of wide band fluorescent lights that constantly shine wide band fluorescent light on the photoreceptor.
These and other features and advantages of this invention are described in or are apparent from the following detailed description of various exemplary embodiments of the apparatuses, systems and methods of this invention.
BRIEF DESCRIPTION OF THE DRAWINGS
Various exemplary embodiments of this invention will be described in detail, with reference to the following figures, wherein:
FIG. 1 is a side view showing the structure of an image forming system incorporating a first exemplary embodiment of a light shock reduction system according to this invention;
FIG. 2 is a side view showing the structure of an image forming system incorporating a second exemplary embodiment of a light shock reduction system according to this invention;
FIG. 3 is a side view showing the structure of an image forming system incorporating a third exemplary embodiment of a light shock reduction system according to this invention; and
FIGS. 4A-4C show a flowchart outlining one embodiment of a control routine using the light shock reduction system of this invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
For simplicity and clarification, the operating principles, design factors, and layout of the light shock reduction systems and methods according to this invention are explained with reference to various exemplary embodiments of light shock reduction systems and methods according to this invention, as shown in FIGS. 1-4C. The basic explanation of the operation of the illustrated light shock reduction systems and methods is applicable for the understanding and design of the constituent components employed in the light shock reduction systems and methods of this invention.
FIG. 1 shows an image forming system incorporating a first exemplary embodiment of a light shock reduction system 100 according to this invention. As shown in FIG. 1, the light shock reduction system 100 includes a light source 110 that is positioned adjacent to a photoreceptor 115 and a controller 112 . In various exemplary embodiments, the light source 110 is one or more florescent lights. The photoreceptor 115 is a belt-type device that rotates in the direction A, and advances sequentially through various xerographic process steps.
A charger 120 is mounted adjacent to the photoreceptor 115 . The charger 120 charges the photoreceptor to a predetermined potential and polarity. A toner dispenser/developer housing 125 is also mounted adjacent to the photoreceptor 115 . The toner dispenser/developer housing 125 stores toner particles and dispenses the toner particles to the photoreceptor 115 to develop the latent image in an imaging/exposure/developing zone 145 . A transfer dicorotron 155 is also mounted adjacent to the photoreceptor 115 . The area between the transfer dicorotron 155 and the photoreceptor 115 form an image transfer zone 135 . A cleaner 130 is also mounted adjacent to the photoreceptor 115 . The cleaner 130 removes residual toner particles from the surface of the photoreceptor 115 after the developed image is transferred to an image recording medium from the photoreceptor 115 .
In various exemplary embodiments, the light source 110 includes two or more lights. In various exemplary embodiments, the light source 110 includes a wide band florescent light. In various exemplary embodiments, the wide band florescent light has an output intensity of 25000 μW per centimeter of length. In various exemplary embodiments, the wide band florescent light has a wavelength that is tuned to optimize the performance of the particular photoreceptor 115 that the light source 110 is used with. In various exemplary embodiments, the light source 110 is a high intensity light source, such as, for example, an incandescent light.
If the light shock reduction system 100 includes multiple modes, the controller 112 is used to control which mode is active and to controllably turn on and off the light source 110 . However, if the light reduction system 110 does not have either multiple modes or a mode that requires controllably turning on and off the light source 110 , the controller 112 can be omitted. It should be appreciated that the controller 112 can be implemented as an independent control device or as a portion of the main controller of the image forming system in which the light shock reduction system 100 is implemented.
During operation of the light shock reduction system 100 according to this invention, as a portion of photoreceptor 115 passes by the charger 120 , the charger 120 charges the photoconductive surface of photoreceptor 115 to a relatively high, substantially uniform potential V 0 . Next, the charged portion of the photoconductive surface of photoreceptor 115 advances through an imaging/exposure/developing zone 145 . In the imaging/exposure/developing zone 145 , portions of the photoconductive surface of photoreceptor 115 are selectively discharged to form a latent electrostatic image. This latent image is developed on the photoconductive surface of the photoreceptor 115 .
The photoreceptor 115 , which is initially charged to a voltage V 0 by the charger 120 , undergoes dark decay to a voltage level V dd . In various exemplary embodiments, the dark decay voltage V dd is equal to about −500V. When developed at the imaging/exposure/developing zone 145 , the exposed portions of the photoreceptor 115 are discharged to an exposure voltage V e . In various exemplary embodiments, the exposure voltage V e is equal to about −50V. Thus, after exposure, the photoreceptor 115 has a bipolar voltage profile of high and low voltages. In various exemplary embodiments, the high voltages correspond to charged areas and the low voltages correspond to discharged or background areas. Thus, the photoreceptor 115 now has an electrostatic latent image formed on the surface of the photoreceptor 115 .
As the photoreceptor 115 continues to move, the imaged portion of the photoreceptor 115 passes the toner dispenser/developer housing 125 . The toner dispenser/developer housing 125 transfers charged toner particles to the imaged portions of the photoreceptor 115 .
As the photoreceptor 115 continues to move, the developed image arrives at the image transfer zone 135 . In the image transfer zone 135 , a recording medium moves along a sheet path 150 in a timed sequence so that the developed image developed on the surface of the photoreceptor 115 contacts the advancing recording medium at image transfer zone 135 .
In various exemplary embodiments of the image forming system, the image transfer zone 135 includes a transfer dicorotron 155 , which applies a bias to the recording medium. In various exemplary embodiments, the dicorotron 155 sprays positive ions onto the backside of the recording medium. This attracts the charged toner particles of the developed image from the surface of the photoreceptor 115 to the recording medium.
After transfer, the recording medium continues to move along the sheet path 150 . The recording medium is separated from the photoconductive surface of the photoreceptor 115 . Then, the recording medium continues to move along the sheet path 150 . A fusing station permanently affixes the toner particles of the transferred image to the recording medium.
As the photoreceptor 115 continues to move, the photoreceptor 115 passes the light source 110 . The light source 110 shines high level, wide band light onto the photoreceptor 115 . This wide band light uniformly light shocks the photoreceptor 115 . This light shock reduces the photoreceptor's sensitivity to ambient room light and other stray light that may enter the image forming system or otherwise impinge on the photoreceptor 115 .
In various exemplary embodiments, the high level, wide band light from the light source 110 also aids in neutralizing any remaining voltages remaining from the electrostatic latent image formed on the surface of the photoreceptor 115 . Thus, any remaining charged toner particles carried on the photoconductive surface of the photoreceptor 115 will no longer be as strongly attracted to the surface of the photoreceptor 115 . As the photoreceptor 115 continues to move, the photoreceptor 115 passes the cleaner 130 . The cleaner 130 removes any remaining toner particles from the surface of the photoreceptor 115 .
In other exemplary embodiments, the light source 110 may be two or more light sources. One or more of the light sources may be oriented to expose a portion of photoreceptor 115 to the high-level wide band light before that portion of the photoreceptor 115 reaches the cleaner 130 . The other one or more light sources may be oriented to expose the portion of the photoreceptor 115 to the high-level wide band light after that portion of the photoreceptor 115 travels past the cleaner 130 . Using two sets of one or more light sources each in this manner tends to make the cleaner 130 more effective and reduce the chance that remaining toner particles will shadow the photoreceptor 115 .
In yet other exemplary embodiments, the light source 110 may be located in another portion of the photocopy machine. In such exemplary embodiments, the high-level wide band light from the light source 110 could shine on the photoreceptor 115 through the use of, for example, a light pipe.
FIG. 2 shows an image forming system incorporating a second exemplary embodiment of a light shock reduction system 200 . As illustrated in FIG. 2, light shock reduction system 200 includes a controller 212 and a light source 210 , which is positioned relative to a photoreceptor 215 , a charger 220 , a toner dispenser/developer housing 225 , a cleaner 230 , and a transfer dicorotron 255 . Each of these elements corresponds to one of the elements discussed above with respect to FIG. 1 .
However, light shock reduction system 200 further includes a number of light sealing elements 245 , 250 and 255 . The light sealing elements 250 and 255 are attached to a housing of the light source 210 . The light sealing element 245 is positioned on the side of the photoreceptor 215 opposite the light source 210 . The light sealing elements 245 , 250 and 255 are positioned to reduce, if not prevent, any stray light from the light source 210 from entering other areas of the imaging forming device that incorporates the light shock reduction system 200 according to this invention. In various exemplary embodiments, at least one of the light sealing elements 245 , 250 and 255 has a reflective surface where the reflective surface faces the photoreceptor 215 . In various exemplary embodiments, the reflective surface of at least one of the light sealing elements 245 , 250 and 255 reflects light from the light source 210 toward the photoreceptor 215 .
If the light shock reduction system 200 includes multiple modes, the controller 212 is used to control which mode is active and to controllably turn on and off the light source 210 . However, if the light reduction system 210 does not have either multiple modes or a mode that requires controllably turning on and off the light source 210 , the controller 212 can be omitted. It should be appreciated that the controller 212 can be implemented as an independent control device or as a portion of the main controller of the image forming system in which the light shock reduction system 200 is implemented.
In other exemplary embodiments, the light sources 110 and/or 210 may be located inside the circumference of the photoreceptor 115 .
FIG. 3 shows an image forming system incorporating a third exemplary embodiment of a light shock reduction system 300 according to this invention. As illustrated in FIG. 3, the light shock reduction system 300 includes a light source 310 that is positioned adjacent to a drum-type photoreceptor 315 and a controller 312 . In various exemplary embodiments, the light source 310 is one or more florescent lights. The photoreceptor 315 is a drum-type device that rotates in the direction B and advances sequentially through various xerographic process steps.
A charger 320 is mounted adjacent to the photoreceptor 315 . The charger 320 charges the photoreceptor to a predetermined potential and polarity. A toner dispenser/developer housing 325 is also mounted adjacent to the photoreceptor 315 . The toner dispenser/developer housing 325 stores toner particles and dispenses the toner particles to the photoreceptor 315 to develop the latent image. A transfer dicorotron 355 is also mounted adjacent to the photoreceptor 315 . The area between the transfer dicorotron 355 and the photoreceptor 315 forms an image transfer zone 335 . A cleaner 330 is also mounted adjacent to the photoreceptor 315 . The cleaner 330 removes residual toner particles from the surface of the photoreceptor 315 after the developed image is transferred to an image recording medium from the photoreceptor 315 .
The light source 310 , the photoreceptor 315 , the charger 320 , the toner dispenser/developer housing 325 , the cleaner 330 , and the transfer dicorotron 355 correspond to and operate similarly to the same elements discussed above with respect to FIGS. 1 and/or 2 .
If the light shock reduction system 300 includes multiple modes, the controller 312 is used to control which mode is active and to controllably turn on and off the light source 310 . However, if the light reduction system 310 does not have either multiple modes or a mode that requires controllably turning on and off the light source 310 , the controller 312 can be omitted. It should be appreciated that the controller 312 can be implemented as an independent control device or as a portion of the main controller of the image forming system in which the light shock reduction system 300 is implemented.
During operation of the light shock reduction system 300 according to this invention, as a portion of the photoreceptor 315 rotates by the charger 320 , the charger 320 charges the photoconductive surface of photoreceptor 315 to a relatively high, substantially uniform potential V 0 . Next, the charged portion of the photoconductive surface of photoreceptor 315 rotates through an imaging/exposure/developing zone 345 . In imaging/exposure/developing zone 345 , portions of the photoconductive surface of the photoreceptor 315 are selectively discharged to form a latent electrostatic image. This latent image is then developed on the photoconductive surface of photoreceptor 315 .
The photoreceptor 315 , which is initially charged to a voltage V 0 by charger 320 , undergoes dark decay to a voltage level V dd . In various exemplary embodiments, the dark decay voltage V dd is equal to about −500V. When exposed at the imaging/exposure/developing zone 345 , the exposed portions of the photoreceptor 315 are discharged to an exposure voltage Ve. In various exemplary embodiments, the exposure voltage V e . is equal to about −50V. Thus, after exposure, the photoreceptor 315 has a bipolar voltage profile of high and low voltages. In various exemplary embodiments, the high voltages correspond to charged areas and the low voltages correspond to discharged or background areas. Thus, the photoreceptor 315 now has an electrostatic latent image formed on the surface of the photoreceptor 315 .
As the photoreceptor 315 continues to rotate, the imaged portion of the photoreceptor 315 passes the toner dispenser/developer housing 325 . The toner dispenser/developer housing 325 transfers charged toner particles to the imaged portions of the photoreceptor 315 .
As the photoreceptor 315 continues to rotate, the developed image arrives at the image transfer zone 335 . In the image transfer zone 335 , a recording medium moves along a sheet path 350 in a timed sequence so that the developed image developed on the surface of the photoreceptor 315 contacts the advancing recording medium at image transfer zone 335 .
In various exemplary embodiments of the image forming system, the image transfer zone 335 includes a transfer dicorotron 355 , which applies a bias to the recording medium. In various exemplary embodiments, the dicorotron 355 sprays positive ions onto the backside of the recording medium. This attracts the charged toner particles of the developed image from the surface of the photoreceptor 315 to the recording medium.
After transfer, the recording medium continues to move along the sheet path 350 . The recording medium is separated from the photoconductive surface of the photoreceptor 315 . Then, the recording medium continues to move along the sheet path 350 . A fusing station permanently affixes the toner particles of the transferred image to the recording medium.
As the photoreceptor 315 continues to rotate, the photoreceptor 315 passes the light source 310 . The light source 310 shines high level, wide band light onto the photoreceptor 315 . This wide band light uniformly light shocks the photoreceptor 315 . This light shock reduces the photoreceptor's sensitivity to ambient room light.
In various exemplary embodiments, the high level, wide band light from the light source 310 also aids in neutralizing any remaining voltages remaining from the electrostatic latent image formed on the surface of the photoreceptor 315 . Thus, any remaining charged toner particles carried on the photoconductive surface of the photoreceptor 315 will no longer be as strongly attracted to the surface of the photoreceptor 315 . As the photoreceptor 315 continues to rotate, the photoreceptor 315 passes the cleaner 330 . The cleaner 330 removes any remaining toner particles from the surface of the photoreceptor 315 .
In other exemplary embodiments, the housing of light source 310 may include the light sealing elements discussed above with respect to FIG. 2 .
In other exemplary embodiments, the light source 310 may include two or more light sources. One or more of the light sources may be oriented to expose a portion of photoreceptor 315 to the high-level wide band light before that portion of the photoreceptor 315 reaches the cleaner 330 . The other one or more light sources may be oriented to expose the portion of the photoreceptor 315 to the high-level wide band light after that portion of the photoreceptor 315 travels past the cleaner 330 . Using two sets of one or more light sources each in this manner tends to make the cleaner 330 more effective and reduce the chance that remaining toner particles will shadow the photoreceptor 315 .
In yet other exemplary embodiments, the light source 310 may be located in another portion of the photocopy machine. In such exemplary embodiments, the high-level wide band light from the light source 310 could shine on the photoreceptor 315 through the use of, for example, a light pipe.
FIGS. 4A-4C are a flowchart outlining one exemplary embodiment of a method for controllably light shocking a photoreceptor according to this invention. A user can toggle between various light shock reduction modes, such as, for example, a “continuous” mode, a “diagnostic” mode, a “non-interference” mode, or an “analysis” mode. In the “continuous” mode, the light source constantly shines on an adjacent photoreceptor. In the “diagnostic” mode, the light source only shines on the adjacent photoreceptor when special diagnostic routines are being performed. This allows a user or service personnel to operate the wide band fluorescent light if print quality appears to be poor, or after, or as part of, a servicing routine. In the “non-interference” mode, the light source only shines on the adjacent photoreceptor during a time period when the image forming system is not printing. The time periods when the image forming system is not printing could include, for example, time periods when the image forming system is in a warm-up or a shut-down cycle. Finally, in the “analysis” mode, the light source shines on the adjacent photoreceptor if a fault diagnostic system determines that the image forming system is in a condition requiring analysis or problem solving, such as, for example, any time that the doors of the image forming system are open.
As shown in FIGS. 4 A— 4 C, beginning in step S 100 , control continues to step S 110 , where a determination is made whether a light shock reduction mode has been selected. If, in step S 110 , a light shock reduction mode has not been selected, control advances to step S 120 . Otherwise control jumps to step S 140 .
In step S 120 , the light source is operated in a default light shock reduction mode. In the default light shock reduction mode, the light source is turned on. Then, in step S 130 , a determination is made whether there has been a change to the selected light shock reduction mode. If there is a change in the selected light shock reduction mode control routine returns to step S 110 . Otherwise, if there is no change to the selected light shock reduction mode, control returns to step S 120 , and the light source continues to be operated in the predetermined default light shock reduction mode.
In step S 140 , a determination is made whether a “continuous” light shock reduction mode has been selected in step S 110 . If the “continuous” light shock reduction mode was selected in step S 110 , control advances to step S 150 . Otherwise, control jumps to step S 170 .
In step S 150 , the light source is turned on. Next, in step S 160 , a determination is made whether there has been a change to the selected light shock reduction mode. If there is a change to the selected light shock reduction mode, control returns to step S 110 . Otherwise, if there is no change to the light shock reduction mode input, control returns to step S 150 , and the light source continues to be operated on the continuous light shock reduction mode.
In step S 170 , a determination is made whether a “diagnostic” light shock reduction mode was selected in step S 110 . If the “diagnostic ” light shock reduction mode was selected in step S 110 , control advances to step S 180 . Otherwise, control jumps to step S 220 .
In step S 180 , a determination is made whether a diagnostic cycle is operating in the image forming system. If so, control jumps to step S 210 . Otherwise, control advances to step S 190 .
In step S 190 , the light source is turned off. Then, in step S 200 , a determination is made whether there has been a change to the selected light shock reduction mode. If there is a change to the selected light shock reduction mode input, control returns to step S 110 . Otherwise, if there is no change to the selected light shock reduction mode, control returns to step S 180 .
In step S 210 , the light source is turned on for a limited period of time. Once the light source has been on for the limited period of time, control returns to step S 110 .
In step S 220 , a determination is made whether a “non-interference” light shock reduction mode was selected in step S 110 . If the “non-interference ” light shock reduction mode was selected in step S 110 , control advances to step S 230 . Otherwise, control jumps to step S 270 .
In step S 230 , a determination is made whether the image forming system is printing. If the image forming system is printing, the control advances to step S 240 . Otherwise, control jumps to step S 250 .
In step S 240 , the control routine turns the light source off control directly then jumps to step S 260 . In contrast, in step S 260 , the control routine turns the light source on. Then, in step S 260 , a determination is made whether there has been a change to the selected light shock reduction mode. If there is a change in the light shock reduction mode input, control returns to step S 110 . If there is no change to the selected light shock reduction mode input, control returns to step S 230 .
Once the light source is turned on, the control system returns to step S 110 .
In step S 270 , a determination is made whether an “analysis” light shock reduction mode was selected in step S 110 . If the “analysis” light shock reduction mode was selected in step S 110 , control advances to step S 280 . Otherwise, control returns to step S 110 .
In step S 280 , a determination is made whether a fault diagnostic system has determined that the image forming system is in an analysis or problem solving condition requiring actions, such as, for example, a door to be opened, that will permit ambient light to illuminate the photoreceptor member. If in step S 280 , the image forming device is not in an analysis or problem solving condition, control advances to step S 290 . Otherwise, control jumps to step S 300 .
In step S 290 , the light source is turned off. Control then jumps to step S 310 . In contrast, step S 300 , the light source is turned on. Then, in step S 300 , a determination is made whether there has been a change to the selected input light shock reduction mode. If there is a change to the selected light shock reduction mode, control returns to step S 110 . Otherwise, if there is no change to the selected light shock reduction mode, control returns to step S 280 .
It should be appreciated that, if any one of the above described light shock reduction modes is omitted from any particular embodiment, the flowchart outlined in FIGS. 4A-4C will be modified accordingly. Similarly, should the implemented light shock reduction system include additional light shock reduction modes, the flowchart outlined in FIGS. 4A-4C will be adjusted accordingly to incorporate steps similar to those described above for these additional light shock reduction modes. Similarly, the default light shock reduction mode could in fact be any one of the implemented light shock reduction modes.
Furthermore, it should be appreciated that, rather than the user selecting the light shock reduction mode, the light shock reduction mode could be determined automatically by the image forming system based on various control parameters, such as, for example, the light shock reduction mode could be automatically selected based on any number of control criteria. Such control criteria could include, for example, the age of the photoreceptor, the length of time since the image forming system was last serviced, the diagnostic history of the image forming apparatus and/or any other desired control criteria.
In various exemplary embodiments described above, the light exposure systems have been described with reference to a florescent light source. However, it should be appreciated that any known or later developed high intensity light source can be used in conjunction with, or in place of, the light source described above. Furthermore, the light exposure systems described above have been described within a single color electrophotographic marking process. However, it should be appreciated that any known or later developed image forming system that uses a photoconductive member could be modified to incorporate the light exposure systems and methods according to this invention.
The controllers 112 , 212 , and 312 shown in FIGS. 1-3, if implemented as independent control devices, can be implemented using a programmed microprocessor or microcontroller and peripheral integrated circuit elements, and ASIC or other integrated circuit, a digital signal processor, a hardwired electronic or a logic circuit such as a discrete element circuit, a programmable logic device such as a PLV, PLA, FPGA or PAL or the like. In other exemplary embodiments, where the controllers 112 , 212 and/or 312 are implemented as part of the control system of the image forming apparatus in which the light shock reduction system 100 , 200 or 300 , respectively is implemented, the controllers 112 , 212 and/or 312 can be implemented using a programmed general purpose computer or any other device capable of implementing the general control system for the image forming system. Such other devices include a special purpose computer, a programmed microprocessor or microcontroller and a peripheral integrated circuit elements, and ASIC or other integrated circuit, a digital signal processor, a hardwired electronic or logic circuit such as discrete element circuit, a programmable logic device such as a PLV, PLA, FPGA or PAL or the like. In general, any device, capable of implementing a finite state machine that is in turn capable of implementing the flowchart shown in FIGS. 4A-4C, can be used to implement the controllers 112 , 212 and/or 312 .
While this invention has been described in conjunction with the exemplary embodiments outlined above, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art. Accordingly, the exemplary embodiments of the invention, as set forth above, are intended to be illustrative, not limiting. Various changes may be made without departing from the spirit and scope of the invention.
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A light source within a photocopy machine continuously shines high level, wide band fluorescent light on the photoreceptor to maintain the photoreceptor in a uniformly light-shocked condition. This constant level of light shock has no adverse effects on either the life or performance of the photoreceptor in normal operation. Thus, the photoreceptor becomes less sensitive to unintentional, uneven ambient room light and random, long lasting delta voltages within the print area are reduced so that print quality defects are minimized.
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This application is a continuation of prior application Ser. No. 07/435,124, filed Nov. 13, 1989, now abandoned.
FIELD OF THE INVENTION
This invention relates to a microcomputer interface arrangement and particularly to an interface arrangement which enables identification of a faulty interface unit amongst a plurality of such units coupled to a microcomputer unit.
BACKGROUND OF THE INVENTION
It is known to couple a plurality of interface units, such as power switching units to a microcomputer which controls the switching of the units via respective control lines.
Each such unit is usually provided with a fault indicating output which provides a fault indicating output signal in the event of a fault occurring in the unit. It is common to couple all the fault indicating output terminals together in a wired OR configuration and to the interrupt input of the microcomputer unit.
In the event of a fault occurring in one of the interface units an output signal at its fault indicating output will interrupt the microcomputer to alert it to the fault. In view of the wired OR configuration, it has hitherto not been possible to identify the unit originating the fault indicating signal without separate diagnostic procedures requiring the provision of an extra diagnostic pin and the disturbing of the output states of the units.
SUMMARY OF THE INVENTION
According to the invention there is provided a microcomputer interface arrangement comprising:
a microcomputer unit having a plurality of input/output (I/O) terminals and an interrupt indicating input terminal;
a plurality of interface units each having an input terminal coupled by a two way control line to a respective I/O terminal of the microcomputer unit, an output terminal and a fault indicating terminal, the fault indicating terminals of the plurality of interface units being coupled together and to the interrupt indicating terminal of the microcomputer; output means coupled between the input and output terminals; fault indicating means responsive to a fault condition at the output terminal for providing a fault indicating signal at the fault indicating terminal to interrupt the microcomputer unit and for inverting the input state of the interface unit without affecting the output state whereby the interface unit having a fault condition may be identified.
The fault indicating means preferably includes diagnostic means for providing an output signal in response to a fault condition at the output terminal.
The fault indicating means may further include a controllable switch having an input coupled to the output of the diagnostic means and an output coupled to the fault indicating terminal to provide the fault indicating signal.
The controllable switch may have an output for providing an output voltage in response to the output signal of the diagnostic means and a comparator may be provided for comparing the output voltage with a reference voltage.
Typically the reference voltage is greater than the said output voltage of the controllable switch and current injection means is provided for injecting current into the controllable switch to increase its output voltage above the level of the reference voltage whereby an output signal is provided at the output of the comparator.
Preferably the output means includes latch means is coupled between the input terminal and the output means.
Typically a second controllable switch is coupled between the input terminal and the latch means, the latch means being coupled to one selectable terminal of the switch and an inverter being coupled between the output of the latch means and a second selectable terminal.
The output of the comparator is preferably coupled to a control input of the second controllable switch.
BRIEF DESCRIPTION OF THE DRAWINGS
An exemplary embodiment of the invention will now be described with reference to the accompanying drawings in which
FIG. 1 is a block schematic of a microcomputer interface arrangement in accordance with the invention; and
FIG. 2 is a more detailed block diagram of an interface unit of FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1 a microcomputer unit (MCU) 10 has a plurality of I/O terminals P1, P2, P3 through Pn and an interrupt indicating terminal PINT which may be a unique interrupt terminal or an I/O pin used as an interrupt terminal.
The I/O terminals P1, P2, P3, Pn are coupled by means of respective two way control lines 20 to input terminals 25 of respective interface units 30a, 30b, 30c . . . 30n.
Each interface unit 30a through 30n also has a fault indicating terminal 35 and an output terminal 40. All the fault indicating terminals 35 are coupled together in wired OR configuration and to the interrupt terminal PINT of the MCU 10, by means of a fault line 45.
Each interface unit provides an appropriate output state (depending on its function) in response to a data input signal fed to its input terminal 25 from the respective I/O terminal of the MCU 10.
A PNP transistor 50 has its base electrode coupled to a terminal P5 of the MCU 10 and its emitter and collectors coupled respectively to a supply line 55 and to the fault line 45.
In the event of a fault occurring within one of the interface units 30a through 30n a fault indicating signal will appear at the fault indicating output 35 of the faulty unit and will be fed via the fault line 45 to the interrupt input PINT, where it will interrupt the MCU 10.
On being interrupted the MCU initiates a diagnostic procedure to determine which of the interface units is faulty. A signal is applied to the base of the PNP transistor 50 from the terminal P5 of the MCU 10 to turn on the transistor 50. Current is injected by the transistor 50 onto the fault line 45 and into the fault indicating terminal 35 of each interface unit 30.
In response to the current injected onto the fault line 45, the logical value of the data state of the faulty interface unit previously set by the MCU 10 is caused to be inverted whilst the non-faulty units have their data states latched to their originally set values.
With the I/O terminals P1 through Pn set to input mode by the MCU 10, the MCU reads the data values presented at the terminals 25 of the interface units 30 and determines the faulty unit by virtue of its inverted data value. The faulty unit is thus identified without changing the output data values of the interface units.
Referring now to FIG. 2 there is shown a block schematic of an exemplary interface unit of FIG. 1. In this example the interface unit is a controlled high-side switch for coupling a supply voltage VDD applied to the VDD supply terminal, to the output terminal 40, in response to a digital value applied to the input terminal 25 by the MCU 10.
The input terminal 25 is coupled to the input 61 of a controllable switch 62, which has selectable terminals 63 and 64, selectable in response to a control signal applied to a control input 65.
The switch 62 normally has its input 61 coupled to the terminal 64 to which is also coupled latch 66.
The latch 66 has an output 67 which is coupled via an inverter 68 to the second selectable terminal 63 of the switch 62.
The output 67 of the latch 66 is coupled to the control input 68 of a power switch 69 coupled between the VDD supply terminal and the output terminal 40.
On application by the MCU 10 of an appropriate digital value to the input terminal 25 this value is held at the output of the latch and closes the controllable switch to couple the supply voltage VDD to the output terminal 40 for application to a load.
The output terminal 40 is coupled to a respective input 72, 73 of each of two comparators 70, 71. The comparator 70 is a voltage sensing comparator whose second input 74 receives a reference voltage and provides an output signal in the event of the output voltage falling too low; such a situation might occur if the load resistance becomes too low but is not zero.
The comparator 71 is a current sensing comparator and its second input 75 is coupled to the output terminal 40 via a resistor 76. The comparator 71 senses the voltage drop across the resistor and provides an output signal if the drop becomes too large indicating too high a current flow due to, for example, a short circuit load.
The comparators 70 and 71 have outputs 78 and 77, which are coupled to a diagnostic circuit 80 which is also coupled to the output 67 of the latch. The logic state of the latch output 67 indicates to the diagnostic circuit 80 the intended output state and this intended state is compared with the output states of the comparators 70 and 71 to determine if a fault condition exists.
The diagnostic circuit 80 has an output 81 coupled to the gate control electrode 91 of a MOS transistor 90, the drain of which is coupled to the fault indicating terminal 35, whilst its source is coupled via a resistor 92 to ground reference terminal 93.
The source terminal of the transistor 90 is coupled to one input 101 of a comparator 100 whose other input 102 receives a reference voltage. The comparator 100 has its output 103 coupled to the control input 65 of the controllable switch 62.
In the event of a fault being detected by the diagnostic circuit 80, an output signal is provided at its output 81 and is applied to the gate 91 of the transistor 90 to turn ON the transistor. Current flows in the transistor 90 and a fault indicating voltage is developed at the fault indicating terminal 35. The fault indicating voltage is applied to the interrupt terminal PINT of the MCU 10.
Current flowing through the transistor 90 also develops a voltage across the resistor 92, which voltage appears at the input terminal 101 of the comparator 100. The value of the reference voltage applied to the reference input terminal 102 of the comparator 100 is chosen to be greater than that developed on the resistor 92 so that, at this stage, the comparator provides no output signal. This is to ensure continued normal operation until the MCU 10 initiates a diagnostic test.
As explained above, on initiation of the diagnostic test the I/O terminals of the MCU 10 are switched to input to read the logic state at the input terminals 25 of the interface units 30 and current is injected by the transistor 50 into the fault indicating terminals 35 of each interface unit.
The injected current increases the current flow through the transistor 90 and accordingly the voltage drop across the resistor 92 for the faulty interface unit. The voltage applied to the input 101 of the comparator 100 increases and now exceeds the reference voltage applied to the input terminal 102.
The comparator 100 provides an output signal which switches the controllable switch to couple the input terminal 25 to the selectable terminal 63. At this terminal 63 will appear the inverted logic state to that originally applied to the input terminal 25 and now appearing at the output 67 of the latch 66, due to the connection of the inverter 68. Thus the input terminal 25 will also indicate the inverse logic state to that set by the MCU 10 and latched at the output 67 of the latch 66.
In all other interface units where no fault is detected, the respective transistor 90 will not be turned ON and the controllable switches 62 will maintain the coupling of the input terminals 25 to the non-inverted outputs 67 of the latches 66 and the MCU will accordingly read the originally set logic states.
Thus the interface arrangement of the invention allows the detection not only of a fault condition, but also the identification of a faulty interface unit without losing or otherwise changing the output states of the correctly operating units.
After completion of the diagnostic test the transistor 50 is turned off and the I/O terminals P1 through Pn are once more set in output with their original data values restored. The removal of the current injected into the transistor 90 will result in the removal of the output signal of the comparator 100 and the switch 62 will revert to its original condition in which the input terminal 25 is coupled to the input of the latch 66.
The embodiment described is by way of example only and modifications may be made without departing from the scope of the invention. For example although described with reference to a high side switch interface, the invention is applicable to any kind of interface in which the output logic state is controlled in dependence upon an input logic state supplied by a microcomputer output. Also the particular fault conditions detected are exemplary and other or additional fault detecting means may be employed, such as open circuit load detection and thermal limit detection.
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A microcomputer interface arrangement includes a microcomputer having I/O ports coupled to individual interface units. A fault detection circuit detects a fault in an interface unit, interrupts the microcomputer and inverts the input state of the faulty unit without affecting the output states so that the faulty unit can be identified by the microcomputer by reading inputs of the interface units.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the priority benefit of U.S. provisional application titled “PROGRAMMABLE GAIN ANALOG-TO-DIGITAL CONVERTER” filed on May 11, 2001, Ser. No. 60/290,427. All disclosures of this application is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the invention:
[0003] The present invention relates to an analog-to-digital converter, and more particularly, to a pipelined 4-stage ADC with digital gain, and offset control.
[0004] 2. Description of related art
[0005] Analog-to-digital converters are circuits commonly used in communications, instrumentation, and consumer devices. A preferred embodiment of the invention utilizes its design in a video-graphics conversion circuit of a flat-panel monitor. Currently most personal computers utilize video cards that convert digital signals into RGB analog signals for displaying graphics on CRT monitors. It is therefore necessary for flat-panel displays to be able to interface with current video graphics systems. FIG. 1 shows a typical flat-panel video graphics conversion circuit. The flat-panel display requires an analog interface 16 to change the analog RGB signals from the RAMDACs 14 into the digital signals required by the graphics controller 18 . The RAMDACs 14 are configured at a pixel rate based on the resolution of the screen to convert the digital signals from the graphics processing engine 12 in the PC graphics card 10 into an analog 256-level pulse amplitude modulated signal which is transmitted along with timing signals to the analog interface 16 of the flat panel display. The analog interface 16 , which requires high-speed ADCs to convert the data into a digital format for processing, receives the analog graphics data. During the ADC conversion it is also necessary to alter the offset and gain of the signal for adjusting image quality. In a display device, increasing the gain setting results in an image with more contrast. The offset control is independent for the red, green, and blue channels and serves to shift the entire input range, resulting in a change in image brightness. Therefore a need exists for a high-speed, high resolution ADC with offset and gain control, that has low power consumption.
SUMMARY OF THE INVENTION
[0006] It is therefore, an object of the present invention to provide a pipelined analog-to-digital converter with offset and gain control. It is also an object to provide a pipelined analog-to-digital converter that has reduced power consumption.
[0007] To accomplish these and other objects of the present invention, a 4 stage pipelined analog-to-digital converter with a programmable gain stage is provided. The programmable gain stage comprises two capacitor arrays that serve as digital-to-analog converters. Each capacitor array is composed of a binary-weighted section that is further composed of two stages capacitively coupled together to reduce the capacitor ratios. An input analog signal is inputted to a programmable gain stage wherein the offset and gain of the signal can be manipulated using a digital control. A fully differential signal is then sent to the first stage of the pipeline ADC. The first stage outputs a 1.5 bit digital output and provides an extra gain of 2 to the signal. The extra gain allows the programmable gain stage to use less power, and therefore less power consumption in the overall circuit. The second and third stages each provide 2.5 bit digital outputs each. The final stage provides a 3 bit digital output.
[0008] It is to be understood that both the foregoing general description and the following detailed description are exemplary, and are intended to provide further explanation of the invention as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The accompanying drawings are included to provide a further understanding of the invention, and are incorporated in and constitute a part of this specification. The drawings illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention. In the drawings,
[0010] [0010]FIG. 1 is a block diagram of the video graphics conversion circuit of the present invention according to a preferred embodiment.
[0011] [0011]FIG. 2 is a schematic diagram of the multi-stage gain ADC of the present invention according to a preferred embodiment.
[0012] [0012]FIG. 3 is a circuit diagram of the programmable gain stage of the present invention according to a preferred embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0013] In the following detailed description of the preferred embodiments, reference is made to the accompanying drawings which form a part hereof, and in which is shown by way of illustration specific preferred embodiments in which the invention may be practiced. The preferred embodiments are described in sufficient detail to enable these skilled in the art to practice the invention, and it is to be understood that other embodiments may be utilized and that logical changes may be made without departing from the spirit and scope of the present invention. The following detailed description is, therefore, not to be taken in a limiting sense, and the scope of the present invention is defined only by the appended claims.
[0014] [0014]FIG. 2 shows a preferred embodiment of the invention. An analog signal is inputted into a programmable gain stage 20 . The programmable gain stage 20 outputs a fully differential signal, which is fed into a 4 stage 8-bit pipeline ADC. The 1 st stage 22 of the ADC pipeline provides a 1.5 bit digital output. The 2 nd stage 24 and 3 rd stage 26 each provides a 2.5 bit digital output. The 4 th stage 28 provides a 3 bit digital output. The extra 0.5 bit in each of the first 3 stages are used for redundancy and error correction. The bits in the 4 different stages are summed together to give a total result of 8 bits. Each stage of the pipelined architecture must also provide a dc gain sufficiently high to ensure that the final settled value of the amplified residue is accurate. The dc gain requirement of the first stage is determined by the resolution of the pipeline ADC. The first stage used in the invention provides an extra gain of 2, reducing power usage in the programmable gain stage 20 , therefore reducing overall power consumption.
[0015] [0015]FIG. 3 shows the programmable gain stage 20 of the invention that consists of 2 capacitor arrays that serve as digital-to-analog converters. Each capacitor array is composed of a binary-weighted section along with a few additional capacitors. The binary-weighted section is further composed of 2 stages capacitively coupled together by capacitors 34 and 35 to reduce the capacitor ratios. Referring to FIG. 3, only a portion of the capacitor arrays will be discussed in details as each of the subsequent following portions is substantially the same. An upper capacitor 31 and lower capacitor 33 are connected by a switching device 32 . The switching device is inputted with an analog signal, a high voltage level, and a low voltage level (also can be a reference ground). The switching device is also inputted with a plurality of digital input signals controlling the internal switches. The internal switches (not shown) serve to connect the upper capacitors 31 and lower capacitors 33 with the input signals. By using appropriately sized capacitors within the array, a proper digital-to-analog conversion is achieved. This allows the control of the gain and offset of the input signal which in a preferred embodiment provides 8 bits or 256 steps of adjustment. The size of the least-significant-bit in offset adjustment is proportional to the full-scale output range which is not affected when the gain is adjusted. The programmable gain stage also provides good common mode rejection by switching the bottom plates of the corresponding capacitors in the two capacitor arrays together during an integration phase. The charges sampled by the capacitor arrays are integrated to capacitors 37 with the help of an amplifier 36 and switching devices 38 that are controlled by a plurality of digital input signals. In this way, the gain stage can sample a single-ended signal and convert it into a differential signal with a prescribed common mode value. The amplifier serves to provide the required gain to the signal.
[0016] In another embodiment of the invention, a number of the ADCs described hereinabove are interleaved together to give a higher throughput rate.
[0017] Various additional modifications may be made to the illustrated embodiments without departing from the spirit and scope of the invention. Therefore, the invention lies in the claims hereinafter appended.
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A multi-stage high-speed analog-to-digital converter with gain and offset adjustment. A programmable amplifier consisting of two capacitor arrays, and digitally controlled switching devices to manipulate an inputted analog signal. A four stage pipeline ADC provides an 8 bit digital output with redundancy and error correction.
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FIELD OF INVENTION
[0001] The invention relates to doped partially stabilized zirconia ceramics that exhibit high strength, high fracture toughness and excellent resistance to wear, and a method of producing the same. More particularly, the invention relates to the simultaneous addition of yttria (Y 2 O 3 ), ceria (CeO 2 ) and chromia (Cr 2 O 3 ) to partially stabilized zirconia (ZrO 2 ) in order to create a microstructure possessing high fracture toughness and strength.
DESCRIPTION OF THE PRIOR ART
[0002] It is well known that zirconia ceramics exist in three different structural forms: cubic form, tetragonal form and monoclinic form, depending on the temperature. It is also known that the addition of stabilizing agents such as yttria (Y 2 O 3 ) and ceria (CeO 2 ) to zirconia serves to stabilize the tetragonal phase to room temperature and impart desirable mechanical properties. Although it is accepted that both yttria and ceria are useful as stabilizing agents, their role is quite different. For example, the addition of CeO 2 to zirconia polycrystals results in a very high fracture toughness but low fracture strength and hardness as described in Journal of Materials Science, Vol. 20, 1985, pp 1178-1184. To compensate the disadvantage of lower strength and hardness in ceria-doped partially stabilized zirconia, alumina (Al 2 O 3 ) ceramics were added to zirconia as described in Advances in ceramics, 24, science and Technology of zirconia III, The American Ceramic Society, Westerville, Ohio, 1988, pp 721-728. In this work, it has been shown that the strength reached values of up to 900 MPa but the fracture toughness dropped from 20 MPa to 5.5 MPa with increasing alumina content. To further improve the fracture strength, the ceria stabilized zirconia was doped with TiO 2 which is known to dissolve in tetragonal zirconia and acts as a stabilizing agent in a similar manner to Y 2 O 3 and CeO 2 , as described in Ceramics International 24, 1998, pp 497-506. Similarly, small amounts of tantalum oxide (Ta 2 O 5 ) dissolved in yttria stabilized zirconia was found to increase both fracture toughness and bending strength as described in U.S. Pat. No. 4,886,768. Yttria was most frequently used to stabilize zirconia and also to impart higher strength to the resultant body. To enhance the strength and thermal stability, a zirconia ceramic composition consisting essentially of zirconia containing yttria, ceria and alumina has been proposed in Japanese Patent No. 61-77665 and a zirconia ceramic composition consisting essentially of yttria, magnesia (MgO) and alumina has been proposed in U.S. Pat. No. 4,820,667. The U.S. Pat. No. 4,820,667 also states that the strength of partially stabilized zirconia ceramics is greatly influenced by the ratio of oxides in the mixture and if the mixture ratio is outside of the predetermined range, the bending strength of the partially stabilized zirconia ceramics may not be increased. For example, the highest bending strength was achieved in samples containing 3 mol % yttria, 0 mol % ceria and alumina/magnesia ratio of 90/10. However, no data on the effect of the composition on fracture toughness of the sintered body was reported in the former publication. It has been generally accepted that the zirconia ceramic compositions containing yttria as a stabilizing agent are not useful to enhance fracture toughness, whereas the zirconia ceramic compositions containing ceria as a stabilizing agent are not useful to enhance the strength. It is therefore desirable to provide a zirconia ceramic and a process for producing the same, that has a bending strength equal or higher than that of zirconia ceramic stabilized with yttria and fracture toughness at the level of equal or higher than that of zirconia stabilized with ceria.
[0003] In the present invention it was found that if yttria, ceria and chromia are added to zirconia in a proper proportion, both high bending strength and high fracture toughness can be achieved in PSZ. It is, therefore, a primary objective of the present invention to provide a partially stabilized zirconia ceramic superior in bending strength and fracture toughness on the basis of determining an optimum concentration of yttria, ceria and chromia (Cr 2 O 3 ).
SUMMARY OF THE INVENTION
[0004] The present invention is directed in overcoming the problems set forth above. Briefly summarized, according to one aspect of the present invention there is provided a process for producing a zirconia ceramic possessing bending strength of over 1150 MPa and fracture toughness of over 15 MPa.m 1/2 . According to another aspect, the present invention provides zirconia ceramics that contain yttria from about 1 mol. % to about 2.5 mol. %, ceria from about 4 mol. % to about 7 mol. %, and chromia from about 0.01 mol. % to about 0.035 mol. % and that average crystal grain size constituting the ceramics is less than 0.5 μm, and at least 80% of the crystal grains are tetragonal grains The first step of the process of the invention comprises mixing of the stabilizing agents and a dopant in the presence of water soluble binder and dispersants, drying the mix at 110° C. for 6-8 hours and compacting the powder under the pressure of 150 MPa. In order to achieve high green density, the compacting is carried out for a time sufficient to compact the powder to form a green part having a density in the range of about 3.1 g/cm 3 to about 3.6 g/cm 3 . A preferred density is about 3.4 g/cm 3 . The second step of the process comprises of: sintering the green part by heating the green part from room temperature at the heating ramp in the range of about 1° C./min. to about 2° C./min. to a sintering temperature T 1 in the range of about 1450° C. to about 1580° C.; maintaining the sintering temperature for about 2 hours; cooling the sintered part from the sintering temperature at the cooling ramp in the range of from about 6° C./min to about 10° C./min.
[0005] The zirconia ceramic produced by the process of the invention consists essentially of tetragonal phase crystal grain over the specific range of dopant level. The invention overcomes the disadvantages of the prior art by providing a microstructure consisting essentially of tetragonal phase over a certain range of additive level, having the bending strength of over 1150 MPa and fracture toughness of over 15 MPa.m 1/2 , improved wear resistance and service lifetime, and is useful in applications such as weld/guide pins.
BRIEF DESCRIPTION OF TH FIGURES
[0006] FIG. 1 is an X-ray diffraction curve before fracture (as received samples) for a zirconia ceramic of the invention doped with 6.5 mole percent CeO 2 , 1.8 mole percent Y 2 O 3 , 0.01 mol percent Cr 2 O 3 and 91.7% mol ZrO 2
[0007] FIG. 2 shows polished and etched surface of a zirconia ceramic doped with CeO 2 , Y 2 O 3 and Cr 2 O 3 .
[0008] FIG. 3 shows fracture surface of a zirconia ceramic doped with CeO 2 , Y 2 O 3 and Cr 2 O 3
DETAILED DESCRIPTION OF THE INVENTION
[0009] Most additives in ZrO 2 go into solid solution at the sintering temperature and affect the polytype of zirconia retained and hence affect the fracture toughness and bending strength. Such additives include CeO 2 , Y 2 O 3 , MgO and lanthanide oxides. Cr 2 O 3 does not go into solid solution with zirconia to a large extent and is an effective grain growth inhibitor. Fracture surface observations revealed that the addition of Cr 2 O 3 to zirconia does limit the grain growth resulting in higher hardness and strength. It is also found that the presence of Cr 2 O 3 does not have an adverse effect on fracture toughness resulting in zirconia ceramics having both high fracture toughness and high bending strength. By controlling the amount of CeO 2 , Y 2 O 3 and Cr 2 O 3 , partially stabilized zirconia ceramics can be made with strength of over 1150 MPa which is similar to yttria-doped tetragonal zirconia particle (Y-TZP) with the added benefit of higher fracture toughness that can be achieved in ceria-doped tetragonal zirconia (Ce-TZP). It has been discovered that a fracture toughness of over 15 MPa.m 1/2 and bending strength of over 1150 MPa can be achieved in partially stabilized zirconia provided that the level of Y 2 O 3 is kept below 2.5 mol. %, the level of CeO 2 is kept below 7 mol. % and the content of Cr 2 O 3 is kept below 0.035 mol. % but not less than 0.01 mol. %. It has also been discovered that only with the simultaneous addition of all three additives in proper proportion can both high fracture toughness and high strength be achieved. For the purpose of the present invention, the terms high toughness and high strength refer to values in excess of 15 MPa.m 12 and in excess of 1150 MPa, respectively. If the level of Y 2 O 3 is increased above about 2.5 mol. % the strength of the resultant zirconia will increase but the fracture toughness will decrease to less than 6-7 MPa.m 1/2 . Similarly, if the level of CeO 2 is increased to above 7 mol. % the fracture toughness will increase to above 15 MPa.m 1/2 but the bending strength will decrease below 800-900 MPa. In the present invention, the enhancement of fracture toughness coincides with optimum addition of cerium oxide and the enhancement of bending strength coincides with optimum addition of yttrium oxide and chromium oxide. High toughness and high strength can sometimes be achieved by adding whiskers or short fibers to a ceramic matrix, as has been demonstrated for SiC whisker-reinforced alumina. However, the problem with this composite is that the presence of whiskers in the matrix inhibits sintering and so far it was impossible to densify the composite to a level above 98% of theoretical density using pressureless sintering.
[0010] Conventional powder processing techniques can be used to make high density ceramics. Although the additives (Y 2 O 3 , CeO 2 and Cr 2 O 3 ) can be used in the form of commercially available powders, co-precipitation or sol-gel processing can be used to synthesize the powders first before using them in that form as raw materials.
[0011] When using conventional powder processing techniques, the selected reactants can be mixed by ball milling, vibratory milling, attrition milling, jet milling, high shear mixing or another suitable technique. The powder is then formed by pressing, injection molding, slip casting, extrusion, tape casting, or any other conventional method used for ceramic processing.
[0012] The sintering is generally done at temperatures ranging between 1350° C. and 1750° C. in a heating furnace and held at the sintering temperature for several hours, for example 1-4 hours. The sintering atmosphere may be optionally chosen depending on the purpose. For example, air, oxygen, non-oxidizing atmosphere such as a vacuum, nitrogen, argon, or the like or first in the air and then in the non-oxidizing atmosphere can be used.
[0013] Furthermore, the matrix consists of a tetragonal crystal structure which contains yttrria and ceria as stabilizers and chromia as a grain growth inhibitor. The obtained zirconia of this invention is of fine grain with equiaxed grains between 0.1 and 3 μm, preferably below 0.5 μm in diameter which provides very high strength without lowering the fracture toughness below 15 MPa.m 1/2 .
[0014] As explained in detail thereabove, this invention provides zirconia ceramics which contains CeO 2 and Y 2 O 3 as stabilizers, and Cr 2 O 3 as a grain growth inhibitor, having very small average grain size, at the level below about 3 μm and preferably below about 0.5 μm, of the tetragonal crystal phase, which is superior to CeO 2 -containing zirconia ceramic in bending strength and markedly superior to Y 2 O 3 -containing zirconia ceramics in fracture toughness and in bending strength as compared with those containing CeO 2 and Y 2 O 3 individually and not in combination. The zirconia ceramics of this invention are useful for applications as weld/guide pins, engine parts, extrusion and drawing dies, ball for boll point pens, mechanical seals, and solid electrolyte materials such as oxygen sensors.
Examples 1-4
[0015] Zirconia powders comprising 1 to 2.5 mol. % Y 2 O 3 , 3 to 7 mol. % CeO 2 , 0.01 to 0.0.035 mol. % Cr 2 O 3 and 89.5 mol. % to 90.5 mol. % ZrO 2 , were mixed for 6 hours in a plastic jar with methanol as the vehicle and zirconia balls as the milling media. The slurry was dried in a dryer at 75° C. for 12 hours. The powder mixture was dry screened to −40 mesh before uniaxial pressing at 150 MPa, followed by cold isostatic pressing at 250 MPa. The rectangular shape specimens (35×16×8 mm) were sintered in air at temperatures in the range from 1450° C. to 1650° C. for 1 to 4 hours.
[0016] The rate of heating was as follows: 0.5° C./min to 500° C., 1° C./min from 500° C. to sintering temperature. Fracture toughness was determined by the indentation method on the polished surfaces and the fracture strength was determined by four-point bending from the fracture of the bend specimens at cross head speed of 0.5 mm/min. Properties of sintered samples containing 6 mol. % ceria and various levels of ytria are given in Table 1.
[0017] Detailed scanning microscopy and X-ray diffraction analysis revealed the presence of 13.63 vol. % monoclinic phase with the remaining phase being the tetragonal phase. The results of Table 1 also show that the resultant zirconia body has fine grain structure and the highest bending strength is achieved with material having lowest mean particle size.
Examples 5-8
[0018] A series of tests were performed in which starting powders were prepared from the co-precipitation of the aqueous solution of zirconium oxi-chloride (ZrOCl 2 ), yttrium nitrate (YNO 3 ) 3 , cerium nitrate and chromium nitrate. The composition of the powder was the same as in examples 1-4. The obtained precipitates were dried and transformed to the oxides by calcination. The as synthesized powder was milled to particle sizes below 1 μm, followed by drying, crushing and sieving through the sieve −40 mesh size. The rectangular shape bars (35×16×8 mm) were isostatically pressed and sintered in air at temperatures in the range from 1450° C. to 1650° C. for 1 to 4 hours. Mechanical properties of the sintered samples as a function of ceria content are presented in Table 2. The level of ytria was kept at the level of 2 mol. %. The highest fracture toughness was obtained in samples having the highest mole percent of ceria additive.
Examples 9-11
[0019] In this set of samples, the initial powder was prepared from the co-precipitation of aqueous solutions of zirconia, yttria, ceria and chromia. The concentrations of ceria was kept at 6 mol. % and yttria at 2 mol. %. The chromia content was varied from 0.2 to 0.9 mol. %. The obtained precipitates were dried, screened, milled, pressed and sintered in the same manner as in examples 1-4. The resultant mechanical property data is presented in Table 3. The results in Table 3 show that as the amount of chromia is increased, the bending strength of the sintered body is increased.
[0020] The process and product of this invention are explained in detailed in the proceeding examples which are illustrative only. Those skilled in the art will recognize that there are numerous modifications and variations and that the present invention is not limited to such examples.
[0000]
TABLE 1
Fracture
Mean
toughness
Bending
particle
Yttria
K IC ,
strength
size
content
Sample
MPa · m 1/2
MPa
μm
Mol. %
No. 1
6.6
1150
0.35
1.0
No. 2
12.0
850
0.7
2.5
No. 3
15.7
1100
0.50
1.5
No. 4
16.0
900
0.7
2.0
[0000]
TABLE 2
Fracture
Mean
toughness
Bending
particle
Ceria
K IC ,
strength
size
content
Sample
MPa · m 1/2
MPa
μm
Mol. %
No. 5
6.5
1180
0.30
3
No. 6
13.0
900
1.0
4
No. 7
14.7
1100
0.35
6
No. 8
15.0
1100
0.5
7
[0000]
TABLE 3
Fracture
Mean
toughness
Bending
Chromia
particle
K IC ,
strength
content
size
Sample
MPa · m 1/2
MPa
Mol. %
μm
No. 9
6.0
1220
0.01
0.2
No. 10
12.5
1100
0.02
0.5
No. 11
15.9
980
0.03
0.9
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A process for the production of high-density zirconia-based ceramics having high fracture toughness and strength suitable for use as nonconductive weld/guide pins, engine components and wear resistant parts. The process consists of mixing zirconia (with formula ZrO 2 ) yttria (Y 2 O 3 ) and ceria (CeO 2 ) in proper proportions to produce partially stabilized zirconia (PSZ) and then doping the PSZ with chromium oxide (Cr 2 O 3 ) to enhance the mechanical strength of the resultant body. The resultant sintered body has fracture toughness in excess of 15 MPa.m 1/2 , Vicker's Hardness in excess of 8.5 GPa and flexural strength of 1150 MPa.
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FIELD OF THE INVENTION
This invention relates to building panels, and more particularly, to building panels that are electromagnetic interference resistant.
BACKGROUND OF THE INVENTION
The proliferation of sensitive electronic equipment has accentuated the problem of electromagnetic interference. In some cases, electronic equipment is subject to malfunction when exposed to any appreciable electromagnetic interference. In others, as in military applications, electromagnetic signals generated by operation of the equipment itself can be used to pinpoint the location whereat such equipment is housed.
The problems becomes particularly acute where the electronic equipment is to be housed in structures that are not intended to be permanent structures in the strictest sense of the word. For example, relocatable and rapidly erectable temporary structures or enclosures may be employed by the military to house the electronic equipment because of their ability to be deployed rapidly at any desired sight as may be required in the course of a military operation. In the case of such enclosures, because mobility and speed of deployment is all important, it is not feasible to provide the means for preventing the radiation of electromagnetic interference in the same way as that might be attended to in a far more permanent installation.
Not untypically, such relocatable and rapidly erectable enclosures are made up of a series of panels, which are each generally self-supporting and which are fastened together to define a structure. In the usual case, each panel includes a polygonal frame sandwiched by two skins. The frame and the skins are typically metal and a low density core is disposed within the frame and between the skins. Metallic and non-metallic honeycomb, rigid foams and balsa are typical core materials.
The skins are bonded to the frame by means of an adhesive and in many instances, a thermal barrier is interposed between one of the skins and the frame to minimize thermal transfer.
These panels work well in terms of providing durable, relocatable and rapidly erectable structures. However, because the skins are bonded by an adhesive to the frame, creating electrical isolation through which unintended radio frequency emissions from sensitive electronic equipment contained within an enclosure formed of such panels may escape detection of the equipment is allowed. Alternatively, electromagnetic interference may enter the structure and interfere with the operation of equipment contained therein.
The present invention is directed to overcoming one or more of the above problems.
SUMMARY OF THE INVENTION
It is the principal object of the invention to provide an electromagnetic interference resistant enclosure panel. It is also an object of the invention to provide a method of increasing the electromagnetic interference shielding across the joint of adhesively joined metallic members.
According to the invention there is provided an electromagnetic interference resistant structure that includes a metal frame and a metal skin having an interface with the frame. A series of peaks and valleys are located on either or both of the frame and the skin at the interface. The peaks are in intimate or near intimate contact with the other of the frame and the skin while adhesive is located in the valleys to bond the panel to the frame.
In a highly preferred embodiment, the peaks are in substantial electrical contact with the other of the frame and the skin to minimize electrical resistance between the two to thereby provide a barrier or shield against electromagnetic interference.
The method contemplated by the invention includes the steps of forming a series of peaks and valleys on one of two metal members to be adhesively joined at an interface. The peaks and valleys are located at the intended location of the joint. Thereafter, an adhesive is placed at the intended location of the joint and the members are brought into substantial abutment at the intended location of the joint. The members are then pressed together to bring the peaks on the one member into intimate or near intimate contact with the other member while causing the adhesive to extend between the two members to bond the same together.
The metal employed is preferably aluminum or steel. The adhesive employed is preferably an epoxy resin.
Typically, the frame is in the form of a polygon and made of tubular material or the like. The frame is sandwiched by two metal skins as is a core which may typically be formed of foam or honeycomb. A thermal barrier may be interposed between one of the skins and the frame.
Other objects and advantages will become apparent from the following specification taken in connection with the accompanying drawings.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of an enclosure panel made according to the invention;
FIG. 2 is an enlarged, fragmentary, sectional view of the panel taken approximately along the line 2--2 in FIG. 1;
FIG. 3 is a further enlarged, fragmentary, expanded view of part of the panel;
FIG. 4 is a photo micrograph of part of a joint between a frame used in the panel and a skin secured to the frame, magnified 120 times;
FIG. 5 is a perspective view of part of the panel frame.
DESCRIPTION OF THE PREFERRED EMBODIMENT
An exemplary embodiment of an enclosure panel made according to the invention is illustrated in the drawings and with reference to FIG. 1 is seen to be generally polygonal in shape having sides 10, 12, 14 and 16 as well as a top 18 and a bottom 20. Typically, each panel will be self-supporting such that a plurality of the panels can be secured together in any conventional way to define an enclosure which may house, for example, electrical equipment capable of generating electromagnetic emissions or susceptible to being affected by the presence of electromagnetic interference.
As seen in FIG. 2, each panel includes a tubular, peripheral frame 22. As illustrated, the tubular frame 22 is a rectangular tube but other shapes could be used if desired. Channels (not shown) could also be employed. The upper side 18 is defined by a skin 24 adhered to one side wall 26 of the frame 22 while the bottom 20 of the panel is defined by a similar skin 28 which is adhered to a bottom side 30 of the frame 22 with a thermal barrier 32. The thermal barrier 32 may be formed of any material that is a poor heat conductor. Typically, a reinforced plastic or wood is used for the purpose. Within the confines of the frame 22 and between the skins 24 and 28, a core 34 is located. Preferably, the core 34 is either a rigid foamed material or a non-metallic honeycomb as is well known.
In the usual case, both the frame 22 and the skins 24 and 28 will be made of the same metallic material. Typically, aluminum or steel will be used for the purpose.
According to the invention, at the location whereat the skin 24 is to be adhered to the frame 22, the surface of one or both of such elements, preferably a surface 34 on the side 26 of the frame 22, is roughened as with a knurling tool to provide a series of peaks 36 and interposed valleys 38. An adhesive layer 40, preferably an epoxy resin adhesive, is interposed between the frame and the skin 24 as illustrated in FIG. 3.
Turning now to FIG. 4, which is a photo micrograph of the joint between the skin 24 and the frame 22 where the frame 22 has been roughened and magnified 120 times, it will be seen that a peak 36 is in intimate or near intimate, that is, in substantial electrical contacting engagement, with the skin 24. Because of the way in which the peaks 36 are formed, there may not be actual contact along their entire length but in view of measured reduction in the resistance between the skin 24 and the frame 22, it is believed that each peak 36, at least in part, is in electrical contact with the adjacent skin 24.
The valleys 38 on either side of the peak 36 contain adhesive 40 which then serves to accomplish the bonding between the frame 22 and the skin 24.
As seen in FIG. 5, the peaks 36 may be located in rows. The rows are separated by about 0.1 inches by valleys 38 and the individual peaks 36 in each row are likewise separated by a valley 38. Approximately 6 or 7 peaks per inch are provided in each row. Of course, these dimensions may be widely varied, dependant upon the frequencies involved and the attenuation desired. The height of the peaks 36 above the surface 34 is in the range 0.006-0.010 inches. Too short of a height will not provide sufficient attenuation while too great of a height can result in a weakened joint.
Returning to FIG. 4, it will be seen that immediately adjacent one side of the peak 36, the valley 38 has a deep furrow 42. The peaks 36 are formed not by stamping with a knurling wheel, but rather, by literally "plowing" the surface 34 of the frame 22 that is to be roughened. That is to say, part of the material of the surface is actually literally moved to one side creating the furrow 42 as well as the adjacent peak 36. This can be accomplished by placing the knurling wheel at a 10°-15° angle to the direction in which it is moved relative to the frame 22 much as a farmer discing a field has the rotational axis of the disc at a non-90° angle to the direction of movement of the disc through the field.
As presently understood, it is preferred to form a sufficient number of the peaks 36 so that there is a density of about 60 peaks per square inch of the surface 34. However, other densities may be employed dependent upon row spacing, etc.
The panels may be assembled using either vacuum bag curing, in which case, the pressure applied to the skins 24 and 28 pressing them toward the frame 22 will be on the order of 15 psi. More preferably, the components are bonded together in a heated press at a pressure in the range of 20-35 psi and a temperature in the range of 270°-290° F. Press residence time will be typically in the range of 35-60 minutes.
Those skilled in the art will recognize that the temperature and pressures may vary to some extent depending upon the specific adhesive employed. Those given above are for an epoxy structural film meeting the standards of ASTM E865.
The resulting panel has a significant decrease in the resistance between the skin 24 and the frame 22 to provide a substantial shield to electromagnetic interference across the overall panel. As a consequence, the panels are ideally suited for structural use where such electromagnetic interference resistance is required in housing electronic equipment.
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Electromagnetic interference across a structural panel is minimized in a construction wherein a metal skin (24) is bonded to a metal frame (22) by an adhesive (40) by providing a series of peaks (36) and valleys (38) at the area of the intended joint between the skin (24) and the frame (22). The peaks (36) penetrate through the adhesive (40) to establish substantial electrical contact between the skin (24) and the frame (22) to provide shielding against electromagnetic interference while the adhesive (40) bonds the two together to provide a structurally sound panel.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to a lighting apparatus capable of protecting eyesight and, more particularly, to a lighting apparatus capable of protecting eyesight that additionally emits light having wavelengths that are not emitted by existing fluorescent lighting apparatuses, but are essential to the action of eyesight.
2. Description of the Related Art
Various types of lighting apparatuses using fluorescent lamps are used as main lighting apparatuses in public facilities and homes. Meanwhile, fluorescent desk lamps, such as that shown in FIG. 1 , are widely used as auxiliary desk lighting apparatuses in study rooms and laboratories.
In the meantime, when 60 Hz home Alternating Current (AC) power is used for fluorescent desk lamps without conversion, the fluorescent lamps flicker 120 times per second, which fatigues the eyes. Accordingly, fluorescent inverter desk lamps, which convert existing 60 Hz AC power into 44 KHz high-frequency power using electronic ballasts equipped with inverter circuits and apply the 44 KHz high-frequency power to lamps, so that the fluorescent lamps flicker 80,000 to 90,000 times per second, thereby preventing the eyes from detecting such flickering, are mainly used at present.
Furthermore, although lighting apparatuses using fluorescent lamps as main lighting lamps sometimes use electronic ballasts which are not equipped with inverter circuits, electronic ballasts equipped with inverter circuits have been used recently.
Meanwhile, since natural light (solar light) has a wide wavelength range of 380 to 780 nm and humans' eyesight is adapted to natural light, humans feel comfortable and, simultaneously, humans' eyesight can be protected when humans view objects that are illuminated with natural light.
Conventional fluorescent lamps are inexpensive (one to three dollar). However, since the fluorescent material applied to the inner glass of the fluorescent lamps is mainly a phosphate, silicate or tungstate compound, large amounts of blue light in a wavelength range of 430 to 450 nm, red-orange light in a wavelength range of 600 to 620 nm and yellow-green light in a range of 530 to 560 nm are emitted, and small amounts of pure red light in a wavelength range of 620 to 700 nm and pure green light in a wavelength range of 498 to 530 nm are emitted, as shown in the upper graph of FIG. 2 , and thus the light emitted from the fluorescent lamps is different from natural light, which is composed of red, green and blue colors. Therefore, the conventional fluorescent lamps have problems related to color rendering, and thus they fatigue the eyes when humans' photoreceptor cells are used for a long time.
Meanwhile, humans' photoreceptor cells consist of cone cells and rod cells. The three types of cone cells, which detect color, are relatively sensitive to light at 420 nm, light at 530 nm, and light at 560 nm, respectively, and rod cells are relatively sensitive to light at about 495 nm.
In particular, recent research has proven that cone cells and rod cells participate in vision through interaction therebetween. This means that bluish green light at about 495 nm, to which rod cells, which have not been considered to be important in discerning red, green and blue light based on the conventional theory, in which only cone cells participate in the detection of color, are sensitive and improve sharpness, and thus they play an important role in vision.
However, existing fluorescent lamps emit slight amounts of bluish green light at about 495 nm, and thus they do not provide optimal conditions for the activity of photoreceptor cells.
In brief, the existing fluorescent lamps have problems rendering colors because they emit small amounts of pure red light in the wavelength range of 620 to 700 nm and pure green light in the wavelength range of 498 to 530 nm, and do not improve sharpness because they emit small amounts of bluish green light at about 495 nm.
In order to mitigate the shortcomings of the existing fluorescent lamps, full-spectrum fluorescent lamps, which are constructed by adding a phosphorus compound to fluorescent material for the existing fluorescent lamps and can emit light at red wavelengths, have been invented. However, it is impossible to manufacture them at low cost because the phosphorus compound is a rare material, and thus the material cost is increased, and because the yield thereof is low.
SUMMARY OF THE INVENTION
Accordingly, the present invention has been made keeping in mind the above problems occurring in the prior art, and an object of the present invention is to provide a lighting apparatus that emits light that is visually similar to natural light and can be manufactured at low cost.
In order to accomplish the above object, the present invention provides a lighting apparatus using one or more fluorescent lamps, including one or more sockets for accommodating the fluorescent lamps; a board for supporting Light Emitting Diodes (LEDs) for emitting green light in a wavelength range of 498 to 530 nm, LEDs for emitting red light in a wavelength range of 620 to 700 nm, and LEDs for emitting bluish green at about 495 nm; a ballast for providing a ballast function to the fluorescent lamps; and a Direct Current (DC) power supply for supplying DC power to the LEDs.
BRIEF DESCRIPTION OF THE DRAWINGS
The patent or application file contains at least one drawing executed in color. Copies of this patent or patent application publication with color drawing(s) will be provided by the office upon request and payment of the necessary fee.
The above and other objects, features and advantages of the present invention will be more clearly understood from the following detailed description, taken in conjunction with the accompanying drawings, in which:
FIG. 1 is a perspective view showing a desk lamp using a conventional fluorescent lamp;
FIG. 2 is a diagram showing the distribution of wavelengths in the conventional fluorescent lamp and the distribution of wavelengths in a lighting apparatus according to the present invention;
FIG. 3 is a diagram showing a board that is used for a desk lamp capable of protecting eyesight according to an embodiment of the present invention;
FIG. 4 is a diagram showing a board assembly that is constructed by fitting a fluorescent lamp into the board of FIG. 3 ;
FIG. 5 is a diagram showing a structure in which the board assembly of FIG. 4 is fitted into a desk lamp shade; and
FIG. 6 is a perspective view showing a desk lamp capable of protecting eyesight according to the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Reference now should be made to the drawings, in which the same reference numerals are used throughout the different drawings to designate the same or similar components.
Currently, commercial Light Emitting Diodes (LEDs), which emit light having various colors, are being marketed. However, since manufacturing a lighting apparatus by combining LEDs for various colors so as to emit light similar to natural light requires hundreds of LEDs to emit sufficient amount of light for such a lighting apparatus, a manufacturing cost higher than that for a fluorescent lamp is incurred, and it is difficult to control the considerable amount of heat emitted from the hundreds of LEDs, it is not desirable to manufacture a lighting apparatus for emitting light similar to natural light using only LEDs from the aspects of the manufacturing cost and the emission of heat.
Accordingly, in the present invention, a lighting apparatus is constructed using an inexpensive fluorescent lamp, which is currently the most efficient light source, as an inexpensive basic light source, and using LEDS, which are capable of forming light having wavelengths that are not emitted from such a fluorescent lamp but are essential to the formation of light similar to natural light, as will be described below, along with the fluorescent lamp, so that improved color rendering and sharpness can be realized, thereby being able to provide an inexpensive lighting apparatus capable of emitting light similar to natural light.
According to the research of the inventor of the present invention, it is concluded that, when sufficient green light in a wavelength range of 498 to 530 nm and sufficient red light in a wavelength range of 620 to c495 nm, which are emitted in small amounts from a fluorescent lamp, are added to the light emitted from the fluorescent lamp, as shown in the lower graph of FIG. 2 , color rendering is significantly improved, with the result that a human feels natural when he or she views objects, and thus his or her eyesight can be protected. Here, the wavelength c495 nm is obtained by combining a red wavelength with a violet wavelength. In practical implementation, it can be created by combining red wavelengths in a range of 620 to 700 nm and violet wavelengths in a range of 380 to 400 nm.
As a result, when green light in a wavelength range of 498 to 530 nm, red light in a wavelength range of 620 to 700 nm and violet light in a wavelength range of 380 to 400 nm are added to light emitted from an existing fluorescent lamp (see the lower graph of FIG. 2 ), color rendering is improved and objects can be naturally viewed, thereby protecting a viewer's eyesight.
Meanwhile, it was found that the case in which red light in a wavelength range of 620 to 700 nm was added was more effective in the provision of a natural sensation than the case in which violet light in a wavelength range of 380 to 400 nm was added.
Accordingly, when green light in a wavelength range of 498 to 530 nm and red light in a wavelength range of 620 to 700 nm are added to light emitted from an existing fluorescent lamp, a viewer can have a sensation in which resulting light is similar to natural light. When violet light in a wavelength range of 380 to 400 nm is further employed, as shown in the lower graph of FIG. 2 , the sensation in which light is more similar to natural light can be realized.
Furthermore, bluish green light having a wavelength of about 495 nm, at which rod cells have high sensitivity, is further added, so that most photoreceptor cells are highly activated, thereby improving sharpness.
Next, a fluorescent desk lamp capable of protecting eyesight will be described below as an embodiment of the eyesight protection lighting apparatus manufactured using the results of the research of the inventor.
In the desk lamp of the present invention, LEDs that emit green light in a wavelength range of 498 to 530 and red light in a wavelength range of 620 to 700 nm are added to an existing fluorescent lamp.
Now, a method of manufacturing the desk lamp capable of protecting eyesight according to the present invention will be described below with reference to FIGS. 3 to 6 .
In order to produce green light in a wavelength range of 498 to 530 nm and red light in a wavelength range of 620 to 700 nm at low cost, a plurality of LEDs are used.
First, as shown in FIG. 3 , two rows of LEDs 1 for green light in a wavelength range of 498 to 530 nm and two rows of LEDs 2 for red light in a wavelength range of 620 to 700 nm are alternately arranged on a board 4 , and a socket for a fluorescent lamp is disposed between the LEDs 1 and 2 . AC power wiring (not shown) for applying AC power from an inverter ballast 12 for a fluorescent lamp and DC power wiring (not shown) for applying DC power from a DC power supply 13 for LEDs 1 and 2 is disposed on the back of the board 4 . Since the AC and DC power wiring is located on the back of the board 4 in FIG. 3 , the AC and DC power wiring is not shown in FIGS. 3 to 5 . In this case, the number of LEDs 1 and 2 is appropriately determined in consideration of the intensity of the light of the fluorescent lamp 7 , inserted into the socket 3 , and the intensity of the light of each of the LEDs 1 and 2 .
Now, the board 4 , including a fluorescent lamp, is constructed by inserting the fluorescent lamp 7 (although a U-shaped fluorescent lamp is shown in FIG. 4 , a tube-shaped fluorescent lamp may be used) into the socket 3 on the board 4 of FIG. 3 , as shown in FIG. 4 .
Thereafter, a desk lamp shade assembly according to the present invention is constructed by fastening the board 4 to a desk lamp shade 8 using screws or by fitting the board 4 into elastic fastening members 9 attached to the desk lamp shade 8 , as shown in FIG. 5 , and the eyesight protection desk lamp according to the present invention is constructed by combining the desk lamp shade assembly with an arm 10 and a base 11 , as shown in FIG. 6 .
In this case, the inverter ballast 12 for a fluorescent lamp and the DC power supply 13 for LEDs are disposed inside the base 11 , and wiring for the output of AC power from the inverter ballast 12 for a fluorescent lamp and wiring for the output of DC power from the DC power supply 13 for LEDs are respectively connected to the above-described pieces of wiring, disposed on the board 4 , through the arm 10 .
When home AC power is supplied to the inverter ballast 12 and the DC power supply 13 , disposed in the base 11 , by turning on a switch 14 , the output of the inverter ballast 12 is supplied to the socket 3 for a fluorescent lamp, while the output of the DC power supply 13 is supplied to the LEDs 1 and 2 through the DC power wiring.
As described above, when a user turns on the switch 14 , LEDs 1 and 2 , together with the fluorescent lamp 7 , are turned on, so that blue light in a wavelength range of 430 to 450 nm, red-orange light in a wavelength range of 600 to 620 nm and yellow-green light in a wavelength range of 530 to 560 nm are mainly emitted from the fluorescent lamp 7 , and green light in a wavelength range from 498 to 530 nm and red light in a wavelength range of 620 to 700 nm are mainly emitted from the LEDs 1 and 2 . As a result, blue light, red light and green light are emitted at similar intensities, thereby emitting light that has improved color rendering and is similar to natural light.
Meanwhile, as explained above, according to the research of the inventor of the present invention, when violet light in a wavelength range of 350 to 400 nm is further added, color rendering is further improved, and emitted light is more similar to natural light, and thus violet LEDs capable of emitting light in a wavelength range of 350 to 400 nm may be disposed on the board 4 , in addition to the above-described LEDs 1 and 2 .
Furthermore, it is possible to further add LEDs capable of emitting bluish green light having a wavelength of about 495 nm, to which rod cells are highly sensitive.
Moreover, when an anti-glare filter is additionally attached to the lamp shade 8 of FIG. 5 , glare can be prevented.
Furthermore, although only the eyesight protection desk lamp using a fluorescent lamp has been described above, the principle of the present invention, in which light similar to natural light can be realized by combining a fluorescent lamp with LEDs, can be applied to various types of fluorescent lamp lighting apparatuses used in homes and offices.
For example, in the case of square fluorescent lamps, which are widely used in homes, a square fluorescent lamp capable of protecting eyesight is constructed by appropriately arranging fluorescent lamp sockets and LEDs capable of emitting green light in a wavelength range of 498 to 530 nm and red light in a range of 620 to 700 nm on a board, inserting fluorescent lamps into the sockets and fastening the board to a lamp shade in a manner similar to that for the above-described desk lamp.
Meanwhile, although one or more fluorescent lamp sockets, together with LEDs, have been described as being disposed on a board above, it is possible to dispose only LEDs on a board and to dispose one or more sockets for one or more fluorescent lamps at a separate location.
According to the above-described present invention, it is possible to provide an eyesight protection lighting apparatus that is constructed by combining one or more inexpensive fluorescent lamps with LEDs, thereby emitting light similar to natural light.
Although the preferred embodiments of the present invention have been disclosed for illustrative purposes, those skilled in the art will appreciate that various modifications, additions and substitutions are possible, without departing from the scope and spirit of the invention as disclosed in the accompanying claims.
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Disclosed herein is a lighting apparatus using one or more fluorescent lamps. The lighting apparatus according to the present invention includes one or more sockets, a board, a ballast, and a Direct Current (DC) power supply. The sockets accommodate the fluorescent lamps. The board supports Light Emitting Diodes (LEDs) for emitting green light in a wavelength range of 498 to 530 nm, LEDs for emitting red light in a wavelength range of 620 to 700 nm, and LEDs for emitting bluish green at 495 nm. The ballast provides a ballast function to the fluorescent lamps. The DC power supply supplies DC power to the LEDs.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a national stage entry under 35 U.S.C. §371 of PCT/US99/02732, filed Feb. 8, 1999, which claims the benefit of U.S. Provisional Application No. 60/075,708 filed Feb. 24, 1998 (now abandoned).
FIELD OF THE INVENTION
The present invention relates to cyclic pro-perfumes capable of releasing at least one fragrance raw material alcohol, preferably a tertiary fragrance raw material alcohol. The novel pro-perfumes of the present invention can be modified by the formulator to control the rate at which the fragrance raw material alcohol is released once the material is applied, for example, to human skin.
BACKGROUND OF THE INVENTION
Humans have applied scents and fragrances to their skin since antiquity. Originally these aesthetically pleasing materials were commonly isolated in raw form as resins, gums or essential oils from natural sources, inter alia, the bark, roots, leaves and fruit of indigenous plants. These resins, gums, and oils were directly applied to the body or diluted with water or other solvent, including in some cases, wine. With the advent of modern chemistry, individual components responsible for the odor properties of these resins, gums and oils were isolated and subsequently characterized. Modern perfumery involves the artful compounding of fragrance materials to achieve novel fragrance compositions having defined “characteristics”.
Many modem fragrances are no longer derived from natural sources but are synthesized by modern chemical methods as highly pure fragrance raw materials (FRM). These FRM's are currently formulated to produce fine perfumes, colognes, eau de toilettes, after-shave lotions, and other personal fragrance compositions. Those skilled in the art of preparing these fragrance-containing compositions have categorized fragrances into three types based on their relative volatility; top, middle, and base notes.
Top, middle, and base notes each serve a different purpose in the blending of fragrances and when properly formulated produce a “balanced fragrance” composition. Based on volatility, these notes are described by those skilled in the art as: the base notes having the most long lasting aroma; the middle notes, have a medium volatility; and the top notes are the most volatile. Key to successfully formulating a fragrance-containing composition is the precise balance between these three groups of materials producing a fragrance-containing composition that diffuses during its evaporation in a manner which has an aesthetic quality.
It has been the goal of those skilled in the art of perfumes and fragrances to provide aesthetically pleasant odor compositions wherein the initial top, middle, and base note balance is maintained for an extended period of time. Due to the uneven rate of evaporation of the components which comprise a fine perfume or fragrance, the initial fragrance may be quite different than the aroma perceived several hours later. This problem is solved in many different ways by the user. One method is to “load up” on the perfume initially and rely on the natural evaporation rate to diminish the fragrance to a suitable level several hours later when the desired effect is needed. Another method which is used is to continually renew the fragrance by reapplying small amounts of the perfume to the skin at short time intervals. Neither of these solutions is adequate to overcome the diminishing level of top and middle notes over time. In fact, base notes which are present over a protracted period by virtue of their low volatility, begin to accumulate with each “re-freshing” of perfume. After some time these base notes overwhelm the other fragrance notes and destroy the original fragrance balance.
However, despite these artful approaches and compensating for the physical properties of perfume ingredients, formulators have not been able to well control the rate at which fragrance raw materials, especially fragrance raw material alcohols, are released when applied, for example, on human skin, hair, etc. Therefore, there has been a long felt need for a means of releasing at least one fragrance raw material alcohol, preferably tertiary alcohols, at a controllable rate.
It has now been surprisingly discovered that the novel cyclic pro-perfumes, which are the subject matter of the present invention, can not only release fragrance raw material alcohols but can be modified to release said alcohols within a range of time desirable to the formulator. In addition, the cyclic pro-perfumes described herein are capable of delivering highly desirable tertiary alcohols.
SUMMARY OF THE INVENTION
The present invention meets the aforementioned needs in that it has been surprisingly discovered than certain cyclic pro-perfumes can be modified to release their fragrance raw material alcohols at variable rates after being exposed to an acid milieu inter alia human skin.
A first aspect of the present invention relates to cyclic pro-perfumes capable of releasing at least one fragrance raw material alcohol, said pro-perfumes having the formula:
wherein —OR is a unit derived from a fragrance raw material alcohol; R 1 is hydrogen, C 1 -C 22 alkyl, C 1 -C 22 alkenyl, C 6 -C 12 aryl, C 6 -C 22 alkylenearyl, C 3 -C 20 substituted or unsubstituted alkyleneoxyalkyl, and mixtures thereof; R 2 , R 3 , R 4 , and R 5 are each independently selected from hydrogen, C 1 -C 30 substituted or unsubstituted linear alkyl, C 3 -C 30 substituted or unsubstituted branched alkyl, C 3 -C 30 substituted or unsubstituted cyclic alky, C 2 -C 30 substituted or unsubstituted linear alkenyl, C 3 -C 30 substituted or unsubstituted branched alkenyl, C 3 -C 30 substituted or unsubstituted cyclic alkenyl, C 2 -C 30 substituted or unsubstituted linear alkynyl, C 3 -C 30 substituted or unsubstituted branched alkynyl, C 6 -C 30 substituted or unsubstituted alkylenearyl, C 6 -C 30 substituted or unsubstituted aryl, C 2 -C 20 substituted or unsubstituted alkyleneoxy, C 3 -C 20 substituted or unsubstituted alkyleneoxyalkyl, C 7 -C 20 substituted or unsubstituted alkylenearyl, C 6 -C 20 substituted or unsubstituted alkyleneoxyaryl, and mixtures thereof, or any two R 2 , R 3 , R 4 , or R 5 can be taken together to form a fused ring or spiroannulated ring having from 3 to 8 carbons and optionally one or more heteroatoms in said ring, said ring is optionally further substituted by one or more C 1 -C 22 alkyl, C 1 -C 22 alkenyl, C 6 -C 12 aryl, C 6 -C 22 alkylenearyl units, and mixtures thereof, Y is —CR 6 R 7 —, C═O, and mixtures thereof, wherein R 6 and R 7 are independently hydrogen, hydroxyl, nitro, nitrilo, C 1 -C 30 substituted or unsubstituted linear alkyl, C 3 -C 30 substituted or unsubstituted branched alkyl, C 3 -C 30 substituted or unsubstituted cyclic alkyl, C 2 -C 30 substituted or unsubstituted linear alkenyl, C 3 -C 30 substituted or unsubstituted branched alkenyl, C 3 -C 30 substituted or unsubstituted cyclic alkenyl, C 2 -C 30 substituted or unsubstituted linear alkynyl, C 3 -C 30 substituted or unsubstituted branched alkynyl, C 6 -C 30 substituted or unsubstituted alkylenearyl, C 6 -C 30 substituted or unsubstituted aryl, C 2 -C 20 substituted or unsubstituted alkyleneoxy, C 3 -C 20 substituted or unsubstituted alkyleneoxyalkyl, C 7 -C 20 substituted or unsubstituted alkylenearyl, C 6 -C 20 substituted or unsubstituted alkyleneoxyaryl, and mixtures thereof, or R 6 and R 7 can be taken together to form a spiroannulated ring or taken together with any R 2 , R 3 , R 4 , or R 5 to form a fused ring, said spiroannulated or fused ring having from 3 to 8 carbons and optionally one or more heteroatoms in said ring, said ring further optionally substituted by one or more C 1 -C 22 alkyl, C 1 -C 22 alkenyl, C 6 -C 12 aryl, C 6 -C 22 alkylenearyl units, and mixtures thereof; n is from 0 to 3.
The present invention also relates to fine fragrance compositions inter alia perfumes, colognes, after shaves, and eau de toilettes comprising said cyclic pro-perfumes. In addition, personal care and personal hygiene articles may comprise the cyclic pro-perfumes described herein. Non-limiting examples of these personal care items include deodorants, body lotions or creams, sun tan lotions, and shampoos.
The present invention also relates to a fragrance delivery system which comprises at least one cyclic pro-perfume as described herein. Preferably said fragrance delivery system delivers at least one tertiary fragrance raw material alcohol. These and other objects, features and advantages will become apparent to those of ordinary skill in the art from a reading of the following detailed description and the appended claims.
All percentages, ratios and proportions herein are by weight, unless otherwise specified. All temperatures are in degrees Celsius (° C.) unless otherwise specified. All documents cited are in relevant part, incorporated herein by reference.
DETAILED DESCRIPTION OF THE INVENTION
The present invention relates to cyclic pro-perfumes capable of releasing at least one fragrance raw material alcohol. Surprisingly, the cyclic pro-perfumes of the present invention are capable of releasing in a controlled manner desirable tertiary perfume raw material alcohols inter alia linalool, ethyllinalool, dihydromyrcenol, and tetrahydrolinalool.
The pro-perfumes of the present invention are essentially orthoesters. Orthoesters, in general, may be considered to be “acetals” of carboxylic acid esters which can be formed by the reaction of an ester with two equivalents of alcohol. Treatment of orthoesters with sufficient acid catalyst in the presence of moisture results in the “reversion” of orthoesters back into a mixture of ester and alcohol. In the instance where the ester alcohol is not the same as the orthoester forming alcohol, and depending upon the structure and reactivity of the orthoester components, one of the alcohols released from the reversion reaction may be the original ester alcohol resulting in one of the “orthoester forming” alcohols now comprising the ester. In this instance, “transesterification” has occurred.
Without wishing to be limited by theory, the release rate of the fragrance raw material alcohol from the cyclic orthoesters of the present invention may be controlled, for example, by adjusting, separately or in combination, either the relative basicity of the orthoester oxygen atoms in the cyclic moiety or the torsional ring strain of the resulting cyclic orthoesters. One result of these adjustments is to provide increased or decreased ring opening kinetics and thereby a means for regulating the release rate of the fragrance raw material alcohol.
Cyclic Pro-perfumes
The cyclic pro-perfumes of the present invention have the formula:
wherein the moiety —OR is derived from a fragrance raw material alcohol having the general formula ROH. Non-limiting examples of fragrance raw material alcohols which can be suitably released by the cyclic pro-perfumes of the present invention include 2,4-dimethyl-3-cyclohexene-1-methanol (Floralol), 2,4-dimethyl cyclohexane methanol (Dihydro floralol), 5,6-dimethyl-1-methylethenylbicyclo-[2.2.1]hept-5-ene-2-methanol (Arbozol), 2,4,6-trimethyl-3-cyclohexene-1-methanol (Isocyclo geraniol), 4-(1-methylethyl)cyclohexanemethanol (Mayol), α-3,3-trimethyl-2-norborane. methanol, 1,1-dimethyl-1-(4-methylcyclohex-3-enyl)methanol, 2-phenylethanol, 2-cyclohexyl ethanol, 2-(o-methylphenyl)-ethanol, 2-(m-methylphenyl)ethanol, 2-(p-methylphenyl)ethanol, 6,6-dimethylbicyclo-[3.1.]hept-2-ene-2-ethanol (nopol), 2-(4-methylphenoxy)ethanol, 3,3-dimethyl-Δ 2 -β-norbornane ethanol, 2-methyl-2-cyclohexylethanol, 1-(4-isopropylcyclohexyl)-ethanol, 1-phenylethanol, 1,1-dimethyl-2-phenylethanol, 1,1-dimethyl-2-(4-methyl-phenyl)ethanol, 1-phenylpropanol, 3-phenylpropanol, 2-phenylpropanol (Hydrotropic Alcohol), 2-(cyclododecyl)propan-1-ol (Hydroxy-ambran), 2,2-dimethyl-3-(3-methylphenyl)propan-1-ol (Majantol), 2-methyl-3-phenylpropanol, 3-phenyl-2-propen-1-ol (cinnamyl alcohol), 2-methyl-3-phenyl-2-propen-1-ol (methylcinnamyl alcohol), α-n-pentyl-3-phenyl-2-propen-1-ol (α-amyl-cinnamyl alcohol), ethyl-3-hydroxy-3-phenyl propionate, 2-(4-methylphenyl)-2-propanol, 3-(4-methylcyclohex-3-ene)butanol, 2-methyl-4-(2,2,3-trimethyl-3-cyclopenten-1-yl)butanol, 2-ethyl4-(2,2,3-trimethyl-cyclopent-3-enyl)-2-buten-1-ol, 3-methyl-2-buten-1-ol, 2-methyl4-(2,2,3-trimethyl-3-cyclopenten-1-yl)-2-buten-1-ol, 3-hydroxy-2-butanone, ethyl 3-hydroxybutyrate, 4-phenyl-3-buten-2-ol, 2-methyl-4-phenylbutan-2-ol, 4-(4-hydroxyphenyl)butan-2-one, 4-(4-hydroxy-3-methoxyphenyl)butan-2-one, 3-methyl-pentanol, 3-methyl-3-penten-1-ol, 2-methyl-4-phenylpentanol (Pamplefleur), 3-methyl-5-phenylpentanol (Phenoxanol), 2-methyl-5-phenylpentanol, 2-methyl-5-(2,3-dimethyltricyclo[2.2.1.0(2,6)]hept-3-yl)-2-penten-1-ol (santalol), 4-methyl-1-phenyl-2-pentanol, (1-methyl-bicyclo[2.1.1]hepten-2-yl)-2-methylpent-1-en-3-ol, 3-methyl-1-phenylpentan-3-ol, 1 ,2-dimethyl-3-(1-methylethenyl)cyclopentan-1-ol, 2-isopropyl-5-methyl-2-hexenol, cis-3-hexen-1-ol, trans-2-hexen-1-ol, 2-isoproenyl-4-methyl4-hexen-1-ol (Lavandulol), 2-ethyl-2-prenyl-3-hexenol, 1-hydroxymethyl-4-iso-propenyl-1-cyclohexene (Dihydrocuminyl alcohol), 1-methyl4-isopropenycyclohex-6-en-2-ol (carvenol), 6-methyl-3-isopropenylcyclohexan-1-ol, 1-methyl4-iso-propenylcyclohexan-3-ol, 4-isopropyl-1-methylcyclohexan-3-ol, 4-tert-butylcyclo-hexanol, 2-tert-butylcyclohexanol, 2-tert-butyl4-methylcyclohexanol, 4-isopropyl-cyclohexanol, 4-methyl-1-(1-methylethyl)-3-cyclohexen-1-ol, 2-(5,6,6-trimethyl-2-norbornyl)cyclohexanol, isobornylcyclohexanol, 3,3,5-trimethylcyclohexanol, 1-methyl-4-isopropylcyclohexan-3-ol, 1,2-dimethyl-3-(1-methylethyl)cyclohexan-1-ol, heptanol, 2,4-dimethylheptan-1-ol, 2,4-dimethyl-2,6-heptandienol, 6,6-dimethyl-2-oxymethylbicyclo[3.1.1]hept-2-ene (myrtenol), 4-methyl-2,4-heptadien-1-ol, 3,4,5,6,6-pentamethyl-2-heptanol, 3,6-dimethyl-3-vinyl-5-hepten-2-ol, 6,6-dimethy-3-hydroxy-2-methylenebicyclo[3.1.1]heptane, 1,7,7-trimethylbicyclo[2.2.1]heptan-2-ol, 2,6-dimethylheptan-2-ol, 2,6,6-trimethylbicyclo[1.3.3]heptan-2-ol, octanol, 2-octenol, 2-methyloctan-2-ol, 2-methyl-6-methylene-7-octen-2-ol (myrcenol), 7-methyloctan-1-ol, 3,7-dimethyl-6-octenol, 3,7-dimethyl-7-octenol, 3,7-dimethyl-6-octen-1-ol (citronellol), 3,7-dimethyl-2,6-octadien-1-ol (geraniol), 3,7-dimethyl-2,6-octadien-1-ol (nerol), 3,7-dimethyl-1,6-octadien-3-ol (linalool), 3,7-dimethyloctan-1-ol (pelagrol), 3,7-dimethyloctan-3-ol (tetrahydrolinalool), 2,4-octadien-1-ol, 3,7-dimethyl-6-octen-3-ol, 2,6-dimethyl-7-octen-2-ol (dihydromyrcenol), 2,6-dimethyl-5,7-octadien-2-ol, 4,7-dimethyl-4-vinyl-6-octen-3-ol, 3-methyloctan-3-ol, 2,6-dimethyloctan-2-ol, 2,6-dimethyloctan-3-ol, 3,6-dimethyloctan-3-ol, 2,6-dimethyl-7-octen-2-ol, 2,6-dimethyl-3,5-octadien-2-ol (muguol), 3-methyl-1-octen-3-ol, 7-hydroxy-3,7-dimethyloctanal, 3-nonanol, 2,6-nonadien-1-ol, cis-6-nonen-1-ol, 6,8-dimethylnonan-2-ol, 3-(hydroxymethyl)-2-nonanone, 2-nonen-1-ol, 2,4-nonadien-1-ol, 3,7-dimethyl-1,6-nonadien-3-ol (ethyllinalool), decanol, 9-decenol, 2-benzyl-M-dioxa-5-ol, 2-decen-1-ol, 2,4-decadien-1-ol, 4-methyl-3-decen-5-ol, 3,7,9-trimethyl-1,6-decadien-3-ol (isobutyl linallol), undecanol, 2-undecen-1-ol, 10-undecen-1-ol, 2-dodecen-1-ol, 2,4-dodecadien-1-ol, 2,7,11-trimethyl-2,6,10-dodecatrien-1-ol (farnesol), 3,7,11-trimethyl-1,6,10,-dodecatrien-3-ol, 3,7,11,15-tetramethylhexadec-2-en-1-ol (phytol), 3,7,11,15-tetramethylhexadecl-en-3-ol (iso phytol), benzyl alcohol, p-methoxy benzyl alcohol (anisyl alcohol), para-cymen-7-ol (cuminyl alcohol), 4-methyl benzyl alcohol, 3,4-methylenedioxy benzyl alcohol, methyl salicylate, benzyl salicylate, cis-3-hexenyl salicylate, n-pentyl salicylate, 2-phenylethyl salicylate, n-hexyl salicylate, 2-methyl-5-isopropylphenol, 4-ethyl-2-methoxyphenol, 4-allyl-2-methoxyphenol (eugenol), 2-methoxy-4-(1-propenyl)phenol (isoeugenol), 4-allyl-2,6-dimethoxy-phenol, 4-tert-butylphenol, 2-ethoxy-4-methylphenol, 2-methyl-4-vinylphenol, 2-isopropyl-5-methylphenol (thymol), pentyl-orthohydroxy benzoate, ethyl 2-hydroxy-benzoate, methyl 2,4-dihydroxy-3,6-dimethylbenzoate, 3b-hydroxy-5-methoxy-1-methylbenzene, 2-tert-butyl-4-methyl-1-hydroxybenzene, 1-ethoxy-2-hydroxy4-propenylbenzene, 4-hydrozytoluene, 4-hydroxy-3-methoxybenzaldehyde, 2-ethoxy4-hydroxybenzaldehyde, decahydro-2-naphthol, 2,5,5-trimethyl-octahydro-2-naphthol, 1,3,3-trimethyl-2-norbomanol (fenchol), 3a,4,5,6,7,7a-hexahydro-2,4-dimethyl4,7-methano-1H-inden-5-ol, 3a,4,5,6,7,7a-hexahydro-3,4-dimethyl4,7-methano-1H-inden-5-ol, 2-methyl-2-vinyl-5-(1-hydroxy-1-methylethyl)tetrahydrofuran, β-caryophyllene alcohol, and mixtures thereof
Preferred fragrance raw material alcohols are tertiary alcohols inter alia 3,7-dimethyl-1,6-octadien-3-ol (linalool), 3,7-dimethyloctan-3-ol (tetrahydrolinalool), 3,7-dimethyl-1,6-nonadien-3-ol (ethyllinalool), and 2,6-dimethyl-7-octen-2-ol (dihydromyrcenol).
R 1 is hydrogen, C 1 -C 22 alkyl, C 1 -C 22 alkenyl, C 6 -C 12 aryl, C 6 -C 22 alkylenearyl, C 3 -C 20 substituted or unsubstituted alkyleneoxyalkyl,. and mixtures thereof Preferably R 1 is hydrogen, C 1 -C 4 alkyl, C 7 -C 10 alkylenearyl; more preferably hydrogen, methyl, ethyl, propyl, iso-propyl, t-butyl, phenyl, substituted phenyl, benzyl and substituted benzyl.
R 2 , R 3 , R 4 , and R 5 are each independently hydrogen, C 1 -C 30 substituted or unsubstituted linear alkyl, C 3 -C 30 substituted or unsubstituted branched alkyl, C 3 -C 30 substituted or unsubstituted cyclic alkyl, C 2 -C 30 substituted or unsubstituted linear alkenyl, C 3 -C 30 substituted or unsubstituted branched alkenyl, C 3 -C 30 substituted or unsubstituted cyclic alkenyl, C 2 -C 30 substituted or unsubstituted linear alkynyl, C 3 -C 30 substituted or unsubstituted branched alkynyl, C 6 -C 30 substituted or unsubstituted alkylenearyl, C 6 -C 30 substituted or unsubstituted aryl, C 2 -C 20 substituted or unsubstituted alkyleneoxy, C 3 -C 20 substituted or unsubstituted alkyleneoxyalkyl, C 7 -C 20 substituted or unsubstituted alkylenearyl, C 6 -C 20 substituted or unsubstituted alkyleneoxyaryl, and mixtures thereof. In addition, any two R 2 , R 3 , R 4 , or R 5 units can be taken together to form a fused ring cyclic pro-perfume having from 3 to 8 carbon atoms and optionally one or more heteroatoms in the ring. An example of a fused ring cyclic pro-perfume includes the general formulae:
The fused rings may also optionally comprise one or more heteroatoms, preferably oxygen, nitrogen, sulfur and mixtures thereof An example of a fused ring cyclic pro-perfume comprising a heteroatom has the formula:
wherein R 8 is independently hydrogen, C 1 -C 22 alkyl, hydrogen, C 1 -C 30 substituted or unsubstituted linear alkyl, C 3 -C 30 substituted or unsubstituted branched alkyl, C 3 -C 30 substituted or unsubstituted cyclic alkyl, C 2 -C 30 substituted or unsubstituted linear alkenyl, C 3 -C 30 substituted or unsubstituted branched alkenyl, C 3 -C 30 substituted or unsubstituted cyclic alkenyl, C 2 -C 30 substituted or unsubstituted linear alkynyl, C 3 -C 30 substituted or unsubstituted branched alkynyl, C 6 -C 30 substituted or unsubstituted alkylenearyl, C 6 -C 30 substituted or unsubstituted aryl, C 2 -C 20 substituted or unsubstituted alkyleneoxy, C 3 -C 20 substituted or unsubstituted alkyleneoxyalkyl, C 7 -C 20 substituted or unsubstituted alkylenearyl, C 6 -C 20 substituted or unsubstituted alkyleneoxyaryl, or one or more saccharide units. Non-limiting examples of saccharide units according to the present invention include erythrose, threose, arabinose, ribose, lysose, xylose, glucose, mannose, allose, altrose, talose, galactose, idose, gulose, fiuctose, and combinations thereof. The saccharides of the present invention are preferably in the pyranose (closed ring) form, however, when in solution, an equilibrium may exist wherein some of the material may exist in the non-preferred ring opened form. Any number of saccharides can be linked together. For example, oligosaccharide—two or three saccharides or polysaccharides—more than three saccharides, are suitable for use in the present invention.
The cyclic pro-perfumes of the present invention further comprise spiroannulated rings having from 3 to 8 carbon atoms and optionally one or more heteroatoms in the ring, examples of which have the general formulae:
wherein said fused ring or spiroannulated ring cyclic pro-perfumes may have their rings further substituted by one or more units, said units are independently hydroxyl, C 1 -C 22 alkoxy, C 1 -C 22 alkyl, C 1 -C 22 alkenyl, C 6 -C 22 aryl, C 6 -C 22 alkylenearyl units, and mixtures thereof. The fused rings may also comprise one or more aromatic rings, including heteroaromatic rings. Examples of aromatic and heteroaromatic rings include benzene, naphthalene, pyridine, quinoline, isoquinoline, etc.
Preferably R 2 , R 3 , R 4 , and R 5 are selected such that said units comprise a vicinal diol or 1,3-type diol. For example, when taken together, R 2 , R 3 , R 4 , and R 5 derive from diols non-limiting examples of which include 1,2-propanediol, 1,2-butanediol, 1,2-hexanediol, 1,2-octanediol, 1,3-hydroxyacetone, 1,3-octanediol. All of the preceding examples of diols include a hydroxy moiety at the terminus or the alkyl chain. However, as described herein below, non-terminal hydroxy diols are also preferred.
Spacing unit Y is —CR 6 R 7 —, C═O, and mixtures thereof R 6 and R 7 are independently hydrogen (wherein the moiety —CR 6 R 7 — is a methylene unit), hydroxyl, nitro, nitrilo, C 1 -C 30 substituted or unsubstituted linear alkyl, C 3 -C 30 substituted or unsubstituted branched alkyl, C 3 -C 30 substituted or unsubstituted cyclic alkyl, C 2 -C 30 substituted or unsubstituted linear alkenyl, C 3 -C 30 substituted or unsubstituted branched alkenyl, C 3 -C 30 substituted or unsubstituted cyclic alkenyl, C 2 -C 30 substituted or unsubstituted linear alkynyl, C 3 -C 30 substituted or unsubstituted branched alkynyl, C 6 -C 30 substituted or unsubstituted alkylenearyl, C 6 -C 30 substituted or unsubstituted aryl, C 2 -C 20 substituted or unsubstituted alkyleneoxy, C 3 -C 20 substituted or unsubstituted alkyleneoxyalkyl, C 7 -C 20 substituted or unsubstituted alkylenearyl, C 6 -C 20 substituted or unsubstituted alkyleneoxyaryl, and mixtures thereof, or R 6 and R 7 as described herein above can be taken together to form a spiroannulated ring or taken together with any R 2 , R 3 , R 4 , or R 5 unit to form a fused ring, said spiroannulated or fused ring having from 3 to 8 carbons. In addition, the resulting spiroannulated or fused rings may be further substituted by one or more C 1 -C 22 alkyl, C 1 -C 22 alkenyl, C 6 -C 12 aryl, C 6 -C 22 alkylenearyl units, and mixtures thereof.
The index n is an integer from 0 to 3, preferably 0 or 1, more preferably 0.
For the purposes of the present invention substituted or unsubstituted alkyleneoxy units are defined as moieties having the formula:
wherein R 5 is hydrogen; R 6 is hydrogen, methyl, ethyl, and mixtures thereof; the index x is from 1 to about 20.
For the purposes of the present invention substituted or unsubstituted alkyleneoxyalkyl are defined as moieties having the formula:
wherein R 5 is hydrogen, C 1 -C 18 alkyl, C 1 -C 4 alkoxy, and mixtures thereof; R 6 is hydrogen, methyl, ethyl, and mixtures thereof; the index x is from 1 to about 20 and the index y is from 2 to about 30.
For the purposes of the present invention substituted or unsubstituted alkylenearyl units are defined as moieties having the formula:
wherein R 5 and R 6 are each independently hydrogen, hydroxy, C 1 -C 4 alkoxy, nitrilo, halogen, nitro, carboxyl (—CHO; —CO 2 H; —CO 2 R′; —CONH 2 ; —CONHR′; —CONR′ 2 ; wherein R′ is C 1 -C 12 linear or branched alkyl), amino, alkylamino, and mixtures thereof, p is from 1 to about 34.
For the purposes of the present invention substituted or unsubstituted aryloxy units are defined as moieties having the formula:
wherein R 5 and R 6 are each independently hydrogen, hydroxy, C 1 -C 4 alkoxy, nitrilo, halogen, nitro, carboxyl (—CHO; —CO 2 H; —CO 2 R′; —CONH 2 ; —CONHR′; —CONR′ 2 ; wherein R′ is C 1 -C 12 linear or branched alkyl), amino, alkylamino, and mixtures thereof.
For the purposes of the present invention substituted or unsubstituted alkyleneoxyaryl units are defined as moieties having the formula:
wherein R 5 and R 6 are each independently hydrogen, hydroxy, C 1 -C 4 alkoxy, nitrilo, halogen, nitro, carboxyl (—CHO; —CO 2 H; —CO 2 R′; —CONH 2 ; —CONHR′; —CONR′ 2 ; wherein R′ is C 1 -C 12 linear or branched alkyl), amino, alkylamino, and mixtures thereof, q is from 1 to about 34.
For the purposes of the present invention substituted or unsubstituted oxyalkylenearyl units are defined as moieties having the formula:
wherein R 5 and R 6 are each independently hydrogen, hydroxy, C 1 -C 4 alkoxy, nitrilo, halogen, nitro, carboxyl (—CHO; —CO 2 H; —CO 2 R′; —CONH 2 ; —CONHR′; —CONR′ 2 ; wherein R′ is C 1 -C 12 linear or branched alkyl), amino, alkylamino, and mixtures thereof, w is from 1 to about 34.
Not wishing to be limited by theory, a formulator wishing to increase the degree of torsional strain in the pro-perfume ring may, however, select a diol having two non-terminus alcohols, for example, 2,3-octanediol or 3,4-octandiol. The increase or decrease in the torsional strain of the cyclic pro-perfume ring provides the formulator with a means for adjusting the rate at which the fragrance raw material alcohol is released by the cyclic orthoester. For example, the two cyclic pro-perfumes having the formulae:
will exhibit different release rates of perfume raw material alcohol ROH due in part to the torsional strain provided by the eclipsing interaction of the methyl group with the alkyl chain.
Fragrance Delivery System
The present invention further relates to fragrance delivery systems comprising:
a) at least one cyclic pro-perfume;
b) optionally one or more pro-perfumes, pro-fragrances, or pro-accords capable of releasing one or more fragrance raw materials, said fragrance raw materials selected from the group consisting of aldehydes, ketones, alcohols, esters, nitrites, nitro compounds, linear, branched and cyclic alkenes, ethers, and mixtures thereof;
c) optionally one or more fragrance raw materials; and
d) the balance carriers and adjunct ingredients.
The pro-perfumes, pro-fragrances, or pro-accords which are combinable with the cyclic pro-perfumes of the present invention are preferably the pro-accords. The term “accord” as used herein is defined as “a mixture of two or more ‘fragrance raw materials’ which are artfully combined to impart a pleasurable scent, odor, essence, or fragrance characteristic”. Therefore a material which is a “pro-accord” is capable of releasing a mixture of fragrance raw materials or a fragrance accord. Non-limiting examples of pro-accords and pro-fragrances include orthoesters, acetals, ketals, orthocarbonates, and the like described herein below.
When formulated into a fragrance delivery system, the cyclic pro-perfumes of the present invention will comprise from about 0.1% to about 99%, preferably from about 1% to about 50% by weight, of said fragrance delivery system.
The fragrance delivery systems of the present invention preferably comprise the pro-accords described herein below. When present, said pro-accords comprise singly or as an admixture from 0.1% to about 99%, preferably from about 1% to about 50% by weight of the fragrance delivery system.
In addition, the fragrance delivery systems of the present invention further comprises carriers, fixatives, and other adjunct ingredients which can be added in any suitable amount or ratio to the cyclic pro-perfumes or the optional pro-accords which comprise the balance of the delivery system. Typical carriers are methanol, ethanol (preferred), iso-propanol, polyethylene glycol, as well as water in some instances. Fixatives serve to lower the volatility of certain top and middle notes in order to extend their contact time on skin. Adjunct ingredients include perfume raw material components which are essential oils and are therefore not a single chemical entity. In addition, the adjunct ingredients may be mixtures of synthetic fragrance raw materials which serve a further purpose in addition to providing a pleasurable odor.
Orthoesters
One class of preferred compounds useful as pro-accords according to the present invention are orthoesters having the formula:
wherein hydrolysis of the orthoester releases fragrance raw material components according to the following scheme:
wherein R is hydrogen, C 1 -C 8 linear alkyl, C 4 -C 20 branched alkyl, C 6 -C 20 cyclic alkyl, C 6 -C 20 branched cyclic alkyl, C 6 -C 20 linear alkenyl, C 6 -C 20 branched alkenyl, C 6 -C 20 cyclic alkenyl, C 6 -C 20 branched cyclic alkenyl, C 6 -C 20 substituted or unsubstituted aryl, preferably the moieties which substitute the aryl units are alkyl moieties, and mixtures thereof, preferably R is hydrogen, methyl, ethyl, and phenyl. R 1 , R 2 and R 3 are independently C 1 -C 20 linear, branched, or substituted alkyl; C 2 -C 20 linear, branched, or substituted alkenyl; C 5 -C 20 substituted or unsubstituted cyclic alkyl; C 6 -C 20 substituted or unsubstituted aryl, C 2 -C 40 substituted or unsubstituted alkyleneoxy; C 3 -C 40 substituted or unsubstituted alkyleneoxyalkyl; C 6 -C 40 substituted or unsubstituted alkylenearyl; C 6 -C 32 substituted or unsubstituted aryloxy; C 6 -C 40 substituted or unsubstituted alkyleneoxyaryl; C 6 -C 40 oxyalkylenearyl; and mixtures thereof. By the term “substituted” herein is meant “compatible moieties which replace a hydrogen atom”. Non-limiting examples of substituents are hydroxy, nitrilo, halogen, nitro, carboxyl (—CHO; —CO 2 H; —CO 2 R′; —CONH 2 ; —CONHR′; —CONR′ 2 ; wherein R′ is C 1 -C 12 linear or branched alkyl), amino, C 1 -C 12 mono- and dialkylamino, and mixtures thereof
Acetals and ketals
Another class of compound useful as pro-accords according to the present invention are acetals and ketals having the formula:
wherein hydrolysis of the acetal or ketal releases one equivalent of aldehyde or ketone and two equivalents of alcohol according to the following scheme:
wherein R is C 1 -C 20 linear alkyl, C 4 -C 20 branched alkyl, C 6 -C 20 cyclic alkyl, C 6 -C 20 branched cyclic alkyl, C 6 -C 20 linear alkenyl, C 6 -C 20 branched alkenyl, C 6 -C 20 cyclic alkenyl, C 6 -C 20 branched cyclic alkenyl, C 6 -C 20 substituted or unsubstituted aryl, preferably the moieties which substitute the aryl units are alkyl moieties, and mixtures thereof R 1 is hydrogen, R, or in the case wherein the pro-accord is a ketal, R and R 1 can be taken together to form a ring. R 2 and R 3 are independently selected from the group consisting of C 5 -C 20 linear, branched, or substituted alkyl; C 4 -C 20 linear, branched, or substituted alkenyl; C 5 -C 20 substituted or unsubstituted cyclic alkyl; C 6 -C 20 substituted or unsubstituted aryl, C 2 -C 40 substituted or unsubstituted alkyleneoxy; C 3 -C 40 substituted or unsubstituted alkyleneoxyalkyl; C 6 -C 40 substituted or unsubstituted alkylenearyl; C 6 -C 32 substituted or unsubstituted aryloxy; C 6 -C 40 substituted or unsubstituted alkyleneoxyaryl; C 6 -C 40 oxyalkylenearyl; and mixtures thereof By the term “substituted” herein is meant “compatible moieties which replace a hydrogen atom”. Non-limiting examples of substituents are hydroxy, nitrilo, halogen, nitro, carboxyl (—CHO; —CO 2 H; —CO 2 R′; —CONH 2 ; —CONHR′; —CONR′ 2 ; wherein R′ is C 1 -C 12 linear or branched alkyl), amino, C 1 -C 12 mono- and dialkylamino, and mixtures thereof
Orthocarbonates
Another class of preferred compounds useful as pro-accords according to the present invention are orthocarbonates having the formula:
wherein hydrolysis of the orthoester releases the fragrance raw material components according to the following scheme:
which can continue to hydrolyze and further release two equivalents of one or more fragrance raw material alcohol according to the following scheme:
thereby providing up to four equivalents of fragrance raw material alcohol per equivalent of delivered orthocarbonate, wherein R 1 , R 2 , R 3 , and R 4 are independently C 1 -C 20 linear, branched, or substituted alkyl; C 2 -C 20 linear, branched, or substituted alkenyl; C 5 -C 20 substituted or unsubstituted cyclic alkyl; C 6 -C 20 substituted or unsubstituted aryl, C 2 -C 40 substituted or unsubstituted alkyleneoxy; C 3 -C 40 substituted or unsubstituted alkyleneoxyalkyl; C 6 -C 40 substituted or unsubstituted alkylenearyl; C 6 -C 32 substituted or unsubstituted aryloxy; C 6 -C 40 substituted or unsubstituted alkyleneoxyaryl; C 6 -C 40 oxyalkylenearyl; and mixtures thereof. By the term “substituted” herein is meant “compatible moieties which replace a hydrogen atom”. Non-limiting examples of substituents are hydroxy, nitrilo, halogen, nitro, carboxyl (—CHO; —CO 2 H; —CO 2 R′; —CONH 2 ; —CONHR′; —CONR′ 2 ; wherein R′ is C 1 -C 12 linear or branched alkyl), amino, C 1 -C 12 mono- and dialkylamino, and mixtures thereof
Fragrance Release Half-life
The cyclic pro-perfumes and other pro-accords useful in the fragrance delivery systems of the present invention generally have a delayed release of final fragrance accord in order to achieve the increased fragrance longevity benefits described herein. However, the pro-accords generally also deliver the fragrance accords during a time period useful to the formulator, for example, within a time period desirable to the consumer.
For the purposes of the present invention the pro-accords generally have a “Fragrance Release Half-life” of less than or equal to 12 hours when measured in NaH 2 PO 4 buffer at pH 2.5 and greater than or equal to 0.1 hour when measured in NaH 2 PO 4 buffer at pH 5.3. The “Fragrance Release Half-life” is defined herein as follows.
Pro-accords deliver their corresponding mixture of fragrance raw materials or fragrance accords according to the equation:
Pro-Accord→Accord
wherein the accord which is released may be a binary accord or a multiple fragrance raw material accord.
The rate at which the accord is released is defined by the formula:
Rate=k[Pro-accord]
and can be further expressed by the formula: - [ Pro - accord ] t = k [ Pro - accord ]
wherein k is the release rate constant and [Pro-accord] is the concentration of pro-accord. For the purposes of the present invention the “Fragrance Release Half-life”, t ½ , is related to the release rate constant by the formula: t 1 / 2 = 0.693 k
and this relationship is used for the purposes of the present invention to determine the “fragrance Release Half-life” (FRHL).
Due to the hydrophobic nature of some pro-accords, it is necessary to conduct the determination of t ½ and k in a mixture of 90/10 dioxane/phosphate buffered water. An example of the procedure used to measure the suitability of a pro-accord for use in the fragrance delivery systems at pH 2.5 is as follows. The phosphate buffered water is prepared by admixing 3.95 mL of 85% phosphoric acid (H 3 PO 4 ) and 24 g of sodium dihydrogen phosphate (NaH 2 PO 4 ) with one liter of water. The pH of this solution is approximately 2.5. Next 10 mL of the phosphate buffer is admixed with 90 mL of dioxane and the pro-fragrance to be analyzed is added. The hydrolysis kinetics are then monitored by conventional HPLC at 30° C.
The pro-accord component of the present invention, in order to assure the stability of acid labile pro-accords, may include a source of reserve alkalinity equivalent to at least 0.001 molar (1 milli-molar) sodium hydroxide. This reserve alkalinity generally serves to prevent premature release of the fragrance raw materials by the pro-accords prior to exposure of the pro-accords to skin. For the purposes of the present invention the term “a reserve alkalinity of at least 0.001 molar” is defined as “the amount of alkaline material present in one liter of the second component when placed in an equivalent volume of water, would produce a hydroxide ion equivalent of 0.001 moles or greater”. By way of illustration, 0.0004 g of NaOH present in a 10 mL aliquot of the second component would produce a reserve alkalinity of at least 0.001 molar.
Suitable sources of alkalinity are the alkali metal and alkali earth hydroxides. For example, sodium hydroxide, potassium hydroxide, lithium hydroxide, calcium hydroxide, magnesium hydroxide, sodium carbonate, potassium carbonate, and sodium silicate. However, other suitable sources of alkalinity can be used which are compatible with the pro-accords of the “pro-accord component”.
In addition, the fragrance delivery system of the present invention may be suitably use in a fine fragrance composition. Said perfume compositions provide extended fragrance character impressions, and comprise:
A) a pro-accord component comprising:
i) from 0.1% to 99% by weight, of one or more pro-accords formed from at least one fragrance raw material, said pro-accord releasing upon hydrolysis at least two fragrance raw materials selected from the group consisting of primary, secondary, and tertiary alcohols, aldehydes, ketones, esters, carbonates, and mixtures thereof, provided each pro-accord:
a) is formed from at least one fragrance raw material having a molecular weight greater than or equal to about 100 g/mol;
b) has a molecular weight greater than or equal to about 300 g/mol;
c) has a molecular weight at least two times greater than the lowest molecular weight fragrance raw material which comprises said pro-accord;
d) has a fragrance release half-life of less than or equal to about 12 hours at pH 2.5 or greater than or equal to about 0. 1 hour at pH 5.3 when measured in NaH 2 PO 4 buffer;
ii) the balance carriers, stabilizers, and other adjunct ingredients whereby said pro-accord component is provided with an amount of reserve alkalinity equal to at least 0.001 molar NaOH;
B) a fragrance raw material component comprising:
i) from 0.1% to about 99% by weight, of a mixture of base note fragrances;
ii) from 0.1% to about 99% by weight, of one or more top and middle note fragrances;
ii) the balance carriers, fixatives, and other adjunct ingredients; and
C) from 0.1% to about 99% by weight, of a cyclic pro-perfume component comprising one or more of the cyclic pro-perfumes described herein.
The following are examples of cyclic pro-accords of the present invention which release fragrance raw materials.
EXAMPLE 1
3,4,6tri-O-acetyl-1,2-(ethyllinalyl)orthoacetyl-α-D-glucopyranose
Acetobromoglucose, tetrabutylammonium bromide (0.3 equiv), and ethyllinalool (3 equiv) are suspended in dry collidine and stirred at 65° C. for 3 days. The reaction mixture is diluted with 2 volumes of ether, washed twice with water, and then dried (MgSO 4 ), evaporated, and purified by flash chromatography.
EXAMPLE 2
1,2-(ethyllinalyl)orthoacetyl-α-D-glucopyranose
A solution of 3,4,6-tri-O-acetyl-1,2-(ethyllinalyl)orthoacetyle-α-D-glucopyranose in ethanol is treated with anhydrous Na 2 CO 3 (0.25 equiv.) and stirred for 6-12 h. After filtration and evaporation of solvent, the resulting material is purified by flash chromatography.
The cyclic pro-perfumes of the present invention are also suitable for use in personal care and personal hygiene compositions. The following are examples of a personnel cleanser composition which is prepared by combining the following ingredients using conventional mixing techniques.
TABLE I
Weight %
Ingredients
3
4
5
6
Phase A
Water
QS 100
QS 100
QS 100
QS 100
Disodium EDTA
0.100
0.100
0.100
0.100
Glycerin
4.00
4.00
4.00
4.00
Methylparaben
0.200
0.200
0.200
0.200
C 10 -C 30 alkyl
0.150
0.150
0.150
0.150
acrylate crosspolymer 1
Carbomer 954 2
0.250
0.250
0.250
0.250
Phase B
Stearic Acid
0.110
0.110
0.110
0.110
Stearyl alcohol
0.875
0.875
0.875
0.875
Cetyl alcohol
0.875
0.875
0.875
0.875
Propylparaben
0.150
0.150
0.150
0.150
Steareth-2
—
0.25
0.25
0.25
Steareth-21
—
0.50
0.50
0.50
Phase C
Sodium hydroxide 3
0.130
0.130
0.130
0.130
Phase D
Diisopropyl sebacate
1.50
1.50
1.50
1.50
Isohexadecane
5.00
2.00
5.00
5.00
Mineral Oil 4
—
5.00
—
—
Phase E
Phenoxyethanol
0.5
0.5
—
0.5
Pro-accord 5
1.5
1.5
2.20
1.5
Phase F
Glucose amide
0.96
0.96
0.96
0.96
1 Available as Pemulen ® from B. F. Goodrich Corporation.
2 Available as Carbomer ® 954 from B. F. Goodrich Corporation.
3 As a 50% aqueous solution.
4 Light mineral oil available as Drakeol 5 from Penreco, Dickenson, TX.
5 Cyclic pro-perfume according to Example 2.
The above Examples 3-6 can be suitably prepared as follows. In a suitable vessel, the Phase A ingredients are mixed at room temperature to form a dispersion and heated with stirring to 70-80° C. In a separate vessel, the Phase B ingredients are heated with stirring to 70-80° C. Phase B is then added to Phase A with mixing to form the emulsion. Next, Phase C is added to neutralize the composition. The Phase D ingredients are added with mixing, followed by cooling to 45-50° C. The Phase E ingredients are then added with stirring, followed by cooling to 40° C. Phase F is heated with mixing to 40° C. and added to the emulsion, which is cooled to room temperature. The resulting cleansing composition is useful for cleansing the skin. The emulsion de-emulsifies upon contact with the skin.
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The present invention relates to cyclic pro-perfumes comprising a moiety derived from a fragrance raw material alcohol. Such cyclic perfumes may contain dioxolane and glucosyl orthesters that are suitable for use in delivering enhanced fragrance longevity to human skin.
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TECHNICAL FIELD
The present invention relates generally to accessing a position or location of a workpiece during manufacturing processes and, more specifically, to accessing or touring a large number of individual and distinct positions or locations of a workpiece.
BACKGROUND OF THE INVENTION
During manufacturing, various positions or locations of a workpiece, such as a board or plate, may be required to be accessed or toured for various purposes. Such purposes may include punching or drilling holes at these locations. In some schemes, the workpiece is placed on a movable positioning table, and the tool or processing means is stationary. In other schemes, the workpiece is stationary and the processing means is moved to the various locations of the workpiece. In either scheme, the operating mechanism is generally controlled by an electronic device or a processor unit.
A large number of methods for controlling positioning means exist which differ with regard to their objective.
Most workpieces have a surface which requires numerous distinct positions located thereon to be toured or accessed. One example of such a surface 1 is shown schematically in FIG. 1. The surface 1 includes a plurality of targets arranged thereon. The targets are the individual points or positions 2 which are to be accessed or toured. The location of these targets may be determined, for example, by a rectangular coordinate system X,Y. For functional efficiency, the individual positions 2, which may also be distributed at random, are frequently arranged in a predetermined raster 3. Minimizing the required positioning path normally implies finding a solution to the so-called "Travelling Salesman Problem" (hereinafter referred to as the TSP), i.e., it is required to determine the shortest possible path for accessing each individual position 2. Since accurately computing this problem for a relatively large number of positions (for example, more than 100) generally surpasses the capacity of existing processors, approximation methods have been developed. For minimizing the processing time needed for a workpiece, an essential additional parameter to be included in TSP computations is the acceleration/deceleration characteristic of the positioning mechanism. The positioning paths obtained as a TSP solution depend strongly on the location and the number of predetermined targets. Thus, slight changes of the current pattern arising, for example, from adding or eliminating a few positions, result in a totally different configuration of the respective positioning path. A TSP positioning path 4 is schematically represented in FIG. 2.
In this manner, specific sequences of movements occur for each type of workpiece or variant during the manufacturing process. Consequently, slight (but invariably present) tolerances of the positioning mechanism affect each workpiece differently, i.e. tolerance--related positional deviations vary from one workpiece to another. For manufacturing workpieces for which all the individual positions have to be toured with reproducible accuracy, for instance, in the case of successively produced individual board layers whose plated throughholes have to be accurately aligned during stacking, a pure TSP approach poses precision problems.
The desired accuracy is obtained by abandoning that approach and by positioning each workpiece during the processing cycle according to a predetermined pattern. For this purpose, a predetermined positioning path is travelled irrespective of how the workpieces differ with regard to the location and number of the individual positions to be toured. Examples of this are meander or spiral-shaped paths 5, 6. Such positioning paths are used in engineering and are schematically represented in FIGS. 3 and 4. They allow a very high reproducible accuracy. However, disadvantageously, the very long positioning paths associated with these schemes cause increased time requirements for accessing each position of each workpiece.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide an apparatus and method for controlling positioning means, which minimizes time requirements and allows for a high degree of reproducible accuracy.
In order to accomplish the above object and other objects of the invention, an apparatus and method according to the invention is provided for touring positions on a surface, by arranging the position in a coarse basic pattern and utilizing the course pattern to optimize route (time) requirements. For this purpose, a coarse positioning path structure is provided for each workpiece. In addition, as a result of the minimized route length and time requirements, a positioning path, for example, in the form of a meander is defined in the coarse structure. To this end, the mechanical characteristics of the positioning means may be taken into account. As a result of the existing coarse structure, the positioning path is similar even for different workpieces. The combination according to the invention of utilizing a predetermined coarse structure with local route (time) optimization affords reproducible accuracy values and high positioning speeds.
BRIEF DESCRIPTION OF THE DRAWINGS
Further details and advantages of the invention will be explained below with reference to examples illustrated in the accompanying drawings, in which:
FIG. 1 shows a surface of a workpiece with a multitude of positions located thereon;
FIG. 2 shows a surface of a workpiece with a path for accessing the positions thereon;
FIG. 3 shows a meander positioning path;
FIG. 4 shows a spiral-shaped positioning path;
FIGS. 5A-D illustrate dividing up of the surface area of a workpiece into individual sections;
FIG. 6 shows individual meander paths;
FIG. 7 shows a spiral-shaped configuration of a coarse structure formed by various surface sections;
FIG. 8 shows a continuous positioning path within the spiral-shaped coarse structure of FIG. 7;
FIG. 9 shows a final positioning path after route optimization; and
FIG. 10 also shows a final positioning path after route optimization.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
According to the invention, all the points to be toured on a workpiece surface are divided up into a coarse primary or basic pattern. The coarse structure is essentially the same for all workpieces, i.e. irrespective of individual differences, such as quantity and/or location of targets. The (coarse) sequence of movement for touring the various individual positions is analogous for any type of workpiece. This ensures a reproducible degree of accuracy which corresponds to that of pure meander or spiral routes.
As it is frequently desirable to minimize the time required for positioning, the geometrical lengths of individual routes between two positions may be weighted according the acceleration/deceleration characteristic of the positioning mechanism when the coarse structure is determined. For this purpose, the length of a route section equals the time needed for touring it.
More specifically, the coarse structure is formed by dividing the individual positions into groups, with each group occupying a portion of the workpiece surface. The sequence of the groups on the workpiece surface determines the coarse structure.
FIGS. 5 A-D illustrate a preferred embodiment of the invention. Generally speaking, in the boundary area of the surface 1 to be determined, a group is formed by successively associating individual points or targets 2 with each other according to the selection criteria explained hereinbelow. Then, the next group is formed for an area of the positioning surface 1 rotated through 90°. As a result, the sequence of the groups follows a spiral-shaped course.
Starting from one side of the workpiece surface, the points 2 on the outer-most coordinate line 7 are initially connected to the points 2 on the adjacent parallel coordinate line 8 in the form of a closed polygon 9 (FIG. 5A). The length of this polygon 9 is compared with the length of a meander-shaped connecting line 10 (FIG. 5B) extending through the same points 2. The meander route is obtained by first successively approaching or accessing all the points 2 that are on a common transverse coordinate first line. From the end point of the transverse line section thus obtained, the next point on an adjacent transverse coordinate second line is accessed or approached. If there are several adjacent points 2 on that second line so as to also make up a transverse line section, then the point on the second line with the shortest distance to the next point on the first line is used as the end point from which to access the next point on the first line.
If the route of the closed polygon 9 is shorter than the meander route 10, only the connection of the points on the outer-most coordinate line 7 is retained as a straight line, and route comparison is repeated to other coordinate lines after a 90° rotation of the positioning surface 1.
If the meander route 10 is shorter than the route of the closed polygon 9, a further coordinate line 11 is considered (FIG. 5C) and a new meander route 12 is obtained using the scheme as described hereinabove with respect to meander route 10 of FIG. 5B. The new meander route 12 is then compared with the relevant closed route 13. The closed route 13 is derived from the previous meander route 10 and the linear connection of the new points on the newly added coordinate line 11 (FIG. 5D).
The result of the route length comparison again decides whether the points on a further parallel coordinate line are to be considered or whether the above described scheme should be applied to a new section after a 90° rotation.
In this way, individual polygons 10, 14, 15, 16, 17, 18 or meander routes of different width (FIG. 6) are obtained. (For the example illustrated in FIG. 6 the polygons have been arbitrarily determined.)
When the length of the meander and the closed route are compared, an acceptance value may be set for determining when to use the meander route. For instance, the meander route 10 may be accepted if it is at least 95% of the closed route 17. By altering the acceptance value, the average meander width may be controlled, i.e. if compared with the closed route only substantially shorter meander routes are accepted, discontinuance is likely. Further points on adjacent coordinate lines will not be considered and the meander width will not increase further. Conversely, very wide meanders may result from a less rigid acceptance value. A pure meander (FIG. 3) or spiral (FIG. 4) as extremal structures can thus be obtained in the form of a polygon covering the entire surface area.
After completion of the scheme as described hereinabove, surface area 1 is divided up into several rectangles which, joined in sequence, form a spiral structure, as is shown in FIG. 7.
Thus, a coarse structure is defined which serves to determine a preliminary positioning path which will be defined as described hereinafter.
Next, as shown in FIG. 8, a preliminary positioning path 19 is generated by first configuring individual path sections by linking the individual positions 2 in each section of the coarse structure, i.e., in the rectangles as illustrated in FIG. 7. The individual path sections are, for example, meander-shaped. The individual path sections are then connected to adjacent path sections. When the coarse structure is determined by means of the previously described preferred embodiment, a corresponding meander-shaped path is already obtained. The meander-shaped path thus obtained, although affording a high and reproducible positioning accuracy because of its inherent coarse structure, has still to be optimized with regard to its length.
Generally, since the time required for positioning rather the pure route length must be minimized, individual routes between two positions may also be weighted in the optimization step to follow, according to the acceleration/deceleration characteristics of the positioning mechanism.
As a final step according to the preferred embodiment, the route length and, if desired, also the time required for positioning, are reduced by taking into account the coarse structure. For this purpose, smaller path sections (e.g. groups of about 10 individual positions) are restructured and the entire path length (optionally by considering the time required for acceleration and deceleration, as explained above) is successively minimized by continuous incrementation. For this purpose, suitably adapted TSP solutions may be used. The preferred method uses the so-called threshold accepting method (G. Dueck and T. Schauer in `Journal of Computational Physics`, Vol. 90, No. 1, Sep. 1990, pp. 161-175). The result is a final positioning path which, despite the predetermined coarse structure, has a total--optionally time-optimized--length that falls short of the pure TSP solution by only about a few percent. Compared with pure meander or spiral paths (FIG. 2 or 3), the route length--and the time required for positioning, respectively--can be reduced on an average by about 30 percent.
FIG. 9 shows an optimized positioning path 20 for which only a few individual positions 2 of each path section have been considered for local TSP route optimization, thus retaining the coarse structure in its original form. By predetermining a correspondingly large number of individual positions, which make up a section in an optimization step, details of the coarse structure may be abandoned in favor of a more TSP-oriented positioning path 21 (FIG. 10). In a borderline case, a pure TSP solution path (FIG. 4) is obtained which considers all existing positions.
The method according to the invention also permits defining complex positioning paths with a very large number of individual positions (>several 1000) in a short time. The preferred manner in which the problem of reducing the total route length or the time requirements is subdivided into successively implemented partial optimizations considering only relatively few positions, also lends itself to position optimization in small computer or processor systems. As up-to-date positioning means are normally processor-controlled, the method according to the invention may be used for in situ optimization to allow a flexible response to modifications of workpieces during their manufacture.
While the invention has been described in terms of specific embodiments, it is evident in view of the foregoing description that numerous alternatives, modifications and variations will be apparent to those skilled in the art. Thus, the invention is intended to encompass all such alternatives, modifications and variations which fall within the scope and spirit of the invention and the appended claims.
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A plurality of individual positions arranged on a surface area are toured. The individual positions are grouped such that each group occupies a continuous partial area in the positioning plane. The groups are ordered so that the partial areas adjoin each other, forming in their totality a geometrical coarse structure. The individual positions are continuously indexed such that their sequence follows the geometrical coarse structure. The indexing of the individual positions is altered in sections such that the time required for sequentially touring all the individual positions of a section is minimized.
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[0001] This application claims priority to U.S. Provisional Patent Application Ser. No. 61/632,645 filed Jan. 27, 2012. Among other things, this invention provides a technique for storing and shipping therapeutic amounts of animal tissue containing a therapeutic amount of undenatured Type II collagen and an improved method of preparing and maintaining such collagen in a pure, useful, and undenatured state so it can be consumed and utilized for ameliorating the effects of auto-immune arthritis in warm blooded mammals including equine such as horses, donkeys and mules or canine such as dogs and wolfs, and humans.
BACKGROUND OF THE INVENTION
[0002] Arthritis is a painful and often crippling disease that initially results in painful, swollen, and inflamed joints. It often progresses to deform or completely destroy joints that then require replacement. This disease is a result of the body mistakenly attacking type II collagen, which is the major structural component of cartilage tissue. One function of cartilage tissue is that it serves as a lubricant in the joints, keeping bone from rubbing on bone. As the disease progresses and more of the cartilage is destroyed, bone does begin to wear on bone. The two most prominent types of arthritis are rheumatoid arthritis and osteoarthritis. The usefulness of undenatured Type II Collagen has been shown in ameliorating the symptoms of Osteoarthritis in humans (International Journal of Medical Sciences, 2009; 6(6); 312-321), Horses (Journal of Veterinary Pharmacology and Therapeutics 32, 577-584, 2009), and Dogs (Journal of Veterinary Pharmacology and Therapeutics 28, 385-390, 2005), which are all here fully incorporated by reference.
[0003] In order to initiate rheumatoid arthritis, it appears that an individual must have an inherent susceptibility. There is now evidence that, in susceptible people, this disease is initiated by exposure to the relatively common Epstein-Barr virus. The ability of the Epstein-Barr virus to initiate Rheumatoid Arthritis has been linked to a key amino acid sequence which is identical to a sequence found in human Type II collagen. Thus, in generating antibodies to destroy the Epstein-Barr virus the body generates antibodies that are also capable of attacking its own collagen.
[0004] Osteoarthritis has recently been found to also be an attack by the autoimmune system on cartilage. It is interesting that osteoarthritis occurs in animal species that do not, as a species, have rheumatoid arthritis. These species include canine such as dogs and equine such as horses. Osteoarthritis is strongly related to age in both animals and humans. One likely reason for this age related effect is an alternate method for the autoimmune system to be activated to initiate an attack on the body's cartilage. Such activation method may involve the very life sustaining act of metabolism. In order to convert carbon based food into CO 2 and energy, the body creates massive numbers (many millions) of reactive oxygen species (ROS). In this process of breaking down food and producing energy, DNA chain breakage or other damage, in the average person, is said to occur over a million times per day. A large portion of this damage relates to cleavage of the DNA, which is quickly repaired or destroyed by the immune system. This very routine action of the body's immune system is absolutely vital to human life. Some of the damaged molecules have the potential to cause the immune system to generate antibodies that are then capable of attacking the body's own collagen. When a body ages, a combination of effects cause it to become more susceptible to this osteoarthritis inducement. In some cases the DNA damage repair system becomes weaker. In other cases there may simply be a gradual built up and accumulation of the water soluble molecular fragments that have the potential to generate antibodies that are capable of attacking the body's own collagen. When a sufficient accumulation of these water soluble molecular fragments occurs, the collagen destroying antibodies are activated.
[0005] In order to study the effect of proposed techniques for amelioration of arthritis, it is necessary to have arthritic animals. Two techniques to artificially induce arthritis in rats have been developed. These inducements have been accomplished, more quickly than for osteoarthritis in humans, but in a similar manner. With rats the newer technique is by the intradermal (under the skin) injection of a broken down, water soluble fragment of undenatured Type II collagen (extracted from chicken cartilage). This technique has been termed Collagen Induced Arthritis (CIA). The second and older technique is accomplished by intradermal injection of the well known Microbacterium tuberculosis (MT).
[0006] It was also shown that rats could be prevented from getting arthritis induced or the effects of inducement greatly reduced. This prevention was accomplished by feeding (or arterial injection) of the same broken down, water soluble fragment of Type II collagen for several days prior to the attempted inducement. It was also shown that, once arthritis has been induced, the effects of the disease could be reduced by the continual oral administration of the same broken down, water soluble fragment of Type II collagen. In later clinical studies with humans having arthritis oral administration of the broken down, water soluble fragment of Type II collagen was similarly beneficial in reducing the effects of the disease.
[0007] Oral administration of this broken down, water soluble, undenatured fragment of Type II collagen represents the very first technique for amelioration of the symptoms of arthritis that represented a reversal rather than simply a slowing of the progress of the disease. This oral technique is believed to effectively reverse the debilitating effects of arthritis by causing desensitization to Type II collagen. After this desensitization the body stops producing antibodies that destroy its own collagen. This process has been called “oral tolerization” which is a partially understood process which the body uses to stop a person's immune system from treating food as a hostile foreign body. If foreign proteins are introduced via the digestive system, the body automatically suppresses the immune system responses to these proteins. It is a technique that has been used in the past to ameliorate simple allergies such as an allergic reaction to poison ivy or pollen.
[0008] While this oral administration of a broken down, undenatured, water soluble fragments of Type II collagen represents a long sought and highly desired technique for amelioration of the symptoms of arthritis, the broken down, water soluble fragments of Type II collagen are difficult to prepare. Typically they are extracted from the tiny sterile cartilages of 2.5 week old chicks. In a preparation of this prior art, eighty animals were required to produce 19 g of cleaned sterile cartilage dissected free of surrounding tissue. It is typical of the prior art to perform up to seven operations, consisting of extractions or digestions, on each batch of tissue in order to obtain the broken down, water soluble fragment of Type II collagen. The procedure of this prior art is thus seen to have several serious deficiencies. An extremely large number of animals are required to obtain a small amount of the desired product. The purification procedure is very time consuming, requiring multiple extractions, digestions, and precipitations. Sometimes ultra filtration of the final product is required as a final step to remove pathogens from the water soluble product.
[0009] It was later discovered by Moore that it was not necessary to break the undenatured Type II collagen into a water soluble state to obtain the full anti arthritic effect when ingested. Moore in U.S. Pat. Nos. 5,645,581; 5,637,321; 5,529,786; and 5,750,144 (which are hereby fully incorporated by reference) surprisingly found that the normal digestive process was sufficient. That is, when the whole, undenatured cartilage is digested, the effective amino acid sequence is separated and passed into the blood stream where it can reduce the symptoms of arthritis. This accomplishes the same goal as the earlier experiments with rats where the desired effect was obtained by direct injections of the water soluble fragment into the blood stream. This 26 amino acid sequence has been identified and presented by Trentham in U.S. Pat. No. 5,399,347 (which patent is hereby incorporated in full by reference). It was shown that this sequence, though difficult to prepare from sequencing monomeric amino acids, had amelioration effects for arthritis.
[0010] In the above-referenced Moore patents it was found preferable to utilize the much larger cartilage from young four to six or more month old chickens. Such usage made more cartilage available and was also easier to maintain in a sanitary state. Although Moore preferred chicken cartilage, Moore taught that cartilage from other animal tissue containing Type II collagen could be effectively utilized. Bovine or porcine cartilage, or vitreous humor of eyes, for example, could be used if desired, although the solid cartilage was preferred and chicken sternal cartilage was most preferred. Moore's technique for preparation of cartilage for oral administration to humans consisted of first dissected the cartilage free of surrounding tissues so that the cartilage could be, for example, diced into smaller pieces. The diced cartilage was then sterilized by means known in the art and, for example, formed into capsules containing therapeutic levels of Type II collagen, said levels being at least about 0.01 gram and preferably from about 0.1 to about 0.5 grams of cartilage to provide a therapeutic dose. The use of more mature chickens in the Moore approach was surprising in view of the prior art which taught only the use of chicks of less than three weeks of age. The usefulness of the more mature chickens allowed an almost 100 fold increase in the amount of harvestable cartilage from a single animal. This, of course, made the desired product more readily available in therapeutic quantities, and also greatly decreased the possibility of micro-contamination due to the reduced handling during separation from relatively fewer animals.
[0011] It is difficult to preserve cartilage in its native undenatured state and thus maintain its effectiveness in alleviating the symptoms of autoimmune diseases. In the past, it has been possible to preserve the cartilage by two techniques. First, by cleansing, cooling, and storing the cartilage at very low temperatures Moore in the above patents, demonstrated that the collagen can be preserved successfully for an extended period. This storage is without the growth of harmful pathogens or change in structure of the collagen which would cause it to become denatured and thus lose its effectiveness. This process has the requirement to cleanse prior to cooling, by sterilization, for example, with chlorine producing agents and/or hydrogen peroxide. Second, by drying cleansed cartilage under special low temperature conditions, in the presence of an inorganic salt, the storage life of the collagen is greatly extended. This was shown in the work of Schilling et. al. (U.S. Pat. No. 7,083,820), which is hereby fully incorporated herein by reference. The Schilling procedure has the disadvantage of requiring a long, low temperature drying step.
[0012] In cleaning and preparation for use, the cartilage is difficult to completely free from biological contamination such as pathogens and other microbes in order to maintain its safety. These pathogens, other microbes, and the like must be removed to render the undenatured Type II collagen fit for human or animal consumption, even after extensive storage. It is desired to have the cartilage free of additives and easy to handle, store, ship, and consume.
[0013] The use of carbon dioxide gas to inhibit the growth of micro organisms and extend the storage life of fruits, vegetables and meats is well known. This knowledge goes back to the time of the Romans who would pack caves with fruit to let the off gasses due to ripening, largely CO 2 , accumulate and slow the ripening and thus prolong the eatable quality of the food. This extension in usefulness of the produce is sometimes measured in hours in the case of cut fruit for example. Such extension in useful life is often measured in days for items such as meat and poultry. The inhibition in ripening for uncut apples and other thickly skinned whole fruits is often measured in weeks as is pointed out, for example, in the Journal of food protection (Daniels;volume 48, issue 6, 1985, pages 537-537) which is hereby fully incorporated by reference.
[0014] The use of carbon dioxide has long been recognized as a means to merely retard the deterioration and spoilage of butchered meat or otherwise comminuted food types of substances and thus increase, in a small way, the useful storage life. This retardation has involved addition of at best only a few additional days of useful life. A summary is shown in the above article by Daniels Brecht, (Food Technology Vol 34, 1980; page 45-50) in another summary of the use of controlled atmosphere to retard spoilage of produce cites some negative results on the use of CO 2 . Acetaldehyde accumulation for one example or ultrastructure alterations for another example that suggested that CO 2 induces an uncontrolled breakdown of tissue. The product of our invention does not have these negative results.
[0015] Ogilvy (Food technology; Vol. 5; 1951; pp 97-102; “Post-mortem Changes in Meats II. The Effects of Atmospheres Containing Carbon Dioxide in Prolonging the Storage Life of Cut-up Chicken” examined the effects of CO 2 on prolonging the storage life of cut-up chicken. He used the concentration of slime forming bacteria reaching a count or 2×10 8 per square centimeter as an end of useful life. This level is believed to be well above the slime forming bacteria concentration when a visible haze forms in the slightly contaminated cartilage stored in the aqueous CO 2 of our invention. Ogilvy also noted a common problem when CO 2 is used to store meat or fish. That problem is discoloration, with a undesired dark brown color developing in bird flesh. The products of our invention are surprisingly void of such discoloration at even the highest CO 2 levels. The product of our invention is very white, or clear unless purposefully colored with an added die or other coloring material. Ansuetto et al (“Microatmospheric packaging of Apples”; Paper presented at Institute of Food Technologists Annual Meeting, Anaheim Calif.; Jun. 10-13, 1984) examined straw berries, along with other produce. He cited data showing that strawberries are particularly susceptible to decay. He extended storage from less than 3 days to about 6 days using a 30% CO 2 atmosphere in the packages. He also pointed out some cases where higher levels of CO 2 are harmful, where berries must be shipped with “scrubbers” such as lime.
SUMMARY OF THE INVENTION
[0016] The instant invention solves the above-mentioned problems and the discovery of new applications for the use of carbon dioxide provided the carbon dioxide is dissolved in an “aqueous medium” (defined herein as a liquid medium comprising water, preferably more than fifty percent water by weight, more preferably more than seventy five percent water by weight and yet more preferably more than ninety percent water by weight). The instant invention completely eliminates the requirement to add up to 40-60% or more of a salt to the cartilage. In the preferred practice of the instant invention, the need for the long, low temperature drying step is eliminated. The instant invention further provides a safe method of storing the cartilage (or other tissue). The product of our invention can be packaged so that a consumer can easily vary a dose size to find a preferred dose, and repeat that dose.
[0017] The liquid product packaging of the instant invention offers advantages over the dry product of the '820 patent. These advantages come from the potential to be manufactured, wholesaled, distributed, and consumed by those that have experience with or a preference for a liquid product. A particular advantage is liquid products ability to be promoted by existing distributors that promote liquid packaged products. Liquid product can also be placed into retail locations that are relatively convenient and selectively attractive to thirsty potential consumers. Any company that manufactures, wholesales, distributes, or retails any drink, sports drink, health promoting drink, or joint-health promoting drink might take advantage of their experience with liquid product or the experience of those in their existing supply chain. Liquid packaged product offers the advantage of being co-located with bottled soda and/or liquid health promoting drinks. For example, liquid product appears behind glass doors or refrigerators near cash registers located in grocer stores or health clubs Distinct and convenient point of sale retail locations which allow a consumer to read labels while waiting in line, become informed of the product, and see product which might otherwise only be seen elsewhere at the retail location in more obscure places. We have surprisingly found that when properly prepared cartilage is stored in carbonated water, that the storage life is measured in years and appears to be unlimited. Prior art of CO 2 storage to preserve food value gives no indication of maintaining effectiveness in ameliorating the effect of arthritis.
[0018] More specifically, in one embodiment the instant invention is a method for storing Type II collagen containing tissue in an aqueous medium, comprising the step of surrounding the tissue with the aqueous medium, the aqueous medium containing more than 0.01 percent carbon dioxide by weight. In another embodiment, the instant invention is a method for alleviating the symptoms of arthritis in mammals which comprises orally administering a composition obtained by separating water-insoluble undenatured Type II collagen containing animal tissue from animal tissue not containing Type II collagen, subdividing and sterilizing said tissue under conditions which do not change the original structure of the Type II collagen to produce a subdivided and sterilized product, storing the subdivided and sterilized product in an aqueous medium containing more than 0.01 percent carbon dioxide by weight to produce the composition, which composition is administered in an amount effective and for a time effective to alleviate such symptoms.
[0019] In yet another embodiment, the instant invention is a process for the treatment of arthritis in mammals which consists of the steps of: (a) removing, under sterile conditions, tissue containing mostly Type II collagen to produce a sterile tissue; (b) storing the sterile tissue in an aqueous medium containing more than 0.01 percent carbon dioxide by weight to produce a stored sterile tissue; and (c) orally ingesting therapeutic quantities of said stored sterile tissue. In still yet another embodiment, the instant invention is a method for the prevention of arthritis in mammals comprising the steps of (a) removing, under sterile conditions tissue containing Type II collagen to produce a sterile tissue; (b) storing the sterile tissue in an aqueous medium containing more than 0.0.01 percent carbon dioxide by weight to produce a stored sterile tissue; and (c) orally ingesting a quantity of said stored sterile tissue sufficient to prevent arthritis in the mammal. In another embodiment, the instant invention is a method for the preparation of a nutritional supplement, comprising the steps of (a) separating water-insoluble undenatured Type II collagen containing animal tissue from most animal tissue not containing Type II collagen; (b) subdividing and sterilizing said tissue under conditions which do not change the original structure of the Type II collagen to produce a subdivided and sterilized product; (c) packaging the subdivided and sterilized product in an aqueous medium containing more than 0.01 percent carbon dioxide by weight. In a yet further embodiment, the instant invention is a method for freezing animal tissue containing undenatured Type II collagen by the step of cooling the tissue at a rate sufficiently slow so that the Type II collagen essentially remains in the undenatured state.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] FIG. 1 is a side view, part in full and part in cross-section, of a suspension of Type II collagen containing cartilage particles suspended in carbonated water.
DETAILED DESCRIPTION OF THE INVENTION
[0021] The process of this invention comprises the use of aqueous carbon dioxide (CO 2 ) for the safe storage of type II collagen while maintaining the biological activity of this cartilage tissue (or other tissue containing type II collagen). The process effectively eliminates the growth of trace pathogens as well as microbes that might cause spoilage. More specifically the process of the present invention involves storing said cartilage for relatively long periods of time in the presence of aqueous CO 2 , preferably after treating with antimicrobial agents.
[0022] The minimum concentration of the carbon dioxide in the aqueous medium of the instant invention is about 100 parts per million (PPM) by weight. More preferably, the concentration of carbon dioxide used in the instant invention is 1,000 parts per million or more by weight. Most preferably, the concentration of carbon dioxide used in the instant invention is 3,000 parts per million or more by weight. As storage pressure is increased the CO 2 content of the aqueous medium is increased. The upper limit of CO 2 appears to only be limited by the pressure limit of the desired storage vessel or pressure at which, upon opening the vessel, the product of the instant invention is expelled in an unacceptable manner. When water is used in the instant invention it is preferable that the water be supersaturated with carbon dioxide and stored in a sealed pressure resistant container. Said storage conditions, in addition to eliminating any remaining traces of pathogens and microbes that might cause spoilage, have been shown to surprisingly keep the cartilage in its unaltered, undenatured, and thus most effective state.
[0023] As disclosed in the four previously mentioned patents of Dr. Eugene Moore, the use of undenatured Type II collagen reduces the symptoms of rheumatoid arthritis. As mentioned above, a recent clinical trial (International Journal of Medical Sciences, 2009; 6(6):312-321) has also shown effectiveness of undenatured cartilage against Osteoarthritis. Osteoarthritis combined with Rheumatoid Arthritis present a very serious health problem, affecting a large portion of the worlds aging population
[0024] In a preferred practice of this invention, after first removing most or all visible physical contaminants, an antimicrobial agent is used to remove most pathogens or microbes that might cause spoilage. An antimicrobial agent such as sulfur dioxide, ethylene oxide, chlorine, sodium hypochlorite (NaOCl), or a source of active oxygen such as hydrogen peroxide (H 2 O 2 ) are useful to carry out this sterilization function. Carefully controlled x-rays or the like may in some cases be useful and desired. This treatment might involve x-rays, gamma rays, electron beams or ultra violet light. Preferably the sterilization agent is chlorine, sodium hypochlorite or a source of active oxygen such as hydrogen peroxide. It is important to control the dose so that most pathogens are destroyed without significant denaturing of the collagen. This sterilization function may be carried out initially as well as during processing. The idea is to have most or preferably all of these pathogens and antimicrobial agents removed or destroyed before storage in a CO 2 containing media, thereby lengthening the safe storage period. When carbonated water is used, a visual observation of the stored product is one indicator of undesirable growth of pathogens or other microbial agents. In this case haze or cloudiness is one indicator of growth while another indicator is discoloration. Therapeutic levels of Type II collagen in the instant invention are at least about 0.01 gram and preferably from about 0.1 to about 0.5 grams.
[0025] It is desired that the pathogens and microbes be greatly reduced by the above sterilization type pretreatment. If such pretreatment is not carried out, storage time of the cartilage is significantly shortened. Successful or useful storage time, however, for this untreated cartilage is lengthened by increasing the CO 2 concentration in the liquid.
[0026] While special pressure vessels could easily be obtained to package and ship cartilage in bulk, where desired, we generally prefer to package and ship in readily available containers and bottles that are already designed for the moderate pressures required for commercial carbonated beverages, such as soft drinks, vitamin or mineral drinks, and the like. Plastic bottles such as those produced from polyethylene terephthalate (PET) are preferred for medium term storage, or for longer term storage when thin non permeable coatings are applied internally. Surprisingly, single or multiple dose packaging in thinner plastic bubble like containers using low permeability plastics such as vinyl chloride/vinylidene chloride copolymers are operable. Multiple dose packaging in larger self metering plastic bottles is in some cases desirable. Glass bottles are preferred for longest term storage. The lower permeability of glass allows for almost prefect retention of the CO 2 . However, glass lined plastic bottles (such as plastic bottles the interior of which are coated with a thin glass like layer by a plasma vapor deposition process) are also preferred in the instant invention because such containers are shatter resistant and have greatly reduced permeability. Referring now to FIG. 1 , therein is shown a preferred embodiment 10 of the instant invention wherein a glass bottle 11 having screw cap 12 contains a suspension of Type II collagen containing cartilage particles 14 in carbonated water 13 .
[0027] After the cartilage is free of most or all of the surrounding flesh and preferable treated with one or more antimicrobial agents it can be placed into the aqueous CO 2 environment. If the cartilage is from the chicken sternum, the pieces are small enough to even be stored whole in small readily available containers. If the cartilage is from larger animals such as cows or pigs, special containers may be required to store the cartilage in its original physical shape. Cartilage from chicken sternum cartilage is most readily available and is generally preferred, for this and other reasons. Usually chicken sternum cartilage, as received from chicken processing facilities, will contain 10 wt % or more of attached flesh. It is desired, in most cases, to remove this attached flesh, however we have noted that the use of H 2 O 2 in a final treatment process removes all discoloration and yields a, very pleasing to the eye, all white suspension. Removal of this flesh by hand is labor intensive. We have discovered that mechanical abrasion with material such as common grains or wood pellets for brief periods can remove most of the attached flesh. While there are many approaches to apply this abrasion, we have found that a rotating tumbler works well. When whole cartilage is used it can easily be separated from the smaller abrasive material by common mechanical techniques such as screening. It is preferred to have the abrasive material be combustible. In this combustible case, after separation the abrasive material containing the removed flesh may be dried, if necessary, and used for fuel. In addition to capturing fuel value, a waste disposal problem is avoided
[0028] In most cases it will be desired to reduce the size of the original cartilage particles by any one of the many techniques well known to those familiar with the art of size reduction. This technique could involve “slicing” equipment that would use sharp blades. This slicing may be carried out by hand with razor blades, or stamping equipment using a matrix of blades. Preferable a rotating blade such as found in a common food blender in an aqueous medium in a CO 2 atmosphere. An antifoam agent such as silicon resins, or others familiar to those in the antifoam art, may be used to reduce foam breaking time. In some cases it will be useful to have a large particle, or a collection of particles, equivalent to the desired therapeutic dose individually packaged. This may be accomplished by hand or by automatic weighing equipment. Surface water may be removed by a variety of techniques, such as centrifuging or blotting, before weighing. To get much finer particles, the “blended” chopped particles could be passed through an elongated orifice under very high pressure. The high shear field developed would cause further size reduction. Pressures across a single orifice could be as high as 5-10,000 psig. A series of progressive smaller orifices would allow for progressively smaller particle sizes. In some cases it will be desired to reduce particles to the point that they provide a stable suspension or emulsion. Such emulsions may become semi-transparent of “translucent”. We have found that the collagen found in the vitreous humor of bovine eyes, for example, are particularly useful when comminuted in this manner. They produce smaller particles and do so in lower shear fields. This may be due to the type II collagen being so uniformly dispersed and low in concentration. The limit on such size reduction will be limited, in the extreme, by loss of effectiveness as the key 26 amino acid sequence begins to be broken in a significant amount. Suspending agents or emulsification stabilizers may be employed. If particle size is sufficiently reduced the liquid product would become, translucent or transparent which would be desirable for visual appeal in the marketplace. When cartilage is frozen other reduction techniques are useful. These techniques could involve impacting equipment such as hammer mills or the like that would use impact to break up the particles The size reduction technique could also involve the use of particles of cartilage impacting other cartilage particles at high speed and reduced temperature so as to cause breakage in a process that has been called “micronizing”. Any of these size reduction processes may be carried out at a variety of reduced temperatures. Often it will be convenient to use liquid nitrogen or dry ice to achieve these temperatures. The “thy ice” (CO 2 ) will be preferred because it aids in the practice of this invention by, in addition to maintaining low temperature, providing a desired CO 2 atmosphere during size reduction. In any case it is necessary to control the temperature during grinding, since grinding processes generates heat. Since the collagen structure is changed, that is the collagen is denatured, at elevated temperatures it is necessary to control temperatures during the size reducing comminuting. The exact relationship between temperature and time at that temperature is not known, but suitable conditions will be easily determined by those familiar with the art of size reduction and the denaturization for collagen. Many of the grinding processes, such as those used by Schilling (U.S. Pat. No. 7,083,820) must have instantaneous and localized high temperatures caused by the impacts during grinding. Apparently this heat is applied for too short a time to have a great effect on denaturization of the type II collagen or the effect is too localized (small) to greatly reduce the amount of undenatured collagen. When dealing with bulk average temperatures the following preferences apply in the instant invention. Temperatures approaching 210 F cannot be tolerated except perhaps for only an extremely short time without denaturing the collagen and thus rendering it ineffective for amelioration of the symptoms of arthritis. Temperatures as high as 160 F, can be tolerated for slightly longer times. It is most preferred, however, to have bulk temperatures that do not exceed about 110 F. When temperatures are at this level or lower the cartilage will retain its undenatured structure for at least hours, which is more than enough time for any anticipated, drying, size reduction, or other processing.
[0029] Drying at temperatures of 110 F or below below will in some cases be desirable in the practice of our invention since some of the useful grinding techniques will be most successful on the more brittle, dried cartilage. Small amounts of anti-clumping agents such as lecithin or hydroxypropyl methylcellulose may be used during this drying stage. The process of drying before fine grinding provides an alternate to using very low temperature grinding to get the finest sizes that can be obtained by mechanical means.
[0030] It will often be desirable to have the particles sorted. This sorting might be done during the size reduction stage where particles exit the grinding chamber only when they can pass through a desired screen size. Sorting could also be accomplished by many other techniques familiar to those knowledgeable in the classification art. Techniques such as screening, cyclones, settling, or in an upward flowing gas stream (preferably CO 2 ). This latter technique is often called elution. Alternately the particles could be separated by weight which will be more highly automated as new techniques are developed. Preferably these sorting operations would be carried out in a nitrogen and most preferably a CO 2 atmosphere. In some cases a mixture of the two gases would be preferred.
[0031] The larger particles might be selected to be the proper dose size for humans, equines, or canines so that one particle per day would be taken for each subject. These particles would then be stored in carbonated water until consumed. Further size reduction could then be obtained by the natural process of chewing.
[0032] Finer particles could be blended to produce a slurry, or suspension with carbonated drinks. These drinks would be consumed completely if they contain a single dose. They could alternately be packaged as a concentrate containing a week or a month or more supply. In the case of the concentrate, after mild agitation to promote uniformity, a single dose could be metered out, for example, in a spoon or measuring cup. Special metering containers could also be used. For example, a metering chamber may be provided in a flexible bottle. Squeezing the bottle fills the metering chamber. The contents of the chamber would then be expelled as a therapeutic dose. The container could then be recapped. Such containers are well know in the art of metering gasoline additives, for example. Refrigeration at this point, while not always necessary, would help retain the CO 2 in the container for the relatively short storage period and is preferred.
EXAMPLES
[0033] Examples 1a and 1b, among other things, demonstrate the effectiveness of carbonated water to store cartilage in an essentially unaltered, undenatured, and sanitary state to not only ameliorate the symptoms of arthritis, but to do it more effectively than other techniques that may be known in the art.
Example 1a
[0034] Chicken breasts are purchased from a local supermarket. The sternum cartilage is removed and stripped free of almost all visible flesh. The cartilage is refrigerated for three days then cut into small pieces. One gram is placed into each of four cleaned ordinary plastic carbonated beverage bottles. The cartilage receives no particular surface treatment, such as chlorine or hydrogen peroxide, to destroy microorganisms. In order to test the ability of carbon dioxide to prevent spoilage, CO 2 in water is used at three levels. Standard Schweppes™ brand club soda is used, and is chilled before being opened. Boiled and then chilled tap water is used as the diluent. In Table 1, the High level is undiluted club soda water, the Medium is 50% club soda water, the Low is 25% club soda water, and the Zero is pure boiled tap water.
[0035] Visual observations of the bottle contents are shown in Table 1. These observations clearly demonstrate the short term preservative advantage of water containing CO 2 and the ability, to retard the growth of microorganisms that still remained on the un-pretreated surface of the cartilage.
[0000]
TABLE 1
Effect of CO 2 level on untreated cartilage storage stability
CO 2 concentration
Time
High
Medium
Low
Zero
Start
clear
clear
clear
clear
13 hr
clear
clear
clear
very slight
haze
62.5 hr
clear
very slight
slight haze
cloudy
Haze (1)
132.5 hr
very slight
distinct
cloudy
cloudy
haze
haze
with sides
sucked in
(1) Note that formation of a haze is a well known indication of undesirable microorganism growth
Example 1b
[0036] This example, among other things, demonstrates that increased CO 2 content in the water increases storage time. Example 1a is repeated except pressurized CO 2 gas is added to the initial chilled club soda water causing the amount of dissolved CO 2 to increase by a factor of about 1.5. A significant increase in storage time without haze or other visible change being seen. It is anticipated that a higher level of CO 2 would be found that would perform the dual function of : a) destroying pathogens and microorganisms; and b) preserving the effectiveness of the undenatured type II collagen in ameliorating the effects of arthritis.
Example 2
[0037] This example, among other things, demonstrates a preferred technique for removing surface contamination before storage. Chicken breasts are purchased from a local supermarket. The sternum cartilage is removed and stripped free of visible flesh. The cartilage is refrigerated then cut into small pieces as in Example 1. In this case the cartilage is treated with a common chlorine releasing compound (NaOCl) before being cut up. The cartilage is drained then exposed to 3 wt % H 2 O 2 in water as described in Example 1 of U.S. Pat. No. 5,750,144. Two glass bottles of club soda are purchased. One half gram is then placed into a bottle of the, now chilled, club soda and it is tightly resealed. Another half gram is similarly placed into the second bottle that is now filled with previously boiled, to kill any micro organisms, then chilled, water. These samples are then stored at ambient temperatures for an extended period of time and observed periodically. It is surprising to see that storage of cleaned cartilage in the carbonated water retains its original shape and coloration for more than ten years, a much longer time than untreated cartilage sample, of example 1. This is also very much longer than might be anticipated by anyone skilled in the art of using CO 2 in extending the useful life of food substances.
Example 2a
[0038] This example illustrates the surprising difference between the product of our invention and the past art concerning the use of CO 2 in maintaining the usefulness of digestible substances. As shown in the following Table 2, the useful life of past art is measured in days while the product of our invention is shown useful after more than eight years.
[0000]
TABLE 2
USE OF CO 2 IN MAINTAINING USEFULNESS OF DIGESTABLE
SUBSTANCES
TIME
76
6
16
26
3
6
12
2
4
6
8
hours
days
days
days
mon
mon
mon
years
years
years
years
Our
useful
useful
useful
useful
useful
useful
useful
useful
useful
useful
useful
invention
Coyne
useful
useful
useful
max
useful
Haines
max
useful
Ogilvy
max
useful
Anzuetto
useful
max
useful
Coyne (Effect of Carbon Dioxide on Bacterial Growth with Special Reference to the Preservation of Fish″; J. Soc. Chem. Ind.; Vol 52; 1933; pp 19-24) studied the usefulness of 100% CO 2 compared to air in slowing the deterioration of a variety of fresh fish
Haines (Influence of Carbon Dioxide on the Rate of Multiplication of Certain Bacteria as Judged by Viable Counts; J. Soc. Chem. Ind.; Vol 52; 1933; pp 13T-17T; 1933) studied the usefulness of 100% CO 2 compared to air in slowing the growth of Pseudomonas , Proteus, and Achromobacter , chief constituents of of the bacterial flora present on lean meat.
Ogilvy; (Post-Mortem Changes in Meats II. The Effects of Atmospheres Contaiing Carbon Dioxide in Prolonging the Storage Life of Cut-up Chicken; Food Technology; Vol 5, 1951; pp 97-102) studied the effect of 25% CO 2 on the prolonging the storage life of cut-up chicken
Anzuetto; (Microatmospere Packaging of Apples; Inst. Of Food Tech. Annual Meet; June 10-13, 1984) demonstrated the usefulness of 30% CO 2 on retarding decay of strawberries, only 8.3% decay after 6 days while untreated experienced 64.4% decay
Example 3
[0039] This example, among other things, demonstrates the surprising retention of effectiveness of cartilage stored by the technique of this invention in ameliorating the effect of arthritis. It also shows that some patients require a larger dose to see the advantages of our invention. A larger quantity of fresh sternum cartilage is obtained from a chicken processing facility and is prepared as in Example 2 and is cut into about one half gram pieces. About a one month supply of cartilage is then packaged, sealed and stored in each of many glass bottles each with the concentration of CO 2 as in Example 2. They are stored for over three years at room temperature. These samples are used to demonstrate that, after long term storage in CO 2 the cartilage retains its effectiveness.
[0040] After the storage period, the sample container is refrigerated then opened each day to remove a sample for consumption and quickly resealed to retain the CO 2 . The cartilage is consumed by two females suffering from arthritis. The cartilage is consumed as relatively large pieces, often a single piece which is then chewed to reduce the particle size and allow it to be more easily adsorbed. One of the two female finds reductions in the symptoms of arthritis in about a week and the reduction continues to increase most significantly over the first month with slower improvement continuing thereafter for many months. The second female sees little change at the lower dose but then sees a similar improvement when the dose is five times the lower dose. This demonstrates that some patients require a higher dose to trigger the oral tolerization process. The cartilage containing type II Collagen, stored long term in aqueous CO 2 , is surprisingly shown to have retained its effectiveness in ameliorating the effects of arthritis in humans.
Example 3a
[0041] This example, among other things, demonstrates that, effectiveness remains after being stored in aqueous CO 2 , then removed from the water containing CO 2 and stored for short terms at low temperature. Example 3 is repeated except after opening a sealed glass bottle containing about one month supply of cartilage, the cartilage particles are drained and put into a plastic bag and are slowly frozen and stored. A therapeutic amount of this cartilage is consumed each day by two other females with beneficial results.
Example 3b
[0042] This example, among other things, demonstrates the effectiveness of the product of our invention in treating other species of warm blooded animals. Example 3 is repeated except dogs are used. The amount of cartilage in each bottle is reduced. This reduction is to supply about the same cartilage to weight ratio as in the human example. For dogs the stored cartilage is cut into small particles before consumption. A group of dogs suffering from osteoarthritis are given cartilage similarly to humans in Example 3 and similar beneficial results are seen.
Example 3b
[0043] This example, among other things, further demonstrates that storage of undenatured cartilage containing type II collagen in the presence of aqueous CO 2 is capable of maintaining or improving the effectiveness of that stored cartilage in ameliorating the symptoms of arthritis over long periods of time. As in example 2, cartilage samples are stored for over three years in aqueous CO 2 at room temperature except the samples have had an additional 6 months of storage time in aqueous CO 2 as in example 3b. A group of dogs suffering from osteoarthritis are given cartilage and similar, but slightly superior beneficial results are seen. This example again indicates that long term storage in aqueous CO 2 maintains or even improves the effectiveness in ameliorating the effects of arthritis.
Example 3c
[0044] This example, among other things, demonstrates the surprising ability of the product of our invention to show a preventative effect when given to warm blooded mammals before the occurrence of autoimmune arthritis, such as osteoarthritis. The procedure of Example 3b is repeated except a group of older dogs is chosen from a breed that is particularly susceptible to osteoarthritis but have not yet contacted it. The dogs are dosed as above over a period of two years. The incidence of osteoarthritis in this dosed group is compared to a matched group of un-dosed dogs. The dosed dogs are found to have a very significant reduction in the incidence of osteoarthritis.
[0045] The result of this Example demonstrates a surprising, and previously unknown potential of the product of this invention to reduce the incidence of arthritis. This discovery has tremendous potential to reduce the incidence of arthritis in all warm blooded mammals. The use of undenatured chicken cartilage and many pharmaceuticals have shown an ability to reduce suffering from arthritis once it has begun its painful and devastating progress. However, the instant invention is the first to surprisingly show the ability to reduce the inception of arthritis. The product of our invention appears to serve as an apparent “vaccine” against osteoarthritis.
Example 3c2
[0046] This example further illustrates the improved effectiveness of the product of this invention compared to the product of the '820 patent in the treatment of dogs already afflicted with osteoarthritis. Twenty older dogs are selected that are already arthritic and overweight. These dogs are divided into two groups. The first group is randomly selected and treated once a day with the product of the '820 patent containing 10 mg of undenatured type II collagen as dried product. The second group is fed an equivalent amount of type II collagen that had been stored in small glass bottles for over one year in the presence of aqueous CO 2 . In all cases they are fed close to or during meal time. Overall pain is measured on a scale of 1 to 10 with 1 being no visible pain and 10 being severe and constant pain. A physical examination is performed once a month. The dogs are examined rising from a sitting and laying down position as well as laying down from a standing position. The results shown in Table 3 further illustrates the superior performance of the product of this invention and the benefits of the storage of chicken cartilage in carbonated water.
[0000]
TABLE 3
PERFORMANCE OF CO 2 STORED CHICKEN CARTIALGE BASED
ON OVERALL PAIN LEVEL FOR ARTHRITIC DOGS
TIME
O DAY
30 DAY
60 DAY
90 DAY
120 DAY
U.S. Pat. No.
4.8
3.2
2.6
2.3
1.8
7,083,820
Product
This Invention
4.8
2.9
2.3
1.9
1.5
Example 3d
[0047] This example, among other things, demonstrates effectiveness of the product of our invention with horses. It also shows that after amelioration of the symptoms of arthritis that continued usage can surprisingly prevent reoccurrence. The procedure of Example 3 is repeated except a horse suffering from severe arthritis is dosed for several months with a similar cartilage to weight ratio, then varied to find a preferred dose. Significant improvement in the horse's symptoms is seen. When the administration of cartilage is stopped the symptoms return within days. When administration of the CO 2 stored cartilage is resumed the improvement resumes. In addition to demonstrating effectiveness with horses this example demonstrates the ability to prevent re-occurance. An additional advantage is seen in that wet product of the instant invention adheres to the dry grain and is nearly completely consumed. In contrast, the dry product of the '820 invention tends to separate from the grain settle to the bottom of the serving dish and be refused by the horses and more than 10% is thus wasted.
Example 3e
[0048] This example, among other things, demonstrates the superiority of the product of this invention over the dried product of the prior art. This example also demonstrates the surprising effect that some mammals require a larger dose to activate the desired oral tolerization effect. In order to demonstrate the superior performance of the CO 2 stored cartilage a comparative example to the prior art of Schilling's U.S. Pat. No. 7,083,820 a study is arranged. The procedure of Example 3b is repeated and a matched group of dogs is chosen that have arthritis. The product of '820 is purchased from Swanson under the trade name of UCII. The UCII capsule, according to the label contains 10 mg of undenatured type II collagen. When the matched group is dosed with an equivalent amount of the UCII, improvements in the arthritis symptoms in the dogs are seen. These improvements, however, are statistically seen to be significantly less than the improvements for the undenatured type II collagen of the instant invention. Thus the superiority of the product of the instant invention is further demonstrated.
Example 4
[0049] This example, among other things, demonstrates the effectiveness of a uniform slurry of the product of this invention. A quantity of fresh sternum cartilage is obtained from a chicken processing facility. The cartilage is stripped of adhering flesh. The cartilage is then treated at room temperature in a dilute solution of NaOCl (about 1½%) for about 20 minutes. The cartilage is drained, rinsed with carbonated water and reduced in size with a slicing tool then placed into a container which contains 3% stabilized H 2 O 2 in water. After about one hour, the fine sliced and then cross sliced cartilage is drained to remove excess hydrogen peroxide. Several bottles of club soda are purchased to store the sliced cartilage in an aqueous CO 2 environment. A small amount of the carbonated water is drained from each bottle and the drained cartilage is added to produce a slurry of about 10% cartilage. The capped, cartilage containing, bottles are stored at room temperature until shortly before use when they are refrigerated. Once a cooled container is opened, to begin using, it is then continuously maintained cool in order to slow CO 2 loss. Before each use the container is mildly agitated to produce a uniform slurry which is then poured to measure a uniform dose. This product is then shown to be effective in ameliorating the symptoms of arthritis.
Example 4a1
[0050] This example, among other things, demonstrates one of many alternate methods for the preparation of the product of our invention in aqueous slurry form. Example 4 is repeated except the slurry is prepared in a common 6 cup food “chopper/blender”, model RIVAL model TB-170 sold by Wal-Mart. As in example 4, A quantity of fresh sternum cartilage is obtained from a chicken processing facility. The cartilage is stripped of adhering flesh. The cartilage is then treated at room temperature in a dilute solution of NaOCl (about 1½%) for about 20 minutes. The cartilage is drained, rinsed with carbonated water and placed into a container which contains 3% stabilized H 2 O 2 in water. After about one hour the cartilage is drained to remove excess hydrogen peroxide. Forty three grams of clean cartilage are placed into the blender along with 391 grams of bottled soda water along with 6 ice cubes weighing about 17 g each. The blender is operated for 6 minutes then half of the resulting slurry is placed into ordinary kitchen carbonator and carbonated with a standard CO 2 capsule. The product is stored in a sealed bottle for about 6 months. This product is then shown to be effective in ameliorating the symptoms of arthritis.
Example 4a2
[0051] This example, among other things, demonstrates effective use of cartilage slurries at a higher solids level. Example 4a1 is repeated except at a higher solids level of 20% by weight. In this case the CO 2 content is increased by about twenty percent. The product is similarly effective. The upper limit of solids will be apparent to those familiar with the art of liquid/solid slurries and will be effected by the particle size and shape. Suspending agents such as methylcellulose and the like will also have an effect on both the achievable solid content and settling rate.
Example 4a3
[0052] This example, among other things, demonstrates that it is unnecessary to remove attached tissue when the product is in slurry form. Example 4a1 is repeated except with “as received cartilage” that is not stripped of the attached tissue. In this sample, which appears to be typical, it is found that the cartilage contains 16.4% by weight of attached material. Other than a slight increase in slurry viscosity no difference in appearance is seen between the produce of example 4a1 and this product. The product is stored in a sealed bottle for about 6 months. This product is then shown to be effective in ameliorating the symptoms of arthritis.
Example 4a3
[0053] This example, among other things, demonstrates the value of the use of antifoam additive in preparation of the product of this invention in slurry form. Example 4a1 is repeated except immediately prior to use of the blender a small amount of food grade silicon anti foam is added. This addition is found to improve the process by reducing the time required for the foam to dissipate both during the blending and carbonation steps. There are many other compounds that might be used to reduce foam which will be apparent to those skilled in the foam reduction art.
Example 4b
[0054] This example, among other things, demonstrates the beneficial effect of flavor enhancing and/or pH lowering additives. Example 4 is repeated except in addition to the CO 2 , a small amount of phosphoric acid is added in an amount to reduce the pH to about 3.0. The product is found to be similarly effective and has an improved flavor.
Example 5
[0055] This example, among other things, demonstrates the ability to effective use a wide variety of water based liquids in the practice of the instant invention. It also demonstrates that larger doses are required for some consumers. Example 4 is repeated to prepare the fine sliced cartilage to the point that it is drained of excess hydrogen peroxide. In a manner similar to Example 4 the cartilage is placed into containers to produce a slurry with about 10% solids. The containers are then filled with a wide variety of liquids that would normally be considered to be safe and pleasant to consume by humans. Other containers are then filled with a variety of liquids that would normally be considered to be safe, promoting of improved health, and/or pleasant for canines, or equines to consume. The containers are then carbonated with CO 2 , using a common kitchen type carbonator with a small cartridge containing CO 2 , to about the same level as for club soda or more. Other pressurization techniques are well known in the carbonation of beverage art could be used with similar effect. After carbonation the bottles are stored at ambient temperature until opened after which refrigeration is preferred to help retain CO 2 for short term storage periods. As in example 4 the multiple products are shown to be defective in ameliorating the symptoms of arthritis.
[0056] It is found convenient to store multiple doses in a single bottle and to measure single doses from a gently agitated bottle. It is also found convenient to package a single dose per container, which can then be consumed completely. For some it is found useful to consume larger quantities or to consume the same quantity two or more times per day, or to, alternately, consume larger initial (sometimes called loading doses) doses then to gradually reduce dose size until a level is found that is not effective. The dose is then increased back to the lowest previously demonstrated effective dose.
Example 6
[0057] This example, among other things, demonstrates the superior performance of the product of this invention compared to the product of prior art. In this example cartilage that has been prepared according to U.S. Pat. No. 7,083.820, which is assumed to have been dried in the presence of potassium chloride, is purchased as UCII from Swanson. The fine ground cartilage is then soaked in club soda to remove the KCl and any other water soluble materials. The cartilage is then filtered, washed with club soda and re-suspended in club soda. The cartilage is found to be effective in ameliorating the symptoms of arthritis. This product, however, is slightly less effective than the product of the instant invention.
Example 7
[0058] This example, among other things, demonstrates the usefulness of alternatives to the salt of '820 to maintain the sterility during drying. This example produces a product that, is as effective or only slightly less effective than the major product of this invention. Example 4 is repeated except after treating with hydrogen peroxide, the cartilage is reduced in size and then dried at 110 F and then reduced in size in an impact type apparatus. Instead of using salts as in the '820 patent, a small amount of an antibacterial gas, chlorine in this case, is maintained in the recirculating air stream. In several steps, the amount of chlorine is increased until a level is found that prevents biological growth during drying in an equivalent manner to that of the salts of the '820 patent. In this case the warm air is cooled to condense and remove water then reheated before being returned to the drying chamber. A small make up supply of chlorine is added to replace that amount removed with the condensed water. The resulting dried, then fine ground product is suspended and stored in CO 2 containing water. After several months of storage the product is found to be as effective or nearly as effective in amelioration of the symptoms of arthritis as the non dried product and is found to produce a more uniform slurry and to settle more slowly.
Example 7a
[0059] This example, among other things, demonstrates other antibacterial gasses may be used in place of chlorine. Example 7 is repeated except chlorine is replaced with ethylene oxide as the antibacterial gas, with similar beneficial results. It is possible to operable with air as the drying medium and stay well below the explosive limit. To eliminate the possibility of accidentally exceeding the explosive limit, with tragic results, nitrogen is used with ethylene oxide in place of air for the first experiment. In a second experiment CO 2 replaces the nitrogen. As in example 7, the re-suspended, in aqueous CO 2 product, is found to be effective in ameliorating the symptoms of arthritis.
Example 7b
[0060] This example, among other things, demonstrates the usefulness of CO 2 as a gas during drying. Example 7 is repeated except drying takes place in a CO 2 atmosphere with an effective amount of chlorine gas added. A lower level of Cl2 is required than in example 7. As in Example 7 the product is found to be effective in ameliorating the effects of arthritis
Example 7c
[0061] This example, among other things, demonstrates the usefulness of ultraviolet light as an antibacterial agent during drying. Example 7b is repeated an effective amount of ultraviolet light is used as the antibacterial agent during drying.
Example 8
[0062] This example, among other things, demonstrates the ability to grind cartilage that has been slow frozen then ground at low temperature in the presence of dry ice or liquid nitrogen. Example 4 is repeated except the size reduction is carried out using slow frozen cartilage prepared as in example 15, in the presence of a small amount dry ice which is slowly added to an impact type apparatus. It is found that at the low temperature the cartilage is brittle enough to be easily ground. This procedure also allows temperature control which further allows more rapid grinding without over heating. When the preferred CO 2 is used, this procedure has the added advantage of intimately exposing the new cartilage surface to the beneficial effect of CO 2 . When suspended in aqueous CO 2 the product is found to produce a more stable slurry due to the finer particle size. The product is stored for over one year then found effective in ameliorating the effect of arthritis.
Example 9
[0063] Example 8 is repeated except the dry ice is replaced with a cooling quantity of liquid nitrogen. In some cases it is found desirable to add CO 2 or chlorine or another antibacterial gas to gain the antibacterial benefits during grinding.
Example 10a1
[0064] This example, among other things, demonstrates the ability to utilize relatively thin flexible plastic containers with good gas barrier properties to store the product of this invention. Example 4a1 is repeated except the container is changed. Instead of storing in a large rigid container, the cartilage in aqueous CO 2 is stored in a flexible plastic “pouch”. While any relatively non-permeable flexible plastic would do, we use a 4 mil vinyl chloride/vinylidene chloride copolymer, formerly sold under the trade name of SARAN. The container is filled in a CO 2 atmosphere then placed in a pressure chamber at about 20 psig of CO 2 pressure where it is heat sealed. . The product is stored for over one year at room temperature then found effective in ameliorating the effect of arthritis. Part of that time the container was stored in a vessel pressurized with about 5 psig of CO 2 .
Example 10a2
[0065] This example, among other things, demonstrates the usefulness of higher permeable flexible packages when stored in a CO 2 atmosphere. Example 10 is repeated except a more permeable plastic is used for the individual packages. In this case a lightly plasticized Polyvinyl chloride film is used. After filling the capsules are placed in a metal pressure vessel which is then filled with 20 psig of CO 2 for long term storage. It is found that after removal from the 20 psig atmosphere the individual packets retain their usefulness for many days at room temperature. This useful time is extended when the external CO 2 pressure is reduced by storing product under refrigeration. This process is most useful in cases requiring a large number of doses to be administered in a short period of time. This example uses a facility housing many equine mammals, horses in this case. Plastic vessels, particularly plasma coated, and other vessel types known in the art may be substituted for the metal pressure vessel.
Example 10b
[0066] This example, among other things, demonstrates ability to produce small single dose packages using the product of the instant invention. The technique of Example 10a1 is used to produce small single dose packages. These packages are stored for over one year then found effective in ameliorating the effect of arthritis. For part of this time the packages are stored in a pressure vessel with a CO 2 atmosphere.
Example 10c
[0067] This example, among other things, demonstrates the ability to produce many single dose packages on a single sheet.
[0068] The technique of Example 10b is used to produce single dose packages with multiple doses on a single sheet. In the pharmaceutical area these are often called “bubble packs”. In this case the single doses are separated by perforations that allow easy tearing for removal of a single dose or multiple single doses. It is desirable to have each removable segment imprinted with pertinent information such as the cartilage name, dose, time, and date.
Example 11
[0069] This example, among other things, demonstrates the ability to vacuum dry cartilage then grind. The cartilage is first slowly frozen, as in example 15. Example 4 is repeated except after treating with hydrogen peroxide, the cartilage is slowly frozen then vacuum freeze dried at a temperature slightly below 32 F until the moisture content is low enough to allow grinding ease. The freeze dried product is found th have a porous structure which surprisingly renders it much easier to grind. Depending on the grinding process there is an optimum level of moisture. In this case the moisture is below about 5%. The product is then ground and utilized as in Example 7. When the moisture content is varied upward and low temperature grinding used, it is found possible to produce a finely ground product that has no detectable loss in undenatured type II Collagen over a range of moisture contents. Depending on the communication process selected an optimum level will be found by those familiar with the grinding art. A higher moisture content is generally preferred where possible since it is more readily absorbed.
Example 12
[0070] This example, among other things, demonstrates the ability of water soluble thickening type agents to slow the separation of cartilage solids and, when added at lower levels, to stabilize suspensions. Example 4 is repeated except a water soluble thickening agent is added to the blend of CO 2 containing water and the cartilage. There are a wide variety of such useful thickening agents known to those skilled in the art. In this case methyl cellulose is used to provide a medium viscosity slurry. The suspension is seen to retain its uniformity over a wider period of time without the need to agitate as frequently, or to agitate at all. The thickened aqueous solution containing the cartilage and CO 2 is shown to retain its effectiveness in ameliorating the effects of arthritis in humans. When added at lower levels, the methyl cellulose thickening agent is seen to improve the stability of the suspension with only a neglectable or very small increase in viscosity. This suggests surface activity to cause particles in some way to repeal each other.
Example 12a
[0071] This example, among other things, demonstrates the ability to add water soluble polymers at higher levels to form non separating “slurries”. It is found that it is possible to thicken the material to about the consistency of tooth paste and package into single dose pouches as in Example 10b. These pouches are found to be particularly desirable and effective in dosing horses as in Example 3d. It is further found possible to place the tooth paste consistency material into tooth paste type containers and then to expel a dose at a time, then recap as in tooth taste use. As shown in previous examples various materials and storage conditions are useful.
Example 13
[0072] This example, among other things, demonstrates the use of a technique for dose metering from a larger reservoir of the product of our invention. There are many ways to meter a dose known to those familiar with metering techniques and devices. A particularly desirable technique is to use overflow devices on a volumetric unit that is built into a container for a large number of doses. Such a device is fabricated using polyethylene terephthalate. Cartilage prepared as in Example four is stored for several months in this container in the presence of CO 2 . The bottle is very gently agitated to promote uniformity before each use, then the sides are compressed to force a dose into the metering chamber when the compression is released the excess fluid overflows the metering chamber and returns to the reservoir in the body of the bottle. The bottle is refrigerated before the initial opening and the bottle is then stored under refrigeration both to conserve the CO 2 atmosphere, and to prevent expulsion of fluid from the bottom reaching metering tube. After consuming for about a month, an elderly man is found to have greatly reduced symptoms of osteoarthritis demonstrating the effectiveness of the undenatured cartilage stored and dispensed in this manner. As in earlier examples, escape of carbon dioxide can be prevented by storing the entire containers under a few psig of carbon dioxide.
Example 14
[0073] This example, among other things, demonstrates the surprising effect of storage temperature on useful storage life of the product of the instant invention. A series of slurry samples are prepared using the procedure of example 4a1. These samples are stored at a variety of temperatures for 12 months then tested for effectiveness. It is surprising to note that lower storage temperatures are not as useful as ambient temperatures in maintaining effectiveness for ameliorating the effect of arthritis. It is found that a temperatures of 60 to 90 degrees F. are most effective while temperatures of 55 to 95 are useful. Temperatures as low as about 35 degrees or above about 100 degrees are found to be undesirable while temperatures of 35 to about 55 degrees show less effectiveness. Normally lower storage temperatures would be expected to increase the retention of effectiveness of the undenatured cartilage. This surprising, and unexpected effect of reduced effectiveness of material stored at lower temperature is completely unexpected. This unexpected behavior is not understood but perhaps it relates to the reduced partial pressure of the CO 2 at the lower temperatures. The reduction of effectiveness above about 100 degrees is in line with expectations and these experiments simply help to define the limits of our invention.
Example 15
[0074] This example demonstrates that rapid freezing of untreated cartilage denatures a significant portion of the cartilage while slow freezing does not. As in example 3, a quantity of fresh sternum cartilage is obtained from a chicken processing facility. A sample is flash frozen in minutes with extremely low temperature air using a technique that is common to processing chicken. Another sample is slow frozen over a period of several days by placing it into a thick wall, foamed polystyrene container which is then placed into a freezer where the temperature is minus 10 degrees F. The fast frozen sample and the slow frozen sample are both subjected to a measure of the amount of undenatured cartilage remaining using the Enzyme-linked immunosorbent assay (ELISA) technique with a special adaptation that has been developed to detect undenatured type II collagen. Surprisingly the fast frozen sample shows significant loss of the undenatured cartilage while the slow frozen sample shows no significant reduction in undenatured cartilage. This totally unanticipated result allows freezing of the raw cartilage to be used to prepare the product of our invention. The cartilage can then be stored in larger batches with obvious processing advantages. These advantages become even more apparent as consumer demand for this product increases to require large scale manufacturing. One advantage is the ability to use freeze drying under a vacuum or low temperature grinding, where the cartilage becomes brittle. When an additional sample of cartilage is frozen over a period of several hours undenatured cartilage is again shown to be essentially unchanged. Further simple variations will define the shortest freezing times that do not cause cartilage to be denatured. These times will vary with the conditions such as temperature, size of the freezing batch, other heat transfer conditions, or for a continuous process. Persons or engineers familiar with the art of heat transfer will readily determine optimum conditions for a particular application. Perhaps the rapid expansion of water associated with rapid freezing breaks essential molecular bonds while slower freezing allows time for molecular structures to relax and reorient to avoid the breaks.
Example 16
[0075] This example, among other things, demonstrates the use of type II collagen contained in the vitreous humor of eyes to both ameliorate the effect of arthritis and to produce nearly transparent suspensions.
[0076] Fresh porcine eyes were acquired from a pig slaughter house. These eyes were less than 36 hours post mortem and had been stored at 5C.° in a saline solutions. They were obtained from 3-6 month old Chester Whites weighing from 50 to 100 kg. Vitreous humor was removed from the eye. After carefully removing a highly pigmented ring the remaining vitreous humor is placed into a blender with aqueous CO 2 where they are blended for 6 minutes then additional CO 2 added in the previously defined Kitchen carbonator. The product is found to have a degree of transparency. Transparency is a very desirable feature for market appeal. After several months storage, aqueous CO 2 product is used to treat arthritic dogs. After trials to determine an effective amount of the slurry, the product is found effective in ameliorating the effects of arthritis in these cannines.
Example 17
[0077] This example demonstrates a difference in the vitreous humor quality and quantity, depending on the mammal species.
[0078] Porcine eyes of example 16 are compared to bovine eyes.
[0000]
Initial
non soluble
vitrious
eye
solids wt %
solids wt %
humor
weight
Porcein Eyes
0.32
—
2.6 g
6.8 g
Bovine Eyes
1.3-1.7%
0.95%
14.7 g
26 g
[0079] It is seen that porcelain eyes are smaller and thus have much less vitreous humor than the cattle eyes. It is likewise seen that the solids content is much lower. Since it is the solids that contain the type II collagen, it is seen that the quality is higher in the bovine eyes. Bovine eyes are preferred for the practice of our invention.
Example 18
[0080] This example demonstrates the relative ease of reducing the particle size of the collagen contained in vitreous humor (VH). This is accomplished by first placing the vitrious humor from several cow eyes into the blender used in example 4a1. Chopping the VH, along with carbonated water, and Ice cubes in the blender, produces a uniform slurry of medium sized particles of VH which is then passed through a small diameter tube under high pressure which further reduces the particle size. By passing the slurry through successively smaller tubes under higher and higher pressure an extremely fine dispersion is produced. When a small amount of water soluble polymer is added, methyl cellulose in this case, stability of the suspension is increased. When the initial VH is dispersed in water it apparently matches the refractive index of the water and is invisible. When placed into carbonated water, however, the collagen II containing tissue slowly separates and becomes visible. Thus it is important to do the size reduction rapidly once introduced into the carbonated water.
Example 19
[0081] This example demonstrates a technique for removing the “strongly pigmented circle” from the vitreous humor. This is removed by hand only with great difficulty and with a significant loss of vitreous humor when done at ambient temperature. This is because of the elusive nature of the “circle” that makes it difficult to capture and remove. This nature also makes it more difficult to maintain microbe free conditionsl.
[0082] It is found that the pigment removal operation is easy to perform on either frozen eyeballs or on the removed and frozen vitreous humor. Five cow eyeballs are frozen slowly so as to not denature the collagen. They are then dissected free of surrounding tissue while still frozen. When this tissue is removed the pigment circle is visible and more easily removed.
[0083] The cleaned vitreous humor is stored frozen until further processing is desired, then it is thawed and processed as in example 18. It is found desirable, during thawing, to expose the vitreous humor to NaOCl and H 2 O 2 in the manner of Example 2 to improve sterility.
CONCLUSION
[0084] While the instant invention has been described above according to its preferred embodiments, it can be modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the instant invention using the general principles disclosed herein. Further, the instant application is intended to cover such departures from the present disclosure as come within the known or customary practice in the art to which this invention pertains.
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The instant invention is the storage of Type II collagen containing tissue in carbonated water. Such Type II collagen is useful for alleviating the symptoms of arthritis in mammals as well as the treatment of arthritis in mammals. Such Type II collagen is also useful for the prevention of arthritis in mammals. The instant invention is also a method for the preparation of a nutritional supplement that includes the steps of: (a) separating water-insoluble undenatured Type II collagen containing animal tissue from animal tissue not containing Type II collagen; (b) subdividing and sterilizing said tissue under conditions which do not change the original structure of the Type II collagen to produce a subdivided and sterilized product; (c) packaging the subdivided and sterilized product in carbonated water.
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FIELD OF THE INVENTION
[0001] The present invention relates generally to the field of heat exchangers, and more particularly to finned concentric tubular member heat exchangers.
BACKGROUND OF THE INVENTION
[0002] The prior art relates to heat exchangers formed by finned concentric thin walled tubular members defining an intermediate inner annular fluid flow channel therebetween containing a corrugated, helical spirally formed turbulizer strip initially pre-assembled in a prestressed coiled condition and inserted longitudinally into the intermediate inner annular fluid flow channel formed between the two concentric thin walled tubular members.
[0003] While concentric tubular thin walled heat exchanger assemblies are well known in the field and generally provide efficient and effective heat exchange between the fluid flow channel through the center of the concentric inner tubular member and that of a secondary fluid flow confined in the intermediate inner annular fluid flow channel between the paired tubular members, or between a fluid confined between the two paired tubular members and a fluid flow external to the outer tubular member, it has been determined that the heat transfer can be enhanced by improving the heat exchanger flow characteristics within the intermediate inner annular fluid flow channel by providing therein a helical spirally formed, corrugated turbulizer strip anchored to the second inner concentric thin walled tubular member to vary inner fluid flow conductance.
[0004] This turbulizer structure is pre-fabricated during heat exchanger assembly by first applying a predetermined compressive force to the helical, spirally formed turbulizer corrugated strip member so that the turbulizer member is compressed prior to insertion, and then inserted into the fixed confinement within the intermediate inner annular fluid flow channel under the initial pre-stressed compressive force. The turbulizer peaks and valleys then expand to improve contact with the surrounding circumferential surfaces to enhance the efficiency of the heat exchanger. Improvements of the concentric tubular design of pre-existing heat exchangers is desired, as shown in the herein disclosed, invention, to achieve improved heat transfer and heat exchanger versatility.
SUMMARY
[0005] An improved finned tubular heat exchanger assembly comprises an externally finned subassembly in combination with concentrically spaced-apart, thin walled tubular member subassemblies having therebetween an intermediate inner annular fluid flow channel containing an inner turbulizer subassembly. The first outer concentric thin wall tubular member subassembly has a larger inside circumference than the second inner concentric thin walled tubular member subassembly with a smaller outer circumference. The intermediate inner annular fluid flow channel, formed between the heat exchanger first and second concentric thin walled tubular members, defines the sidewalls of the intermediate inner annular fluid flow channel which is coincident with portions of the internal circumferential flow area of the first outer concentric thin walled tubular member subassembly.
[0006] The finned tubular heat exchanger assembly has contained therewithin, along its internal longitudinal axis, at least one intermediate inner annular fluid flow channel. A helical, spiral uniformly wound, corrugated turbulizer strip is concentrically secured within the intermediate inner annular fluid flow channel and is positioned in the form of a helical space-gapped spiral that is longitudinally fixed axially and radially to the second concentric thin walled tubular member that defines the smaller circumferential internal sidewall of the intermediate inner annular fluid flow channel to thermally enhance heat transfer by interconnecting together both the inner circumferential area surface of the outer concentric thin walled tubular member and the outer circumferential area of the smaller second inner concentric thin walled tubular member subassembly.
[0007] In addition to imparting good thermal conduction contact with the second concentric thin walled tubular member surface, the turbulizer strip subassembly is structurally designed and positioned to vary the internal cross-sectional flow area of the second concentric thin walled tubular subassembly member and provides additional control of inner concentric tubular fluid flow through the heat exchanger.
[0008] The spiral turbulizer strip subassembly has corrugations with triangular cross-sectional areas and is constructed from a heat conductive material formed in a predetermined configuration to produce turbulization mixing of the fluid flow passing along and through the longitudinal triangular corrugations of the turbulizer strip subassembly. Fluid flow is confined in the heat exchanger between the intermediate inner annular fluid flow channel sidewalls to generate desired fluid turbulization as the fluid flows through the intermediate inner annular fluid flow channel formed between the inner circumferential surface of the first outer concentric thin walled tubular member and the outer circumferential surface of the second inner concentric thin walled tubular member, and also along the surfaces of the helical spiraled corrugated turbulizer strip, thereby enhancing fluid heat transfer and increasing thermal efficiency of the heat exchanger.
[0009] The turbulizer strip corrugated cross-section triangular shaped longitudinal channels are smooth surfaced to reduce resistance to flow through the channels, and the fluid flow entering each corrugation passageway entrance is directed to and across the turbulizer spiral bridge space-gap to cause the downstream flow exiting from each proceeding corrugation flow channel to cross-mix and impinge upon and enter opposing passageway edges after exiting each succeeding corrugation, then promoting cross mixing across the turbulizer spiral gap before entering each succeeding series of downstream longitudinal corrugations.
[0010] The corrugated turbulizer strip of the present invention extends spirally within the intermediate inner annular fluid flow channel, the corrugations having ridge peaked apexes and valley bottom bases, defining flattened tubular contact areas adjacent to the intermediate inner annular fluid flow channel side wall lines of contact between the corrugation sidewalls and the peripheries of the first outer concentric thin walled tubular member inner circumference and the second concentric thin walled tubular member outer circumference that collectively define sidewall boundaries of the intermediate inner annular fluid flow channel.
[0011] The corrugated strip turbulizer directs the fluid flow leaving a first preceding triangular corrugation to axially flow across the spiral bridge space-gap formed between succeeding subsequent triangular longitudinal corrugations, promoting cross-mixing of fluid flow streams exiting preceding spiral corrugation passageways and then crossing the bridge space-gap separation areas between each of the succeeding spiral corrugated turbulizer flow passageways.
[0012] The fluid flow conductance through the heat exchanger is varied by preselecting the desired second inner concentric tubular member cross-sectional area to produce the desired dynamic flow characteristics required for satisfying the heat transfer requirements of a specific fluid heat source. By varying the internal cross-sectional area of the second inner concentric thin walled tubular subassembly, such as by the turbulizer anchor end, crimping, or by other means reducing the internal diameter of the second concentric thin walled tubular member. Thus resistance to fluid flow resulting from cross-sectional flow area restriction is varied by the turbulizer anchor connection configuration.
[0013] The finned tubular heat exchanger is thus fabricated by concentrically spacing apart two concentric tubular members to define an intermediate inner annular fluid flow channel chamber to place therewithin a turbulizer strip of corrugated sheet metal to extend longitudinally and spirally within the intermediate inner annular fluid flow channel. Adjacent spiral turns of the corrugated spirally formed strip are bridge gap-spaced apart from each other to provide a parallel series of individual longitudinal triangular passageways to define the triangular cross-section channel discharge exits discharging fluid flow between the side edges of each series of adjacent corrugated spiral turn produced parallel passageways. When fluid discharge from each preceding triangular corrugation channel discharges fluid flow across the corrugation spiral turbulizer bridge space-gap, that fluid flow is also directed into the triangular entrance passageways so that the fluid flow enters each succeeding turbulizer corrugated passageway and promotes efficient heat transfer.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] The preferred exemplary embodiment of the invention will hereinafter be described in conjunction with the appended drawings.
[0015] FIG. 1 is an axial cross-sectional view of one embodiment of the present invention.
[0016] FIG. 2 is a cross-sectional end view of a portion of the embodiment of FIG. 1 .
[0017] FIG. 3 is a plan view of a corrugated turbulizer subassembly member after corrugation.
[0018] FIG. 4 is a cross-sectional end view of the turbulizer subassembly member along line 4 - 4 of FIG. 3 .
[0019] FIG. 5 is a cross-sectional side view of a portion of the turbulizer member after insertion.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0020] Referring to FIGS. 1, 2 , 4 , and 5 of the drawings, there is shown an improved finned concentric thin walled tubular member heat exchanger assembly 10 comprised of an external finned subassembly, a first outer concentric thin walled tubular subassembly member 20 having a first larger inside circumference 25 , a second inner concentric thin walled tubular subassembly member 40 having a second smaller outside circumference 45 , and having formed therebetween the two tubular members a longitudinal intermediate inner annular flow channel axial region 60 , within which is positioned an internal turbulizer subassembly member 70 being formed as a corrugated strip with triangular cross-sectional area passageways 72 that extend spiral axially within the intermediate inner annular flow channel axial region member 60 between the first outer concentric thin walled tubular subassembly member 20 having a larger inside circumference 25 and the second inner concentric thin walled tubular subassembly member 40 having the smaller outside diameter 45 . The first outer concentric thin walled tubular subassembly member 20 has externally attached thereto a plurality of longitudinally spaced transverse exterior rippled fins 102 forming an external rectangular fin subassembly 100 that radiate or absorb heat from surrounding areas to provide efficient heat transfer to the heat exchanger fluid flowing through the axial intermediate inner annular flow channel axial region 60 defined between the first outer concentric thin walled tubular subassembly member 20 and the second inner concentric thin walled tubular subassembly member 40 .
[0021] As shown in FIGS. 4 and 5 , the internal turbulizer subassembly member 70 is preformed prior to placement in the longitudinal intermediate inner annular flow channel axial region 60 by pressing it onto the second inner concentric thin walled tubular subassembly member 40 , or otherwise compressed for helical insertion between the first outer concentric thin walled tubular subassembly member 20 and second inner concentric thin walled tubular subassembly member 40 , within the intermediate inner annular flow channel axial region member 60 .
[0022] In one method of fabrication, the second inner concentric thin walled tubular subassembly member 40 having a smaller outside circumference 45 may be expanded slightly so as to compress the turbulizer assembly corrugations between the outer periphery of the second inner concentric thin walled tubular subassembly member 40 having a smaller outside circumference 45 and the inner periphery of the first outer concentric thin walled tubular subassembly member 20 having a larger inside circumference 25 . Mechanical anchor locking of the internal turbulizer subassembly member 70 positionally between the first outer concentric thin walled tubular subassembly member 20 having a larger inside circumference 25 and the second inner concentric thin walled tubular subassembly member 40 having a smaller outside circumference 45 is achieved by mechanically forcing a mandrel of slightly larger circumference than the external circumference of the second inner concentric thin walled tubular subassembly member 40 having a smaller outside circumference 45 through the center of the internal turbulizer subassembly member 70 to expand the turbulizer slightly, and thus mechanically force the corrugated peak apex ridges 92 and the corrugated valley base bottoms 94 of the individual corrugated strip triangular cross section peak apex ridges 92 and valley base bottoms 94 to compress into prestressed contact with the respective peripheries of the first outer concentric thin walled tubular subassembly member 20 , and the second inner concentric thin walled tubular subassembly member 40 . This compressive force is sufficient to assure metal-to-metal contact for effective heat transfer contact between the first outer concentric thin walled tubular subassembly member 20 , and the second inner concentric thin walled tubular subassembly member 40 , and the internal turbulizer subassembly member 70 . The internal turbulizer subassembly member 70 interconnects the first outer concentric thin walled tubular subassembly member 20 , and the second inner concentric thin walled tubular subassembly member 40 to produce a longitudinal fluid flow path adjacent to the second inner concentric thin walled tubular subassembly member 40 having a smaller outside circumference 45 , and the opposing adjacent first outer concentric thin walled tubular subassembly member 20 . Furthermore, in spiral winding the internal turbulizer subassembly member 70 into a helical configuration around the second inner concentric thin walled tubular subassembly member 40 having a smaller outside circumference 45 , in accordance with U.S. Pat. No. 3,197,975 an open spiral gap space 78 , is formed providing a series of gapped non-turbulizer sections in the second inner concentric thin walled tubular subassembly member 40 , formed between adjacent helical turns of the helical spiraled turbulizer subassembly. There is thus defined an open-gapped helical spiral internal fluid flow turbulizer longitudinal passageways 72 , as shown in FIG. 2 , into which each longitudinal passageway series has a periodically open spiral gap space 78 . The longitudinal passageways are thus interrupted by the spiral gap space 78 periodically by the spiral passageway 76 -bridge spiral gap space 78 . These minimize spiral gap space 78 resistance to fluid flow through intermediate inner annular flow channel axial region member 60 and provides for the efficient transfer of heat to and from the fluid passing through the intermediate inner annular flow channel axial region member 60 , as confined by the respective sidewalls of the first outer concentric thin walled tubular subassembly member 20 , and second inner concentric thin walled tubular subassembly member 40
[0023] It has been determined that the fluid flow within the intermediate inner annular flow channel axial region member 60 forms a non-circulating skin film of fluid on the turbulizer surfaces at the edges of the internal turbulizer subassembly member 70 that becomes progressively thicker extending towards maximum circulation at the circumference edge of the gapped spiral turbulizer member, and this condition acts as a heat insulator causing resistance to heat transfer and reducing the efficiency of the heat exchanger system. An advantage of the helical internal fin heat exchanger of U.S. Pat. No. 3,197,975 is that the longitudinal dimensions of each of the individual passageway surfaces of the corrugated turbulizer strip subassembly members prevent the formation of a non-circulating fluid flow film sufficient to interfere materially with the proper transfer of heat between portions of the fluid flow traversing longitudinal intermediate inner annular flow channel axial region member 60 . A more effective heat exchange process occurs by reducing surface area portions of the exterior metallic fin strips by prestress fabricating the internal turbulizer subassembly member 70 , and then inserting it into the intermediate inner annular flow channel axial region member 60 improve the heat exchange properties of the first outer concentric thin walled tubular subassembly member 20 , and second inner concentric thin walled tubular subassembly member 40 employing the internal turbulizer subassembly member 70 .
[0024] In accordance with the present invention the heat exchange fluid causes flow cross mixing by the triangular corrugation longitudinal channel passageways. As mentioned previously, the heat exchanger, width, length, thickness, and the space-gaps between the edges of the helical strip that define the spiral or helical flow path for the fluid flow confined between the first outer concentric thin walled tubular subassembly member 20 and second inner concentric thin walled tubular subassembly member 40 , passes across the spiral gap space 78 in the turbulizer longitudinal passageways 72 defined by the corrugated strip triangular cross section 74 can, by design, substantially vary the effect of the tubulizer anchored end connection 79 of the second inner concentric thin walled tubular subassembly member 40 by varying the quantity of fluid flow passing through the second inner concentric thin walled tubular subassembly member 40 .
[0025] A finned tubular heat exchanger assembly member 10 can thus be constructed by the selective fabrication of the first outer concentric thin walled tubular subassembly member 20 , and second inner concentric thin walled tubular subassembly member 40 . When the first outer concentric thin walled tubular subassembly member 20 , and second inner concentric thin walled tubular subassembly member 40 are assembled together, the second inner concentric thin walled tubular subassembly member 40 is longitudinally positionally centrally within the first outer concentric thin walled tubular subassembly member 20 , whereby the first outer concentric thin walled tubular subassembly member 20 , and said second inner concentric thin walled tubular subassembly member 40 concentrically define the outer surface circumference and inner and outer circumference of the intermediate inner annular flow channel axial region member 60 .
[0026] An internal turbulizer subassembly member 70 is embossed in a manner to provide a lateral triangular cross-sectional area to be inserted within the intermediate inner annular flow channel axial region member 60 to produce therein turbulizer longitudinal passageways 72 . The thus formed internal turbulizer subassembly member 70 is then end anchored to the second inner concentric thin walled tubular subassembly member 40 to anchor the internal turbulizer subassembly member 70 . The internal turbulizer subassembly member 70 is fabricated around the second inner concentric thin walled tubular subassembly member 40 initially with a predetermined compressive force to first contract, and then after insertion, expand to maximize surface contact with the first outer concentric thin walled tubular subassembly member 20 , and said second inner concentric thin walled tubular subassembly member 40 . The internal turbulizer subassembly member 70 , when end anchored to the second inner concentric thin walled tubular subassembly member 40 , produces a turbulizer end anchor connection 80 configuration designed to vary the cross-sectional flow area of the internal circumference of the second inner concentric thin walled tubular subassembly member 40 and the intermediate inner annular flow channel axial region member 60 .
[0027] An anchor end connection slot 82 is machined in the second inner concentric thin walled tubular subassembly member 40 to connect with the anchor end connection tail structure 84 .
[0028] The anchor end connection tail structure 84 protruding through the thin side walled of the second inner concentric thin walled tubular subassembly member 40 having a smaller outside circumference 45 . This turbulizer anchor end connection 79 may limit fluid flow conductance through the second tubular subassembly inner flow channel 27 , thereby by its design providing fluid flow control of the finned tubular heat exchanger assembly 10 .
[0029] One embodiment of the finned tubular heat exchanger assembly member 10 has an internal turbulizer subassembly member 70 positioned in the intermediate inner annular flow channel axial region member 60 , and is constructed with a uniform sided, truncated triangular cross-sectional area having a rounded apex cross-section.
[0030] The heat exchanger has a helically formed turbulizer that is uniform and sequentially gap interrupted passageway and external fins are formed radially with surface, semi-circular uniform corrugations to improve heat transfer by increasing the external surface area.
[0031] The finned heat exchanger assembly in operation combines four walled members comprising a finned exterior, planner member, two concentric tubular members, and a triangular passageway member. The first concentric tubular walled member having a first inner circumference; and a second concentric tubular walled member having a smaller outer circumference than the inner circumference of the first concentric tubular walled member when assembled together, the first concentric tubular walled member is longitudinally centralized positionally within the first concentric tubular walled member to conduct fluid flow through both tubular members. The first concentric tubular walled member and the second concentric tubular walled members concentrically define the outer circumference and inner circumference of an intermediate inner annular fluid flow channel that contains a helically formed, spirally wound turbulizer strip constructed with a lateral triangular cross-sectional configuration surface and is adapted to be inserted into the inner annular fluid flow channel to form therein the longitudinal triangular flow passageway
[0032] By anchor fastening the helical formed turbulizer strip, member end connection to the second concentric tubular walled member turbulizer strip member is to positionally stabilize, and the fluid conducting through and around the tubular subassembly may be varied to contain fluid flow, and thereby heat exchanger, heat transfer characteristics.
[0033] The four fluid flow conductance paths, including the fluid flow comprising the heat exchanger extends the two concentric tubular fluid, the tubular passageway comprises in combination to provide a versatile heat exchange wherein the heat exchange requirements of a system can be satisfied by the proper pre selected design choice of fluid flow paths and media choice. The surface design of the exterior fins may be corrugated to increase surface area, the tubular member wall there has, internal and external diameters may be varied, the intermediates inner annular fluid flow channel may be varied, and the tubular subassembly may be varied to produce the desired heat exchanger heat transfer results.
[0034] While we have shown and described particular embodiments of our invention, it will be obvious to those skilled in the art that various changes and modifications may be made without departing from our invention in its broader aspects; and we, therefore, intend herein to cover all such changes and modifications as fall within the true spirit and scope of our invention.
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An apparatus and method for fabricating an externally finned tubular heat exchanger assembly comprising two concentric thin walled tubular members defining therebetween an intermediate inner annular fluid flow channel, and positionally fixed therewithin an internal turbulizer strip extending longitudinally in a helical spiral. The tubulizer strip is embossed with corrugations prior to installation into the intermediate inner annular fluid flow channel. The corrugated strip is helically spiraled with sequential bridge gap spaces between adjacent serial turns wherein the corrugations form a series of triangular cross-sectional fluid flow passageways. Turbulizer corrugation expansion, after insertion into the inner intermediate annular fluid flow channel, mechanically anchors the corrugated turbulizer strip to the second inner concentric tubular member that has an end groove to provide engagement connection. The turbulizer is utilized to vary conductance and thus control fluid flow through the tubular inner channel of the second concentric tubular member. External fins are attached to the exterior circumferential surface of the first outer concentric tubular subassembly member to further enhance heat exchange.
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FIELD OF THE INVENTION
[0001] The present invention relates broadly to a lubricant supply tube for attachment to a drive shaft of a sealed reciprocating compressor and to a sealed reciprocating compressor.
BACKGROUND
[0002] Sealed motor-driven compressors are used in many applications, and particularly in refrigeration and air conditioning systems. Such compressors are usually of the piston type and compress the gaseous refrigerant into liquid phase. Such sealed motor-compressors include a sump at the bottom of the sealed casing containing a liquid lubricant such as oil. Frequently, lubricant supply tubes are used in which one end of the tube extends downwardly into the sump at an angle with respect to the axis of rotation. The other end extends vertically upward toward the motor shaft to which it is connected. The motor shaft rotates the lubricant supply tube such that the liquid lubricant is forced upwardly in the tube by centrifugal force so as to be supplied to various moving components of the compressor.
[0003] FIG. 1 illustrates a typical prior art supply tube which is more fully disclosed in detail in U.S. Pat. No. 5,088,579. Briefly, tube 1 , which is also referred to as an oil pickup tube, is rotated by a motor shaft 4 such that the oil flows upwardly through oil passage 6 which extends through knob 7 , crank shaft 5 and into shaft 4 . As clearly shown, the plane X defined by the inlet opening 2 of tube 1 is perpendicular to the longitudinal axis Y of the angled portion of the tube.
[0004] In this design, the tube 1 is formed by folding a metal sheet into a cylindrical shape with a gap or fissure extending along the length of the tube where the folded portions meet. A vane portion extends across the fissure at about a mid point along the length of the tube, for structural integrity of the folded tube. While noise reduction may be achieved with such a design due to improve of gas release through the fissure, this design suffers from the higher cost of manufacturing the folded tube including the vane portion.
[0005] A similar form of oil supply tube is disclosed in U.S. Pat. No. 3,858,685. In this design, the tube is also connected to the crankshaft, and extends downwardly therefrom at an angle with respect to the vertical axis of the motor shaft such that the inlet end of the tube is immersed in the liquid lubricant. The tube again includes a longitudinal fissure, a lower portion having a transversal section with a spinal shape, and the same portion includes a paddle extending radially outward of the tube for forming bubbles in the lubricant. However, again this design suffers from the higher cost of manufacturing the relatively complex design of the tube.
[0006] As disclosed in U.S. Pat. No. 5,842,420, it has also been proposed to reduce the noise level of the compressor by providing an angled passage or duct within the crankshaft so as to draw the oil from the sump upwardly by centrifugal force. The lower end of the crankshaft is cut at an angle with respect to the rotational axis of the crankshaft in order to increase the inlet area of the duct, and thereby increase the oil pumping capacity of the duct, and this is said to also reduce the noise level. Integration of the oil pick up into the crankshaft represents a different design solution compared to designs using a separate tube for attachment to the crankshaft for drawing the oil from the sump. However, such integration can reduce the design flexibility as changes in the design require re-design of the entire crankshaft.
[0007] While such prior art designs have been relatively effective in lubricating the compressor components which are adjacent to the outlet ports of lubricant passages, they have not been effective in reaching some of the compressor components, such as will be more fully described hereafter.
SUMMARY
[0008] In accordance with a first aspect of the present invention there is provided a lubricant supply tube for attachment to a drive shaft of a sealed reciprocating compressor comprising an elongated first portion adapted for extending downwardly from the drive shaft and inclined with respect to a rotational axis of the drive shaft for immersion into a lubricant in a lubricant sump of the compressor, and terminating in a substantially elliptical inlet orifice defining a first plane; and wherein the first plane is inclined with respect to a second plane extending perpendicular to a longitudinal axis of the elongated first portion.
[0009] An angle between the first and second planes may be in the order of about 15 to 50 degrees.
[0010] An angle between the first and second planes may be in the order of about 30 to 45 degrees.
[0011] The supply tube may include an elongated second portion inclined with respect to the first portion, and in use, the second portion is adapted for connection to the drive shaft.
[0012] The elongated second portion may be adapted for connection to an eccentric portion of the drive shaft, and such that the inlet orifice rotates substantially on the rotational axis of the drive shaft.
[0013] The elongated second portion may be provided with at least one degassing port on a side closer to the rotational axis of the drive shaft.
[0014] The second portion may be adapted for an interference fit with a corresponding lubricant supply passage formed in the drive shaft.
[0015] The second portion may be inclined with respect to the first portion, and in use, the second portion is adapted for connection to the drive shaft in a direction parallel to but offset from the rotational axis of the drive shaft.
[0016] The lubricant supply tube may be adapted such that lubricant is provided to parts of the compressor due to splashing of the lubricant caused by rotation of the lubricant supply tube in the lubricant sump.
[0017] In accordance with a second aspect of the present invention there is provided a sealed reciprocating compressor comprising a lubricant supply tube as defined in the first aspect.
[0018] The compressor may be an induction compressor.
[0019] The compressor may be an inverter compressor.
BRIEF DESCRIPTION OF DRAWINGS
[0020] Embodiments of the invention will be better understood and readily apparent to one of ordinary skill in the art from the following written description, by way of example only, and in conjunction with the drawings, in which:
[0021] FIG. 1 is an illustration of an oil supply tube of the prior art;
[0022] FIG. 2 is a cross-sectional view of a sealed motor-compressor unit incorporating the lubricant supply tube according to one embodiment of the invention;
[0023] FIG. 3 shows a detail of FIG. 2 ;
[0024] FIG. 4 shows another detail of FIG. 2 ; and
[0025] FIG. 5 is a Table showing one example of the reduction of the compressor noise level achieved by the present invention.
DETAILED DESCRIPTION
[0026] Referring to FIGS. 2 and 3 , a motor-driven piston type compressor is illustrated, and it will be readily understood by those skilled in this art that such units include a sealed casing 10 enclosing a motor 12 . A cylinder block 37 including the cylinder 20 and a bearing 39 for supporting the drive shaft 18 is provided. Motor 12 includes a stator 14 , a rotor 16 , and the output drive., shaft 18 , configured as an induction compressor supplied with typically either a 50 Hz or 60 Hz power supply.
[0027] As also shown in FIG. 2 , and in more detail in FIG. 3 , shaft 18 comprises an off-set or eccentric portion 24 , which in turn, drives connecting rod 26 and piston 28 within cylinder 20 . Connecting rod 26 is connected to piston 28 by a bearing in the form of a piston pin 32 , which is hollow and secured to the piston 28 by way of a locking pin 25 in this example embodiment. The legs of a U-shaped washer 34 extend between the interior wall of the piston 28 and the outer side surface of rod 26 .
[0028] As shown in more detail in FIG. 4 , a lubricant supply tube 40 is connected by a vertical straight portion 40 b to the lower end of the eccentric portion 24 of the shaft 18 so as to rotate with the tip 42 at the open end of an inclined portion 40 a of the tube 40 substantially on the rotational axis 44 of shaft 18 . In this example embodiment, the straight portion 40 b is attached to the eccentric portion 24 by an interference fit into a corresponding oil supply passage 41 internal to the eccentric portion 24 , and extending into the shaft 18 .
[0029] The inclined portion 40 a of the tube 40 extends at an angle, B, with respect to the axis 44 such that a lubricant such as oil from the sump is drawn upwardly within the tube 40 as illustrated in FIG. 4 . Preferably the angle, B, of inclination of portion 40 a is in the order of about 140 degrees to 170 degrees with respect to the axis 44 , and the vertical straight portion 40 b includes at least one degassing port 43 , on a side closer to the rotational axis 44 of shaft 18 .
[0030] A lubricant outlet port 35 is formed in a recess or groove 45 on the eccentric portion 24 , allowing provision of lubricant via the internal passage 38 formed in the connecting rod 26 and to the piston 28 and piston pin 32 (see FIGS. 2 , 3 ). Another lubricant outlet port 47 is formed at the bottom of the drive shaft 18 and in fluid communication with a helical lubricant passage 49 formed on the surface of the drive shaft 18 . The passage 49 terminates above an upper end of the bearing 39 for lubrication during operation of the compressor.
[0031] In the example embodiment, parts of the compressor such as U-washer 34 and the sliding surfaces of the piston 28 and connecting rod 26 (see FIGS. 2 , 3 ) are advantageously additionally lubricated by the splashing created by the rapid rotation of the inclined portion 40 a of the tube 40 .
[0032] Referring more specifically to FIG. 4 , and contrary to the prior art oil supply tubes shown in FIG. 1 , the plane “X” defined by the inlet orifice 42 of the tube 40 extends at an angle, A, with respect to a plane “Y” which extends perpendicular to the longitudinal axis 48 of portion 40 a of the tube 40 . Because of terminating the tube 40 with the inlet orifice 42 at an angle A, it has been found that the noise level of the compressor can be substantially reduced. For example, as shown in Table 1 of FIG. 5 , at both 50 Hz & 60 Hz power supply the-decibel levels can be substantially reduced, and a maximum reduction can be achieved with angle A being in the range of about 30 to 45 degrees, measured at the high frequency band.
[0033] It has been recognized by the inventors that by selecting the angle A in a range from about 15 to 50 degrees and preferably from about 30 to 45 degrees, the height of the vortex 51 can be increased to an extent sufficient for causing splashing of lubricant to adjacent components, including the U-washer 34 and the sliding surfaces of the piston 28 and connecting rod 26 (see FIGS. 2 , 3 ). It has further been recognized by the inventors that this additional lubrication facilitates noise reduction in the operation of the compressor. This noise reduction is in addition to noise reduction facilitated by foaming of the oil in the sump 36 (see FIG. 2 ) as a result of the rotation of the tube 40 , which improves the sound insulating properties of the oil.
[0034] The tube 40 in an example embodiment is made from carbon steel, and advantageously fabricated by tube forming. However, it will be appreciated that the tube can be fabricated from other suitable materials and using different fabrication techniques, in different embodiments.
[0035] From the foregoing description of one embodiment of the present invention, it will be apparent that the foregoing objects are achieved regarding both improved lubrication and noise reduction of compressors which are lubricated by the use of lubricant supply tubes drawing lubricant from sumps. It will also be understood that the foregoing description of one embodiment is purely illustrative of the principles of the invention, rather than exhaustive thereof, and that numerous variations of the illustrated embodiment will become apparent to those skilled in the art of compressors.
[0036] For example, it will be appreciated that the present invention can be equally applied to inverter compressors in which the speed of the motor can be controlled using signals from a control box, as is understood in the art.
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A lubricant supply tube for attachment to a drive shaft of a sealed reciprocating compressor comprising an elongated first portion adapted for extending downwardly from the drive shaft and inclined with respect to a rotational axis of the drive shaft for immersion into a lubricant in a lubricant sump of the compressor, and terminating in a substantially elliptical inlet orifice defining a first plane; and wherein the first plane is inclined with respect to a second plane extending perpendicular to a longitudinal axis of the elongated first portion.
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CROSS REFERENCES TO CO-PENDING APPLICATIONS
This application is related to Application Ser. No. 07/088,428, filed Aug. 24, 1987, "Laminated Zone of Focus Artificial Lens"; Application Ser. No. 07/088,413, filed Aug. 24, 1987, "Cylindrically Segmented Zone of Focus Artificial Lens"; and Application Ser. No. 07/088,249, filed Aug. 24, 1987, "Radially Segmented Zone of Focus Artificial Lens".
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention pertains to an implantable intraocular lens, and more particularly, pertains to a lens containing multiple lens elements.
This invention relates to lenses which have areas which serve to bring impinging rays to a focus in specific areas of the focal plane. Such lenses are called zone of focus lenses and are particularly useful for implantation into the eye as a substitute for the natural lens since, in combination with the brain, they effectively replicate the ability of the natural lens to bring objects at varying distances to a sharp focus.
The invention relates specifically to a zone of focus lens in which the lens is made up of discrete lens elements distributed over the surface of the lens. Each element serves to bring the impinging rays from an object at a predetermined distance to a focus on a particular region of the retina. By selecting various powers for the elements, it is possible to have an object at a given distance brought to an acceptable focus by at least one of such elements. In this manner, an in-focus image (sharp image) is created on a particular portion of the retina serviced by that element. It has been found that the processing of the image by the brain results in the selective consideration of the sharpest image and the virtual discard of the other out-of-focus images created by other elements.
2. Description of the Prior Art
Limited attempts have been made to produce a lens having areas of varying powers. There have been many attempts to produce implantable lenses which serve for both close and far seeing, similar to the bifocal spectacles. In general, such lenses have been produced with two regions having different powers. The light which impinges on the retina passes through one region to the exclusion of the other. In such a system, only one region of the lens is used at a time, and there is no accommodation by the brain to reject an out-of-focus image. Great care and accuracy must be used in the preoperative measurements since both the near and far powers must be accurately determined. Since the near and far powers are not specifically interrelated, the inventory requirements are compounded since a variety of near powers must be available for every far power.
SUMMARY OF THE INVENTION
The lens is a composite of individual lens elements, each of which has a distinct power and focal length. Each element brings the impinging rays to bear on a predetermined portion of the retina, which may be either unique to that element or shared with other elements of like power. The elements are selected to have a sufficient range of powers to accommodate the projected use. That is, the value of the power and the number of elements will be determined by the projected use. Most uses can be accommodated with a lens having two or three powers to accommodate objects at near, far and intermediate distances. These powers can be distributed among a like number of elements or a number of elements which is two, three or even more times the number of powers. The distribution of powers among the elements need not be done equally. For example, if most of the sight is required at close distances, the number of elements for this distance can be increased and the number of elements for far vision correspondingly decreased.
Accommodation of the brain to such an arrangement may be enhanced by adding a distinctive color to the elements of like power. This approach may be utilized where loss or impairment of color vision is of little consequence.
Elements of differing powers can be provided by molding, grinding, lathe cutting or otherwise forming individual lens elements from materials having different indices of refraction and mounting them in an assembly to form a unitary lens structure.
In the alternative, the individual lens elements can be fabricated of like material and the differing powers obtained by grinding, molding or otherwise shaping the surface of the individual lens elements to provide individual curvatures.
Lens is a generic term for intraocular lens, intracorneal lens, or contact lens.
It is a principal object hereof to provide a lens incorporating a multiple element zone of focus.
It is therefore an object of this invention to provide a zone of focus lens which will make the replacement of a defective natural lens available to many who cannot now afford the operation.
It is another object of the invention to provide a zone of focus lens which does not require either an extensive inventory of various powers and combination of powers or extensive preoperative measurement prior to implantation into the eye as a replacement for a defective lens.
Still another object of this invention is to provide an approach to the replacement of a defective lens by providing a very nearly universal lens which provides vision adequate to allow a normal life style.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects of the present invention and many of the attendant advantages of the present invention will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, in which like reference numerals designate like parts throughout the figures thereof and wherein:
FIG. 1 illustrates a plan view of a multiple element zone of focus lens according to the invention;
FIG. 2 illustrates a cross-section of the multiple element zone of focus lens taken along line 2--2 of FIG. 1;
FIGS. 3A and 3B illustrates a schematic isometric view of an optical system in which the zone of focus lens develops images for each like lens element;
FIG. 4 illustrates a cross-sectional view of an embodiment in which the lens elements of the segmented zone of focus lens are round taken along line 4--4 of FIG. 1;
FIG. 5 illustrates a plan view of an embodiment of the multiple element zone of focus lens having rectangular lens elements;
FIG. 6 illustrates a plan view of an embodiment of the multiple element zone of focus lens having a combination of round and pie-shaped lens elements;
FIG. 7 illustrates a plan view of an embodiment of the multiple element zone of focus lens having horizontal divisions between the lens elements;
FIG. 8 illustrates a plan view of an embodiment of the multiple element zone of focus lens having vertical divisions between the lens elements;
FIG. 9 illustrates a plan view of an embodiment of the multiple element zone of focus lens having both horizontal and vertical divisions between the lens elements with the horizontal lens element dominating;
FIG. 10 illustrates a plan view of an embodiment of the multiple element zone of focus lens having both horizontal and vertical divisions between the lens elements with the vertical element dominating;
FIG. 11 illustrates a sectional view taken across a junction between the lens elements to show the anti-reflective coating and masking material; and,
FIG. 12 illustrates a plan view of paired lenses for use in the left and right eyes of a patient.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 illustrates a plan view of a multiple element zone of focus implantable lens 10, of PMMA or other suitable material, which includes an optic 12, a convex anterior surface 14, a posterior surface 16, an edge 18 therebetween, open loop haptics 20 and 22 for fixation of the lens to the interior of the eye and positioning holes 24 and 26. Haptics 20 and 22 secure into holes 24, 28 and 30 by known processes. The shape of lens 10 may be varied to accommodate optical or other requirements. The lens 10 is primarily illustrated as a plano convex lens, but can assume any other convenient shape, such as meniscus, biconvex, or any other desired lens shape. Lens 10 has a plurality of lens elements 32a-32g contained in the lens body 34. Each of the elements 32a-32g have a distinct focal length or power so as to bring objects of differing distance into focus in a common focal plane. In general, it will be found that two or three powers will be optimum in terms of performance within the human eye. Fewer powers will not provide adequate sharp images for consideration by the brain, and may unduly complicate the process of adaption by the patient. With two different powers, the lenses of like power can be positioned to be interspersed with lenses of the other power. Alternatively, lenses of like power may be located in the regions where adaptation is facilitated. Further alternatives include locating the lenses in accordance with physical characteristics of the eye itself to accommodate retinal or corneal defects. While seven lens elements are shown in the embodiment of FIG. 1, it will be appreciated that the invention is not so limited, and either a greater or smaller number of lens elements is permissible. The power of the individual lens elements 32a-32g is determined by their radius of curvature and the index of refraction, either of which may be varied to provide the desired power. In the embodiment of FIG. 1, the radius of curvature for lens elements 32a-32g are the same and the index of refraction of the material is varied to provide the necessary difference in power. In the case where it is desired to make lens 10 of PMMA, the index of refraction can be modified by changing the length of the polymer while maintaining compatibility with the other characteristics, or by the introduction of suitable additives. Alternatively, some of the lens elements can be made from PMMA and others from polycarbonate. If glass is to be used, it is possible to select glass according to the desired index of refraction. Fabrication of the lens 10 may begin with the creation of a composite rod or similar structure in which the cross-section of the rod resembles the plan view of FIG. 1. Such a rod can be made by simultaneous extrusion of the lens elements from differing material or by individual extrusion or other shaping and subsequent joining of the lens elements. While the extrusion process has certain advantages, particularly that of low cost, the individual fabrication of the lens elements and subsequent joining affords the opportunity to mask the junction with an anti-reflective coating. In either case, the resulting blank may be sliced and fabricated into lenses either by further molding in a die which has the radii of curvature for the desired optical characteristics, by conventional lathe cutting, or other similar optical finishing techniques.
FIG. 2 illustrates a cross-sectional view taken along line 2--2 of FIG. 1 where all numerals correspond to those elements previously described.
FIGS. 3A and 3B are schematic illustrations of an optical system utilizing the lens of FIG. 1 which incorporates two illustrations for the purpose of clarity, and where all numerals correspond to those elements previously described. The lens 10 has a plurality of lens elements 32a-32g. The lens elements 32b, 32d and 32f have a common power D1 and bring a far object 36 located at a far distance 38 to focus on a focal area 40, and is shown as image 36a, which lies on retinal focal plane 42 as indicated by an x-y axis at a far focal distance 44, which terminates at the retinal focal plane 42. In FIG. 3 the elements 32c, 32e and 32g have a common power D2 and bring a near object 46, located at a near distance 48 to a focus in focal area 50 at a near focal distance 52 also terminating at the retinal focal plane 42. The lens element 32a can have a third power D3 or can have a power D1 or D2. It can be seen that the lens elements 32b, 32d and 32f of lens 10 each produce an image 36a in the focal plane on a focal area 40. Similarly, elements 32c, 32e and 32g produce an image 46a on a common focal area 50 which is separate and distinct from the focal area 40. Lens element 32a may have a unique power and develop an image in a unique third area, not shown for sake of clarity and brevity, or may have a power and optical orientation to produce a sharp image of far object 36 in the focal area 40 of the retinal focal plane 42, or a power and optical orientation to produce a sharp image of near object 46 in the focal area 50 of the retinal focal plane 42.
It will be appreciated that the lens elements 32b, 32d and 32f, in addition to producing a sharp image of far object 36, will also produce an out-of-focus image of near object 46. Similarly, the lens elements 32c, 32e and 32f will simultaneously produce a sharp image of near object 46 and an out-of-focus image of far object 36. The adaptive power of the brain effectively rejects the out-of-focus image and permits the in-focus image of the desired object to predominate. The adaptive capability varies with individuals and can sometimes be enhanced by selective positioning of the segments in accordance with personal characteristics of the individual.
FIG. 4 illustrates a cross-sectional embodiment of a lens 60 including an optic 62 which includes a convex anterior surface 64, a planar posterior surface 66, an edge 68 therebetween, and a plurality of lens elements 70a-70g where the lens elements 70a-70g are round and affix within a lens body 72 with a suitable adhesive or other material for molding them as an integral part of lens body 72. The plan view of the lens 60 is the same as for the lens 10 in FIG. 1 where the plurality of lens elements 32a-32g correspond in overhead plan view to the corresponding lens elements of this FIG. in which the alphabetic letters correspond such as 70a being equivalent to 32a and so forth. The differing powers are provided by fabricating the lens elements with different radii of curvature. Since the segments do not have a uniform curvature, conventional grind or lathe cutting techniques are not generally adequate for fabrication where the lens elements are an integral assembly with the lens body 72. Where the integral structure is desired, it may be desirable to form the lens in a die having suitable dimensions or, as previously described, individually fabricate the lens elements and join them after the curved surface is fabricated.
FIG. 5 illustrates an embodiment of the zone of a focus lens 80, including an optic 82, in which the lens elements 98a-98u are generally rectangular in shape and having a uniform radius of curvature, including a convex anterior top surface 84, a plano posterior surface 86, an edge 88 therebetween, and positioning holes 90-92 and haptics 94-95 engaged in holes 96-97. A structure such as this can be fabricated by extrusion, using compatible plastic materials which have different indices of refraction. Alternatively, a composite structure can be made by assembling rectangular rods, having different indices of refraction, into a unitary assembly and slicing blanks therefrom. The blanks can be processed into lenses with conventional techniques. The rods can be affixed to each other with suitable adhesive.
In addition to having different indices of refraction, the individual elements can be made of different colors. The individual lens elements 98a, 98c, 98e, 98g, 98i, 98k,98m, 98o, 98q and 98s have like powers; bring incident rays to focus on a common area; and are colored red or some other suitable color. Lens elements 98b, 98d, 98f, 98h, 98j, 98l, 98n, 98p, 98r and 98t have like powers, differing from the common power of the other group of elements; bring incident rays to a focus on a common area distinct from the area of the other group of elements; and are of a different suitable color such as blue. Thus, colors are assigned to specific lens powers to assist the brain in distinguishing the images produced from the two groups of elements.
FIG. 6 illustrates an embodiment of a lens 100, including an optic 102, a convex anterior surface 104, a plan surface 106, an edge 108 therebetween, and positioning holes 110 and 112 and haptics 114 and 116 engaged in holes 118 and 120. An optic 102 includes a cylindrical central lens element 122 and a plurality of peripherally located radial lens elements 124a-124f about the central lens element 122. The lens elements 122 and 124a-124f may be various powers and colors having the lens elements with common powers of the same color. The lens elements with common powers are optically aligned to produce an image on a common area of the retina.
FIG. 7 illustrates an embodiment of a lens 130 including an optic 132, a convex anterior surface 134, a plano surface 136, edge 138 therebetween, and positioning holes 140-142 and haptics 144-146 engaged in holes 148-150. The lens optic 132 is made up of lens elements 150a-150c which are joined along the corresponding horizontal axis between the lens elements 150a-150c. In the case where three different powers are used for the three lens elements 150a-150c, the elements may be optically aligned to produce an image on the retina in the area corresponding roughly to the geometry of the lens 130. The haptics 144 and 146 will be located to provide the optimum ease of adaptation. For some persons, the optimum position for the most commonly used image brought to a focus by lens element 150a, will be the horizontal central portion of the retina. If this is the case, the haptics 144 and 146 will be located to place lens element 150a in a position to bring its image to the central portion of the retina.
FIG. 8 illustrates a three-element embodiment of a lens 160 similar to that of FIG. 7 with the haptics arranged to place the central element in the vertical orientation. The lens 160 includes an optic 162, convex anterior surface 164, posterior surface 166, an edge 168 therebetween, and positioning holes 170-172 and haptics 174 and 176 engaged in holes 178 and 180. The optic 162 includes lens elements 182a-182c joined along the corresponding axis between the lens elements 182a-182c. The lens elements of FIGS. 7 and 8 can be colored blue, red or yellow or be transparent. The lens elements can be of the same or different powers, but it is desirable that like powers share a common area of the retina.
FIG. 9 illustrates a geometric arrangement in which the horizontal central element has substantially more area than the other elements. The lens 190 includes an optic 192, a convex anterior surface 194, a plano posterior surface 196, an edge 198 therebetween, and positioning holes 200 and 202 and haptics 204 and 206 engaged in holes 208 and 210. The optic 192 includes a horizontally aligned lens element 212, vertically aligned lens element portions 214a and 214b perpendicular to the horizontally aligned lens element 212 in a lens body 216 including portions 216a-216d. This geometrical configuration may employ combinations of differing powers and colors as previously described.
FIG. 10 illustrates an arrangement comparable to that of FIG. 9, but with the central lens element arranged in the vertical plane. The lens 220 includes an optic 222, a convex anterior surface 224, a planto surface 226, an edge 228 therebetween, and positioning holes 230 and 232 and haptic 234 and 236 engaged in holes 238 and 240. The optic 222 includes a vertically aligned lens element 242, horizontally aligned lens elements 244a-244n perpendicular to the vertically aligned lens element 242 in a lens body 246 including portions 246a-246d. This geometrical configuration may employ combinations of differing powers and colors as previously described.
FIG. 11 illustrates a cross-sectional view at the junction 250 between elements joined with adhesive or other suitable material taken along line 11--11 of FIG. 1. A lens element 32a is joined to a lens element 32c with a suitable adhesive material 254. An opaque layer 256 of highly pigmented material may be added to reduce reflection caused by the junction between the elements. The adhesive material 254 may contain an anti-reflection material or such material may be applied directly to the abutting surfaces.
FIG. 12 illustrates two lenses 260 and 262 for the right and left eye, respectively, having lens elements of comparable power and color arranged in the same geometric position in each lens. For example, lens element 264a for the left eye, has the same power and color as the lens element 266a for the right eye. In this embodiment, the lens elements 264a-264c for the left eye have powers respectively corresponding to the powers of lens elements 266a-266c for the right eye. This too, is to facilitate the adaptation process.
MODE OF OPERATION
Reduction of the cost of the lenses would have the effect of increasing the availability of this procedure to those who currently lack the economic means to afford such an operation. This is particularly the case in third world countries where costs are often the overriding consideration in medical care.
There is no question that the technique of using less than the entire retina is usually not as desirable as a system which duplicates the normal lens use of the entire retina. There is a loss of acuity which shows up in reduced resolution and contrast, particularly in low light conditions. In addition, the accommodation of the brain to such a system takes a period of time, and the degree of success in such accommodation varies with individuals. There are, of course, minor problems when taken in view of the alternative, which is blindness.
In the case where a defective natural lens is to be replaced, it is customary to make extensive measurements on the eye prior to the removal of the defective natural lens and its replacement with a fixed focus implantable lens. Such measurements allow the selection of a lens having appropriate power for the individual, and the nominal distance to the object which is desired to be brought into focus on the retina. This approach to the problem has the disadvantage that a wide range of powers must be available to the surgeon. Since each lens is individually fabricated, the economic burden of fabricating a wide variety of powers adds substantially to the cost of lenses. It would be much cheaper to manufacture only a few lenses and use them in all patients. The cost of manufacture would be reduced and inventory requirements would be much less burdensome.
Various modifications can be made to the present invention without departing from the apparent scope thereof.
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An implantable or contact lens for replacement of a defective natural lens in an eye in which various portions of the lens have different powers and focal lengths to produce in-focus images on different portions of the retina, of objects which are located at various distances from the eye, thereby substituting for the natural focusing action of the eye. The image processing capability of the brain functions to largely ignore the out-of-focus images and concentrate on the in-focus image of the object selected by the brain for consideration.
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RELATED APPLICATIONS
[0001] This application is a continuation-in-part of copending U.S. patent application Ser. No. 10/592,495, which is a 371 of PCT/FR2004/001259 filed 21 May 2004.
BACKGROUND OF THE INVENTION
[0002] The present invention pertains to trailers intended to be towed by a motor vehicle. These trailers may be used for a variety of purposes including transporting luggage, materials, or sports machines. Such trailers are generally made from metal beams cut to the correct length and welded together. These operations, particularly the welding operation, require welding stations and qualified personnel. Such operations can only be conducted in workshops equipped with specific tooling. Often this tooling is expensive and requires trained workers to operate the tooling. The trailers must then be transported to consumers in an assembled state, which is difficult and costly. It is therefore desired to design a new trailer which requires a minimum number of tools for assembly. It is further desired to design a new trailer which does not require skilled workers, such as welders, to assemble the trailer. It is further desired to design a new trailer which can be assembled on site at the point of sale to reduce the logistical problems associated with transporting the trailers in their assembled configuration.
SUMMARY OF THE INVENTION
[0003] The invention provides a frameless modular trailer. The trailer of the present invention includes a front panel and two opposed side panels. The front and side panels are slidably coupled by a pair of corner posts. The trailer further includes a floor panel which is slidably engaged by the front and side panels.
[0004] The trailer may include a bumper coupled to the floor panel and a hinged ramp slidably coupled to the bumper.
[0005] The trailer may include a top panel which is slidably engaged by any of the front or side panels.
[0006] The front and side panels may be formed with a protrusion on the top surface. The top panel may be formed with a channel formed on the bottom surface. The protrusions of the front or side panels may be slid in the channel of the top panel to slidably engage the top panel to either a front or side panel.
[0007] The front and side panels may be formed with a bolt channel on the bottom surface. A bolt may be slid in this bolt channel. The bolt channel is adapted to engage the head of the bolt so that the bolt cannot rotate within the bolt channel. In this manner a nut can be threaded onto the bolt and items may be attached to the front or side panels by tightening a nut onto the bolt without access to the head of the bolt.
[0008] The trailer may include a floor panel which is made of numerous slidably engaged planks. The floor panel may be formed with a channel for securing objects within the trailer.
[0009] The inside and outside surfaces of the front, side, and top panels may be formed with bolt channels for engaging bolts or channels for securing objects within the trailer.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a perspective view of a prior art trailer.
[0011] FIG. 2 is a perspective view of an embodiment of frameless trailer of the present invention.
[0012] FIG. 3 is an exploded view of an embodiment of frameless trailer of the present invention.
[0013] FIG. 4 is a partially exploded, bottom perspective view of the frameless trailer of FIG. 2 .
[0014] FIG. 5A is a side elevation view of the frameless trailer of FIG. 2 with its ramp locked in the up position.
[0015] FIG. 5B is a side elevation view of the frameless trailer of FIG. 2 with its ramp in the down position.
[0016] FIG. 5C is a rear perspective view of the frameless trailer of FIG. 2 with its ramp in the down position.
[0017] FIG. 5D is a top plan view of the frameless trailer of FIG. 2 .
[0018] FIG. 5E is a front elevation view of the frameless trailer of FIG. 2 .
[0019] FIG. 6 is a side elevation view of an alternative embodiment of the frameless trailer of the present invention, and showing the ramp in the down position.
[0020] FIG. 7A is a top view of the frameless trailer of FIG. 6 .
[0021] FIG. 7B is a perspective view of the frameless trailer of FIG. 6 .
[0022] FIG. 8 is a cross sectional view taken along line 8 - 8 of FIG. 3 and showing a side panel extrusion for use in the frameless trailer.
[0023] FIG. 9 is a cross sectional view similar to that of FIG. 8 , but showing an alternative embodiment of a side panel extrusion for use in the frameless trailer of the present invention.
[0024] FIG. 10 is a cross sectional view taken along line 10 - 10 FIG. 3 and showing multiple side panels slidingly engaged for use in the frameless trailer.
[0025] FIG. 11 is a cross sectional view taken along line 11 - 11 of FIG. 3 and showing top panel extrusion for use in the frameless trailer.
[0026] FIG. 12 is a cross sectional view similar to that of FIG. 11 , but showing an alternative embodiment of a top panel extrusion for use in the frameless trailer.
[0027] FIG. 13 is a cross sectional view similar to that of FIG. 11 , but showing an alternative embodiment of a top panel extrusion for use in the frameless trailer.
[0028] FIG. 14A is an enlarged perspective view of the area designated generally by reference numeral 14 A of FIGS. 5D and 7A .
[0029] FIG. 14B is an enlarged perspective view of the area designated generally by reference numeral 14 B of FIG. 7A .
[0030] FIG. 15 is a close up cross sectional view taken along line 15 of FIG. 3 and showing the hinged engagement of the ramp and bumper sections of a preferred embodiment of present invention with the ramp in the upright closed position.
[0031] FIG. 16 is a close up cross sectional view similar to that of FIG. 15 and showing the hinged engagement of the ramp and bumper sections of a preferred embodiment of present invention with the ramp in the downward opened position, and showing the upright ramp in phantom.
[0032] FIG. 17 is a cross sectional view taken along line 17 of FIG. 7A .
[0033] FIG. 18 is a fragmentary perspective view of an alternative embodiment splice channel according to the present invention, for use in the frameless trailer of FIG. 17 .
[0034] FIG. 19 is a fragmentary perspective view of an alternative embodiment of a splice channel according to the present invention, for use in the frameless trailer of FIG. 17 .
[0035] FIG. 20A is a cross sectional view similar to that of FIG. 17 , but showing an alternative embodiment including alternative flooring.
[0036] FIG. 20B is a fragmentary perspective view of a splice panel for use in the embodiment shown in FIG. 20A .
[0037] FIG. 21 is a fragmentary, partially exploded view of the fender portion of FIG. 6 .
[0038] FIG. 22 is a fragmentary view of the fender portion of FIG. 6 .
[0039] FIG. 23 is a fragmentary, partially exploded view of the fender portion of FIG. 2 .
[0040] FIG. 24 is a fragmentary view of the fender portion of FIG. 2 and showing the fender bracket in phantom.
[0041] FIG. 25 is a fragmentary, partially exploded view of an alternative embodiment of the fender of FIG. 23 .
[0042] FIG. 26 is a fragmentary view of the fender portion of FIG. 25 and showing the fender bracket in phantom.
[0043] FIG. 27 is a perspective view of an alternative embodiment of the frameless trailer of the present invention including a slidably attached back panel which is slidably attached.
[0044] FIG. 28 is a perspective view of an alternative embodiment of the frameless trailer of the present invention and showing a hingedly attached trailer cover in phantom in the open position.
[0045] FIG. 29 is a perspective view of an alternative embodiment of the frameless trailer of the present invention including multiple, slidably engaged side panel extrusions.
[0046] FIG. 30 is a perspective view of an alternative embodiment of the frameless trailer of the present invention having multiple side panel extrusions and a solid top panel.
[0047] FIG. 31 is a front perspective view of an alternative embodiment of the frameless trailer of the present invention including a removable canvas cover.
[0048] FIG. 32 is a front perspective view of the frameless trailer of FIG. 31 and showing the canvas cover partially removed.
[0049] FIG. 33 is an enlarged perspective view of the area designated generally by reference numeral 33 of FIG. 32 .
[0050] FIG. 34 is a fragmentary partially exploded, bottom perspective view of the frameless trailer of FIG. 4 and showing the trailer partially assembled.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0051] Although the disclosure hereof is detailed and exact to enable those skilled in the art to practice the invention, the physical embodiments herein disclosed merely exemplify the invention which may be embodied in other specific structures. While the preferred embodiment has been described, the details may be changed without departing from the invention, which is defined by the claims.
[0052] The invention contemplates the assembly of various cooperating components fabricated from extruded materials such as aluminum. The components feature releasably, slidably engagable profiles. For example, the ability to assemble two components by hand, or only requiring basic tools, and providing such positive engagement that the components will not separate absent an applied sliding longitudinal force. The extruded components may also feature profiles that allow the user to secure items to the trailer.
[0053] FIG. 1 is a drawing of a prior art modular trailer 10 . The prior art modular trailer 10 includes a frame 12 which is bolted together.
[0054] FIGS. 2 and 3 show a modular frameless trailer 14 according to the present invention. The trailer 14 comprises numerous interlocking extrusions which are slid together and secured to form a frameless trailer 14 . The trailer 14 preferably includes a front panel 16 , at least two spaced apart opposed side panels 18 , corner posts 20 , 21 , a bumper 22 , a rear panel 24 , an axle 26 , a pair of tongue brackets 28 , 42 , a tongue 30 , fender brackets 32 , fenders 34 , corner wraps 36 , tires 38 and floor 40 . This configuration allows a number of extrusions to be produced, cut to size, and pre-drilled with holes. The parts can then be shipped, unassembled, to be assembled by the customer or the retailer. This allows for more efficient shipping and storage of the trailers 14 .
[0055] FIG. 4 shows the underside 41 of the trailer 14 . In a preferred embodiment of the invention, the tongue 30 is secured to the trailer 14 by a pair of tongue brackets 28 , 42 . As seen, the first tongue bracket 28 is attached to the front panel 16 . The second tongue bracket 42 is attached to the axle 26 . The preferred embodiment of the trailer 14 preferably includes three cross members; the axle 26 and two additional cross members 44 , however it is contemplated that any number of cross members 44 could be utilized. The underside of the trailer may further include a plurality of wire guides 43 attached to the floor 40 , as will be described in further detail below.
[0056] In the preferred embodiment of the trailer 14 the rear panel is a pivoting ramp 24 . FIGS. 5A and 5B show the operation of the pivoting ramp 24 . As shown in FIG. 5A , the ramp 24 is secured in its upright position by a pair of latches 46 attached to the either end of the ramp 24 and a pair of catches 48 attached to the rear corner posts 21 . The latches 46 and catches 48 are shown in more detail in FIG. 3 . When the latches 46 are released from the catches 48 , the ramp 24 can be pivoted to its downward position, as shown in FIG. 5B . Although the ramp 24 in FIGS. 5A is shown as being taller than the side panels 18 , it is also contemplated that the ramp 24 could be of any height. For example, as shown in FIGS. 7A and 29 , the ramp 24 could be generally the same height as the side panels 18 .
[0057] FIGS. 5D and 5E show a top view and a front view respectively of the preferred embodiment of the frameless trailer 14 of the present invention.
[0058] FIG. 6 shows an alternative embodiment of the trailer 314 with its ramp 24 in the downward position. This embodiment of the trailer 314 does not include the corner wrap pieces 36 as shown in FIGS. 5A and 5B . Instead, the trailer 314 utilizes an alternative embodiment of fender brackets 332 and fenders 334 , as will be described in more detail below. Further, the trailer 314 utilizes a shortened ramp 24 . The shortened ramp may include at least one bumper 45 . The bumper 45 is adapted to engage the ground when the ramp 24 is in its down position. The bumper 45 may be made of any material, however in the preferred embodiment the bumper 45 is made of a rubber material.
[0059] FIGS. 7A and 7B show an alternative views of the trailer of FIG. 6 . The frameless trailer of FIGS. 7A and 7B is similar to the embodiment shown in FIGS. 5A to 5 E, however this alternative embodiment includes a shortened ramp 24 . The frameless trailer may further include at least one bumper 45 .
[0060] FIGS. 8-10 show cross sectional views of various front and side panel extrusions 16 , 18 . Although only the side panel extrusions 18 are shown and described it should be understood that the front panel extrusions 16 may have the same configuration. As shown, the side panel extrusions 18 have an inner face 50 , an outer face 52 , a bottom edge 54 and a top edge 56 . As seen in the cross sectional views of FIGS. 8-10 , the preferred embodiments of the side panel extrusion 18 , 318 , 518 have three sections, a top section 58 , a center section 60 , and a bottom section 62 . The top section 58 and the bottom section 62 have generally the same thickness, with the center section 60 having a relatively smaller thickness. The inner face 50 is generally planar. As seen in FIG. 9 , the inner face 50 may have at least one bolt channel 64 formed on the surface thereof. This bolt channel 64 is adapted to engage a bolt 76 with a bolt retainer 78 . (See particularly FIG. 8 .) The bolt retainer 78 is generally rectangular and includes an aperture (not shown) therethrough for the bolt 76 .
[0061] In the alternative embodiment of a side panel extrusion 318 shown in FIG. 9 , the inner face 50 is formed with two bolt channels 64 , the first bolt channel 64 located in the top section 58 of the panel 318 and the second bolt channel 64 located in the bottom section 62 of the panel 318 . These bolt channels 64 may be used to secure components to the side panels 318 . A benefit of this design is that the components can be secured with bolts 76 using one side tightening. That is, as seen in FIG. 8 , a bolt 76 with an attached bolt retainer 78 can be slid into the bolt channel 64 formed on the bottom surface 54 of the panels 18 . The head 77 of the bolt 76 is held in a nonrotatable position by the interior flanges 74 formed in the bolt channel 64 . A nut 81 can then be threaded onto the free end 79 of the bolt 76 . Because the head 77 of the bolt 76 cannot rotate, the nut 81 can be fastened on the bolt 76 with access to only the free end 79 of the bolt 76 .
[0062] As seen in FIGS. 8 to 10 , at least one flange 66 is formed near the bottom of the inner face 50 . This flange 66 extends generally perpendicularly to the surface of the inner face 50 and extends along the length of the panel 18 , 318 . In the preferred embodiment two spaced apart flanges 66 extend along the length of the panel 18 , 318 . These two flanges 66 form a channel 68 into which the floor panel of the trailer 14 can be slid, as shown in FIGS. 17 and 20 A and described in more detail hereinafter. This double flange 66 provides full encapsulation of the floor 40 with no through panel fasteners required. In an alternative embodiment (not shown), a single flange 66 may be utilized, and the floor panel 40 of the trailer 14 can be dropped into place and will rest upon the single flange 66 . The single flange 66 design would be preferable in embodiments in which planks, such as wood planks are utilized for the floor 40 of the trailer 14 .
[0063] In a preferred embodiment, the outer surface 52 of the panel 18 , 318 , 518 is sloped between the upper section 58 and the center section 60 , and again between the center section 60 and the bottom section 62 . A longitudinally extending hook 70 may be integrally formed to the surface 52 . The hook 70 may extend laterally from the outer surface 52 and run coextensive the length of the outer surface 52 of the center section 60 . This hook 70 is designed to accept and anchor all forms of tie downs and bungee cords (not shown). As may be seen particularly in FIG. 9 , the outer surface 52 of the top section 58 of the panel 318 may be formed with a bolt channel 64 adapted to engage a bolt 76 with a lock 78 as described above. This bolt channel 64 could be used to attach various items to the panel extrusions, such as the rubber bumpers 45 shown in FIGS. 6 and 7 B. To attach the bumpers 45 to a panel extrusion 318 , a bolt 76 may be slid into the bolt channel 64 . The bumper 45 may then be attached to the end of the bolt 76 , for example by placing the bumper 45 on the bolt 76 and threading a nut on the end of the bolt 76 .
[0064] The top edges 56 of the panel extrusions 18 , 318 , 518 may be formed to include an interlocking protrusion 72 . This interlocking protrusion 72 allows the stacking of multiple side panels 18 , 318 , 518 as shown in FIG. 10 as well as top panels 80 , 380 , 580 as will be described below. Because different side panels 18 , 318 , 518 may have different integrated features, such as the bolt channel 64 , and tie down hook 70 , any number of different panels 18 , 318 , 518 could slidingly interlocked to achieve the desired panel height and combination of features, as seen in FIG. 10 . As will be described in more detail below, various top panels 80 , 380 , 580 can be slidingly interlocked with the panel extrusions 18 , 318 , 518 . The interlocking protrusion 72 extends along the length of the panel extrusion 18 , 318 , 518 along the top edge 56 and is adapted to be retained within a corresponding engaging channel 82 formed in a second panel 518 to slidably couple the two panels 18 , 518 as shown in FIG. 10 .
[0065] The respective bottom edges 54 of the panel extrusions 18 , 318 may be formed to include a bolt retaining bolt channel 64 . The bolt retaining bolt channel 64 has a similar configuration to the bolt channel 64 described above with respect to the inner face 50 .
[0066] The trailer 14 may also include a top panel extrusion 80 , 380 , 580 which is adapted to slidingly engage the side panel 18 , 318 , 518 and front panel 16 extrusions. A variety of top panel extrusions 80 , 380 , 580 may be seen in FIGS. 11-13 . As illustrated, the top panel extrusions 80 , 380 , 580 preferably include an inner face 90 , an outer face 92 , a top edge 94 and a bottom edge 96 . The top panels 80 , 380 , 580 may have a flat top surfaces 94 as shown in FIG. 11 , channels 98 formed on the top surfaces 94 as shown in FIG. 12 , or interlocking protrusions 72 formed on the top surfaces 94 as shown in FIG. 13 . The bottom edges 96 of each of the top panel extrusions 80 , 380 , 580 are preferably formed with engaging channels 82 for engaging the interlocking protrusions 72 of a side panel 18 , 318 . The respective inner faces 90 and outer faces 92 of the top panel extrusions 80 , 380 , 580 are generally planar and may be formed with any number of channels 101 , 103 . These channels 101 , 103 may be used to secure the items within the trailer 14 .
[0067] The trailer 14 of the present invention may also utilize a plurality of corner posts. FIG. 14A shows a front corner post 20 connecting the front panel 16 to a side panel 18 . This view shows a front corner of the trailer 14 shown in FIG. 7A . The corner post 20 has a generally square cross section, with two flanges 105 extending from each of two adjacent faces. Each set of flanges 105 defines a channel 106 which engages a panel extrusion 16 , 18 as will be described in greater detail below.
[0068] FIG. 14B shows a rear corner post 21 attached to a side panel 18 . This view shows a rear corner of the trailer 14 shown in FIG. 7A . The rear corner piece has a generally square cross section, with a pair of spaced apart flanges 105 extending laterally from one of the faces 23 of the square. The pair of flanges 105 defines a channel 106 therebetween which is adapted to engage a panel extrusion 18 as will be described in greater detail below. As may be further seen in the view of FIG. 14B , is also contemplated that the ramp 24 could include an end cap 108 at each end thereof. The end cap 108 generally comprises a U-shaped extrusion, wherein an end cap 108 is adapted to be placed over each end of the ramp 24 . The end cap 108 may further include a protrusion 110 . The protrusion 110 prevents the ramp 24 from being pivoting past its closed position and into the trailer. As is best seen in FIG. 7 , a preferred embodiment of the trailer 14 includes both front corner posts 20 and rear corner posts 21 . This is because the preferred embodiment of the trailer 14 includes a rear panel 24 which is pivotably attached rather than slidably attached. In an embodiment in which the rear panel is slidably attached, as shown in FIG. 27 , four front corner posts 20 will be utilized.
[0069] As shown in FIG. 3 , a preferred embodiment of the frameless trailer 14 includes a pivoting ramp extrusion 24 opposite the front panel 16 of the trailer 14 . The operation of the pivoting ramp extrusion 24 is shown in FIGS. 15 and 16 . The ramp extrusion 24 is similar in to the extrusion panels 16 , 18 described above, however the ramp extrusion 24 includes an integrated pivot member 109 . In the preferred embodiment, the bottom section 107 of the ramp extrusion panel 24 is tapered, with the outer face 52 remaining generally planar. The integrated pivot member 109 extends from the tapered end 107 of the ramp extrusion 24 . As is seen in FIG. 15 , the pivot member 109 includes a pivot channel 113 .
[0070] The bumper extrusion 22 , which is attached to the trailer 14 as described hereinafter, includes a frame channel 111 . The frame channel 111 hingedly engages the pivot member 109 . In the preferred embodiment, the frame channel 111 is configured to matingly engage the ramp pivot member 109 when the ramp 24 is in its up position, as shown in FIG. 15 . The frame channel 111 further comprises a member 114 that extends laterally from the bumper extrusion 22 along the entire length of the bumper, and ends in an arcuate member 115 . As is seen in FIG. 16 , as the ramp extrusion 24 is lowered, the arcuate member 115 slides through the pivot channel 113 . The engagement of the end 116 of the arcuate member 115 and the end of the pivot channel 113 will prevent the ramp 24 from further downward rotation. Likewise, the engagement of the pivot member 109 with the top surface 118 of the bumper 22 and the frame channel 111 will prevent the ramp 24 from further upward rotation as shown in FIG. 15 .
[0071] The configuration of the bumper extrusion 22 and the ramp extrusion 24 provides a ramp with no fastener required for attachment of the ramp 24 to the trailer 14 . When the ramp 24 is in its down position, the bumper extrusion 22 and ramp extrusion 24 can be slid together to attach the ramp 24 to the trailer 14 . Likewise, the ramp extrusion 24 and bumper extrusion 22 can be slid apart to disassemble the ramp 24 .
[0072] A cross section of the preferred embodiment of the trailer 14 is shown in FIG. 17 . As seen, the cross section may include opposed side panel extrusions 18 . As previously described, each of the side panel extrusions 18 preferably includes two spaced apart flanges 66 which form a channel 68 therebetween in the lower section 62 of the inner surface 50 of the panels 16 . The floor 40 of the trailer 14 may be made of combinations of floor panels 119 and splice panels 117 which are secured by sliding the panels 117 , 119 into the channels 68 . The embodiment shown utilizes floor panels 119 , and a center splice panel 117 . The first and second floor panels 119 may be made of any material. As seen, the splice panel 117 is an extrusion. The splice panel 117 has a channel 121 formed on each longitudinal end. The channel 121 extends along the entire length of the spice channel 117 . The first and second floor panels 119 are slid into the channels 121 in the splice panel 117 . Then the entire floor section 40 can be slid between the flanges 66 on the first and second side panels 18 . In this manner the floor panels 117 , 119 are attached without the use of additional attachment devices. The splice panel 117 may be formed with a channel 123 . This channel 123 may be used to secure items within the trailer 14 .
[0073] FIG. 18 shows an alternative embodiment of a splice panel 217 that may be used in place of the splice panel 117 shown in FIG. 17 . The splice panel 217 includes a flange 120 extending from each longitudinal end. Each flange 120 is adapted to retain and support a floor panel 119 . The splice panel 217 further includes a pair of longitudinally extending members 122 formed on the underside 128 of the splice panel 217 . The members 122 extend the length of the splice panel 217 and form a channel 126 . The channel 126 is adapted to accept a wire guide 43 (also shown in FIG. 4 ). The wire guide 43 is preferably flexible in order to insert the wire guide 43 into the channel 126 formed between the pair of longitudinally extending members 122 .
[0074] FIG. 19 shows another alternative embodiment of a splice panel 417 that may be used in place of those shown in FIGS. 17 and 18 . The splice panel 417 is formed with a channel 121 formed on each longitudinal end. The first and second floor panels 119 are slid into the channels 121 in the splice panel 417 . Then the entire floor section 40 can be slid between the flanges 66 on the first and second side panels 18 .
[0075] It is contemplated that there could be numerous other floor 40 configurations. For the purpose of example, and not to be considered exhaustive, the floor 40 could be a single piece of wood, a combination of wood planks, or a single metal extrusion. The floor 40 could also be made of a number of floor extrusions 317 , 319 slidingly connected to each other, as shown in FIG. 20A . It is further contemplated that each side panel 18 could be formed with only one flange 66 (not shown). In this manner, the floor 40 could be inserted by dropping the floor 40 inside the trailer 14 and resting the floor 40 on top of the flange 66 .
[0076] FIG. 20A shows a cross sectional view of a trailer 14 with an alternative floor panel configuration. This embodiment utilizes an alternative splice panel 317 and alternative floor panels 319 . Each panel 317 , 319 is formed with a protrusion 125 on one end and a channel 127 on the opposite end. The channel 127 is adapted to engage the protrusion 125 when two panels 317 , 319 are slidingly engaged. The splice panel 317 is formed with a channel 123 , as can be seen in FIG. 20B . As described above, this channel 123 can be used to secure items within the trailer 14 . The splice panel 317 may also include a circular recess 124 . The circular recess 124 operates in connection with the channel 123 . In this manner an attachment member (not shown) may be placed into the circular recess 124 and then slid into the channel 123 in order secure items within the trailer 14 .
[0077] A trailer according to the present invention may also include at least one fender 334 as shown in FIG. 6 . FIGS. 21 and 22 show a first method of attaching fenders 334 to the trailer 314 , as shown in FIG. 6 . The fender bracket 332 is formed with a plurality of holes 135 and a slot 131 on either side of the holes 135 . The fender 334 is formed with a plurality of holes 135 which correspond to the holes 135 on bracket 332 , and a projection 129 on either side of the holes 135 . To mount the fender 334 , the projections 129 on the fender 334 are lined with and inserted into the slots 131 on the fender bracket 332 . This aligns the holes 135 in the fender 334 and the fender bracket 332 . Bolts 133 are inserted through the holes 135 and are secured to attach the fender 334 to the fender bracket 332 . As is shown in FIG. 6 , the fender 334 is attached to the fender brackets 332 in two places, one on either side of the wheel 38 .
[0078] FIGS. 23 and 24 show an alternative embodiment of fender 34 and fender brackets 32 . As is shown in FIG. 4 , the fender brackets 32 are attached to the underside of the side panels 18 , one on each side of the axle 26 . The fender bracket 32 is formed with several holes 137 for attaching to the side panel 18 , and several holes 141 for attaching the fender 34 to the fender bracket 32 . To attach, the fender 34 is placed on top of the fender brackets 32 and bolts 139 are inserted through the holes 141 and are secured.
[0079] FIGS. 25 and 26 show an alternative embodiment of fender 234 and fender brackets 232 . The fender brackets 232 are attached to the underside of the side panels 18 , one on each side of the axle 26 . The fender bracket 232 is formed with several holes 137 for attaching to the side panel 18 , and several holes 141 for attaching the fender 234 to the fender bracket 232 . The fender bracket 232 is attached to the side panel 18 through at least one bolt 76 slid into the bolt channel 64 formed on the bottom of the side panel 18 . In use, the fender bracket 232 is placed onto the bolt 76 and secured using a fastening means such as a nut. The fender 234 is then placed on top of the fender brackets 232 and bolts 139 are inserted through the holes 141 and are secured.
[0080] As shown in FIG. 27 , is further contemplated that the trailer 514 may be configured such that the rear panel 143 is slid into place on the trailer 514 . In this embodiment rear corner posts similar to the front corner posts 20 previously described would be used on the back corners of the trailer 514 . The rear panel 143 may be slid into the channel 106 formed by the flanges 105 of the corner posts 20 .
[0081] It is further contemplated that the trailer 614 may be equipped with a hingedly connected cover 145 , as shown in FIG. 28 . In this embodiment one end 146 of the cover 145 is hingedly attached to the top 56 of a side panel 18 . This embodiment also includes support members 147 for supporting the cover 145 (shown in phantom).
[0082] As described above, it is further contemplated that the sides 15 of the trailer 714 may be formed of various heights. For example, as shown in FIG. 29 , the trailer 714 end panel 16 may be formed by slidably stacking two end panel extrusions 16 and each side panel 18 may be formed by slidably stacking two side panel extrusions 18 . This slidable connection is also shown and described with regard to FIG. 10 . Although the example illustrated in FIG. 29 is shown with two side panel extrusions 18 or end panel extrusions 16 slidably stacked, it is contemplated that the trailer 714 could be made of any number of side panels 18 or end panels 16 slidably stacked upon each other.
[0083] FIG. 30 shows another alternative embodiment of a trailer 814 of the present invention. As illustrated the trailer 814 includes side panels 18 that are formed of two slidably attached side panel extrusions 18 and end panels 16 that are formed of two slidably attached end panel extrusions 16 . The trailer 814 may further include a solid top 145 . The solid top 145 may be hingedly attached as shown in FIG. 28 .
[0084] FIGS. 31 to 33 show an alternative embodiment of a trailer 914 including a canvas canopy 49 . The trailer 914 may include a top panel extrusion 380 as shown in FIG. 12 slidably attached to the side and end panel extrusions. The trailer 914 further includes a plurality of bows 47 . The bows 47 extend across the width of the trailer 914 and are attached at either end of the bow 47 to one of the top panel extrusions 380 . Each end of the bow 47 is attached to a securing member 53 . The securing member 53 may be slid into the channel 98 formed on the top surface of the top panel extrusion 380 . The bow 47 may be secured to the securing member 53 using any known means, such as a screw.
[0085] The canvas canopy 49 may then be placed over the trailer 914 . The canopy 49 may include elastic members 51 to allow the canopy 49 to be pulled over the top of the trailer 914 and secured by slipping the elastic members 51 under the lower corners 73 of the trailer 914 . As shown in FIG. 31 , the bows 47 allow the canvas canopy 49 to be pulled taut across the trailer 914 . It should be understood that any number of side panels 18 and end panels 16 may be slidably stacked in order to create a trailer 914 of the appropriate height.
[0086] As may be seen particularly in FIGS. 3 and 34 , to assemble the preferred embodiment of the frameless trailer 14 the tongue bracket 28 is attached to the bottom of the front panel 16 . To attach the bracket 28 to the front panel 16 at least one bolt 76 is slid into the bolt channel 64 located on the bottom edge 54 of the front panel 16 . The tongue bracket 28 is preformed with at least one aperture 75 for receiving at least one bolt 76 . The tongue bracket 28 is then placed on the bottom of the front panel 16 , aligning the bolts 76 with the apertures in the tongue bracket 28 . The tongue bracket 28 is secured in place by placing a nut 81 on the at least one bolt 76 and tightening the nut 81 .
[0087] A corner post 20 is slid onto each end of the front panel 16 . Each corner post 20 is formed with at least one aperture 75 for receiving a bolt 76 . The front panel 16 is formed with at least one aperture 75 for receiving a bolt 76 at each end thereof. The apertures 75 in the front panel 16 are aligned with the apertures 75 one of the corner posts 20 . The corner posts 20 are then secured to the front panel 16 by inserting a bolt 76 through the aligned apertures 75 and tightening a nut 81 on the free end of each bolt 76 , as is generally shown in FIG. 14A .
[0088] A side panel 18 is then slid onto each end of the corner posts 20 . At each end of the side panel 18 the face of the panel 18 is preformed with at least one aperture 75 for receiving a bolt 76 therethrough. The apertures 75 in the side panels 18 are aligned with the apertures 75 in the corner posts 20 . The side panels 18 are then secured to the corner posts 20 by inserting a bolt 76 through the aligned apertures and tightening a nut 81 on the free end of each bolt 76 as is generally shown in FIG. 14A .
[0089] A number of bolts 76 may be then slid into the bolt channel 64 formed in the bottom edge 54 of each side panel 18 . These bolts 76 will be used to attach the fender brackets 32 and corner wraps 36 and to secure the axle 42 and cross members 44 . The fender brackets 32 are attached as described above. The remaining elements are attached in a similar fashion. The design of the bolt channel 64 in the side panel 18 allows these elements to be attached by simply aligning the preformed holes in the element with the bolts 76 , and tightening a nut 81 onto each bolt 76 . The use of bolt retainers 78 , as shown in FIG. 9 , causes the inner flanges 74 of the bolt channel 64 to engage the head 77 of the bolt 76 in a nonrotatable manner. This allows the user to tighten a nut 81 onto the bolt 76 with one hand, and without the use of additional tools. However, it is also contemplated that a user may utilize tools in securing a nut 81 to a bolt 76 .
[0090] A rear corner post 21 is slid onto each end of the side panel 18 . The rear corner post 21 is secured to the end of the side panel in a similar fashion as described above with respect to the corner post 20 . It should be understood that in an trailer 514 as shown in FIG. 27 , without a pivoting ramp 24 , corner post 20 may be utilized in each of the four corners of the trailer 514 .
[0091] Each rear corner post 21 is formed with at least one aperture for receiving a bolt 76 . The side panels 18 are formed with at least one aperture for receiving a bolt 76 at each end thereof. The apertures in the side panels 18 are aligned with the apertures in one of the corner posts 21 . The rear corner posts 21 are then secured to the side panels 18 by inserting a bolt 76 through the aligned apertures and tightening a nut 81 on the free end of each bolt.
[0092] The floor 40 is then slid into the channel 68 formed by the double flanges 66 on the lower inner portion of the side 18 and front 16 panels. The floor 40 can be made of any appropriate number of pieces. In the preferred embodiment the floor 40 is made of two side floor pieces 119 which are slid into a center floor piece 117 . The entire floor 40 is then slid into place as described above. The floor 40 may be made of any rigid material such as aluminum sheet, aluminum extruded plank, steel, plywood, wood plank, plastic or composite.
[0093] At least one cross member 26 , 44 is attached to the trailer 14 . The preferred embodiment includes a front cross member 44 , a center cross member 26 and a rear cross member 44 . Each cross member 26 , 44 is formed with an aperture (not shown) at each end. The apertures in the cross members 26 , 44 are lined up with the aforementioned bolts 76 located in the bolt channel 64 of the side panels 18 . A nut 81 is then tightened on each bolt 76 to secure the cross members 26 , 44 to the side panels 44 . The center cross member 26 includes a hub 137 at each end thereof. The center cross member 26 also includes a second tongue bracket 42 in the center of the member.
[0094] In the preferred embodiment, at least a portion of the bumper extrusion 22 extends underneath the trailer 14 . The bumper extrusion 22 formed with a number of apertures and is attached to the side panels 18 in the same manner as described above with respect to the abovementioned cross members 26 , 44 . The corner wraps 36 are attached in the same manner. The tongue 30 is then secured in place at the tongue brackets 28 , 42 and the wheels 38 are attached to the hubs 137 . Up to this point, the assembly is completed with the trailer 14 upside down. The trailer 14 can now be turned upright. Finally, the ramp extrusion 24 is sliding coupled to the bumper 22 as described above.
[0095] The foregoing is considered as illustrative only of the principles of the invention. Furthermore, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described. While the preferred embodiment has been described, the details may be changed without departing from the invention, which is defined by the claims.
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A frameless modular trailer for towing behind a motor vehicle is provided. The trailer is made of slidably coupled extrusions for easy assembly. The front and side panels include a protrusion on the top surface. This protrusion allows for the stacking of additional panels for vary the height of the trailer. Additionally, one of a variety of top panels may be stacked on the front and side panels to multiple configurations for securing objects within the trailer.
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BACKGROUND OF THE INVENTION
The present invention relates to a method for preventing leaching of contaminants from the surface of a solid or, in particular, to a method for preventing contamination of a material in contact with a solid such as a glass, ceramic, metal and the like by the ingredients leached out of the surface of the solid.
In various kinds of fine technologies such as the manufacture and processing of semiconductors or semiconductor devices, preparation and storage of medicines and microanalytical procedures, it is of utmost importance to avoid contamination of the materials or chemicals under handling by trace amounts of impurities, especially, such as alkali metals originating in the solid surface with which the material or the chemical in question is in contact. For example, contamination with an alkali metal element is unavoidable when the material or chemical is contained in a vessel or handled with a tool made of a glass because containers for photoresist materials, glass bottles for reagents and medicines, ampules, beakers and flasks made of glass cannot be free from the problem of exudation or leaching out of the ingredients of the glass such as alkali metals so that the chemicals contained in such vessels are always subject to contamination with an alkali metal. In the manufacuture of semiconductors, in particular, contamination with a trace amount of alkali metal ions may sometimes be very detrimental for the performance of the semiconductor produced under the contamination.
Most of the glass vessels or tools used for handling chemicals are made of a glass belonging to the class of so-called soda glass and are rather disadvantageous from the standpoint of contamination by the ingredients leached out of the surface even when they are used after the most careful cleaning treatment by dipping in a chromic acid mixture or in a strong alkali solution for several days to have the surfaces freed from the contaminants.
When the contamination from the vessels or tools must be minimized to an extremely low extent, several kinds of materials with little leaching out of the ingredients, such as borosilicate glass, high-silicate glass and fused quartz glass, are employed or, alternatively, a protective film of a fluorocarbon polymer is provided on the surface of the vessel or tool. These vessels or tools are, however, very expensive and they are not always suitable for industrial uses. Accordingly, it has long been desired to develop a simple and effective means with less expensive materials by which the leaching out of contaminants can be prevented regardless of the materials of the substrate solid surfaces.
SUMMARY OF THE INVENTION
Thus, it is an object of the present invention to provide a novel method for preventing leaching of contaminants from the surface of a solid to cause contamination of the materials in contact with the solid surface.
The present invention has been established on the basis of the discovery as a result of the extensive investigation undertaken by the inventors to solve the above described problem, according to which the exudation or leaching of the contaminants from the surface of any conventional vessels or tools can be effectively prevented by providing an oxidized film of silicon on the surfaces thereof by use of a coating solution as specified below.
The method of the present invention for preventing leaching of contaminants from the surface of a solid comprises
(a) providing a coating layer on the surface of the solid with a coating solution containing a hydroxysilane compound represented by the general formula
R.sub.n Si(OH).sub.4-n (I)
where R is a group selected from the class consisting of hydrocarbon groups, alkoxy groups and acyloxy groups and n is a number of 0, 1, 2 or 3, and
(b) heating the thus coated solid at a temperature not lower than 150° C.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
As is understood from the above description, the hydroxysilane compound as the main ingredient of the coating solution used in the inventive method has at least one silanolic hydroxy group and represented by the above general formula (I). In the general formula (I), the groups denoted by R are each a group selected from the class consisting of hydrocarbon groups, alkoxy groups and acyloxy groups. When two or more of the groups R are present in a molecule, they may not be identical with each other.
The hydrocarbon group suitable as the group R is exemplified by alkyl groups such as methyl, ethyl, propyl and butyl groups, aryl groups such as phenyl group and alkenyl groups such as vinyl and allyl groups.
The alkoxy group suitable as R is exemplified by methoxy, ethoxy, propoxy, butoxy and pentoxy groups, of which the most preferred are methoxy and ethoxy groups. The acyloxy group suitable as R is exemplified by acetoxy and propionyloxy groups, of which acetoxy group is preferred.
In the preferred embodiments of the invention, the groups expressed by R are selected from the class consisting of alkoxy groups, e.g. methoxy and ethoxy groups, and acyloxy groups, e.g. acetoxy group so that the hydroxysilane compound can be represented by the general formula ##STR1## where, preferably, R 1 is a methyl or ethyl group; R 2 is a methyl group and a and b are each zero or a positive integer with the proviso that a+b is not exceeding 3.
The procedure for the preparation of the coating solution used in the inventive method is now described below.
First, for example, 1 mole of an alkoxysilane is admixed with 2 to 5 moles of a carboxylic acid and 2 to 10 moles of an alcohol together with a small amount of a reaction promotor. It is necessary that the amount of the alcohol is at least equimolar to the carboxylic acid. The reaction takes place even at room temperature with temperature elevation by the heat evolved in the exothermic reaction and an ester of the carboxylic acid and a hydroxysilane compound are formed, the latter being the hydrolysis product of the alkoxysilane compound with the water produced in the esterification reaction. It is usual that the starting alkoxysilane disappears within 2 to 5 hours from the start of the reaction and the amount of the carboxylic acid gradually decreases reaching 20% or smaller of the initial amount after 2 to 5 days at room temperature. When the content of the carboxylic acid has decreased to the extent as above, the reaction mixture is suitable as a coating solution since a reaction mixture containing an excessive amount of the carboxylic acid cannot spread evenly over the surface of various substrate materials. Thus the resultant hydroxysilane is a mixture of several types of the compounds represented by the general formula (II) above.
The second method for the preparation of the coating solution is the reaction of an acyloxysilane compound, which is obtained by the reaction of a carboxylic acid and a halogenosilane, with an alcohol to produce a hydroxysilane, in which some of the acyloxy groups in the starting acyloxysilane have been replaced with the alkoxy groups, and an ester of the carboxylic acid. In this case, at least 4 moles of an alcohol is employed per mole of the acyloxysilane which in turn is prepared by the reaction of one mole of a halogenated silane with 4 to 6 moles of the carboxylic acid.
It was noted in carrying out the reaction of an acyloxysilane with an alcohol that the carboxylic acid was first liberated from the acyloxysilane by the ester exchange with the alcohol followed by gradual decrease of the content of the carboxylic acid by the esterification reaction with the remaining portion of the alcohol. When the content of the carboxylic acid has decreased to 20% or less of the theoretical amount calculated on the assumption that 4 moles of the carboxylic acid are liberated from 1 mole of the acyloxysilane, the reaction is complete and the reaction mixture is suitable for use as the desired coating solution. The reaction is complete within about 48 hours at room temperature but may be accelerated by heating.
In the third method for the preparation of the coating solution, an alkoxysilane, water and a monovalent alcohol, e.g. methyl alcohol, ethyl alcohol, propyl alcohol, butyl alcohol and amyl alcohol, are blended together with a small amount of a reaction promotor. The mixing ratios of the water and the alcohol to the alkoxysilane are 2 to 5 moles of water and 3 to 30 moles of the alcohol per mole of the alkoxysilane.
The alkoxysilane compound used in the first and the third methods is exemplified by orthomethylsilicate, methylitriethoxysilane, orthoethylsilicate, ethyltriethoxysilane, orthopropylsilicate, orthobutylsilicate, tetraphenoxysilane, vinyltrimethoxysilane, vinyltriethoxysilane and the like.
The reaction promotors used in the above reactions are exemplified by several inorganic and organic acids such as hydrochloric acid, sulfuric acid, nitric acid, carbonic acid, hydrogen bromide, perchloric acid, phosphoric acid, boric acid, oxalic acid, citric acid, salicylic acid, picric acid, maleic acid, chloroacetic acid and benzenesulfonic acid as well as salts and oxides of several metallic elements such as gold chloride, zinc chloride, aluminum chloride, iron chloride, copper chloride, nickel chloride, chromium chloride, arsenic chloride, antimony chloride, tin chloride, gallium chloride, indium chloride, platinum chloride, titanium tetrachloride, copper sulfate, zinc sulfate, lead nitrate, zinc nitrate, aluminum nitrate, iron nitrate, copper nitrate, nickel nitrate, indium nitrate, boron oxide, phosphorus pentoxide, arsenic trioxide and the like. Preferred reaction promotors are hydrochloric acid, nitric acid, sulfuric acid, phosphoric acid, boric acid and carbonic acid. These reaction promotors are used in an amount of 0.001 to 20% be weight based on the amount of the alkoxysilane or acyloxysilane according to the desired reaction velocity.
The proceeding of the reaction in the reaction mixture formulated as described above can readily to traced by means of gas chromatography, infrared absorption spectroscopy and other suitable methods and the formation of hydroxy-containing silane compounds can be detected. When an equilibrium of the esterification reaction or the transesterification reaction has been established in the reaction mixture, the reaction mixture can be used as a stable coating solution with which various kinds of substrate surfaces are provided with a smooth and uniformly spreading film of the oxidation product of silicon with subsequent heating.
It is of course optional that the reaction mixture is diluted with a suitable organic solvent to have a viscosity or consistency suitable for application to the substrate surfaces and, if necessary, the solution is filtered with a filter having micropores of a diameter of 1 μm or smaller.
The diluent solvent as mentioned above is not limitative in so far as it can dissolve all of the constituents in the reaction mixture and spread uniformly over the surface of the solid substrate to which the solution is applied depending on the kind of the material of the solid and is exemplified by alcohols, ketones, polyvalent alcohols and esters thereof and β-diketones as well as mixtures thereof. Alcohols are exemplified by methyl alcohol, ethyl alcohol, propyl alcohol, butyl alcohol, amyl alcohol and the like, esters are exemplified by methyl acetate, ethyl acetate, propyl acetate, butyl acetate and the like, ketones are exemplified by acetone, methyl ethyl ketone, methyl isobutyl ketone, cyclohexanone and the like, and polyvalent alcohols and esters thereof are exemplified by ethyleneglycol, ethyleneglycol monomethyl ether, ethyleneglycol monoethyl ether, ethyleneglycol diethyl ether, ethyleneglycol monoisopropyl ether, ethyleneglycol monobutyl ether, ethyleneglycol dibutyl ether, propyleneglycol, glycerine and the like. The concentration of the coating solution upon dilution with the organic solvent is usually in the range from 1 to 20% by weight calculated as SiO 2 .
The material of the objective solid articles to be coated with the thus prepared coating solution includes glass, ceramics, mica, metals, e.g. stainless steel, plastics and the like and the shapes of the articles are not limitative including plates, rods, tubes, balls, bottles and any other irregular forms.
The coating procedure with the coating solution is conventional according to the shapes of the objective articles including dipping method, spraying method, pouring method, brushing and the like. The solid article coated with the coating solution is then subjected to air-drying to remove the solvent or solvents by evaporation to leave a coating film of a hydroxy-containing silane compound which is further converted to a film of oxidized silicon by the silanol condensation between the hydroxy groups when kept standing in atmospheric air or further baked at 150° C. or higher.
The baking temperature is preferably as high as possible in so far as the material of the solid substrate can withstand in order to enhance the hardness of the baked film of the oxidized silicon. The length of the baking treatment is also as long as possible but it is usually in the range from 10 to 60 minutes from the standpoint of working efficiency. It is sometimes advisable to admix the coating solution with a vitrification promotor such as phosphorus pentoxide and boron oxide in an amount smaller than 10% by weight of the SiO 2 content in the solution so as that the baking temperature may be decreased. The addition of these vitrifying agents is recommendable only when the presence of such an ingredient is not undesirable.
In practicing the above described method of the invention, the surface of the solid substrate, e.g. inner walls of a vessel, is provided with a continuous coating film having a thickness of 0.1 to 1.0 μm and having no pin-holes composed of high purity oxidized silicon readily and economically so that the exudation or leaching out of contaminants from the solid surface can be effectively prevented giving advantages in various industrial applications.
In the following, the method of the present invention is further illustrated in detail by way of examples.
EXAMPLE 1
Into a mixture composed of 152 g of orthomethylsilicate, 240 g of glacial acetic acid and 240 g of methyl alcohol kept at room temperature was added 10 g of finely pulverized oxalic acid with agitation. The reaction took place exothermically and the temperature of the reaction mixture increased to about 40° C. as the reaction proceeded. The gas chromatographic and infrared absorption spectral analyses indicated the formation of large amounts of methyl acetate and hydroxy-containing silane compounds.
After standing at room temperature for 3 days, the reaction mixture was analyzed for the solid content which was found to be 12.5% by weight as measured by heating at 140° C. for 3 hours. The reaction mixture was diluted by adding isopropyl alcohol to give a solid content of 5.9% weight followed by filtration with a filter having micropores of 0.45 μm diameter to give a coating solution.
The impurity levels of several metallic elements in the coating solution were determined by atomic absorption spectrophotometry to give the results below.
______________________________________Impurityelement Na K Ca Mg Zn Al Fe Cu______________________________________Concentration, 0.01 0.05 0.1 0.1 0.1 0.1 0.1 0.1p.p.m.______________________________________
About 50 ml of the thus prepared coating solution was introduced into a narrow-necked glass bottle of 1,000 ml capacity and whole surface of the inner wall of the bottle was wetted with the solution by tumbling the bottle followed by discharging of the solution and dripping of the excessive solution by keeping the bottle upside down for a while. After spontaneous evaporation of the solvent for about 30 minutes, the bottle was gradually heated up to a temperature of 500° C. where it was kept for 30 minutes followed by gradual cooling to room temperature. The resultant thin film of silicon dioxide formed on the inner walls of the glass bottle had a thickness of about 0.2 μm.
Several of the physical and chemical properties of the above obtained coating film were as follows as determined with a glass plate with the same coating solution simulating the above described coating procedure.
______________________________________Refractive index 1.44Dielectric constant 4.0Thermal expansion coefficient 5 × 10.sup.-7 /°C.Sheet resistance 1 × 10.sup.15 ohm/□Velocity of etching 100 A/second (1 molar HF, 25° C.)______________________________________
Comparisons were made for the leaching velocity of the ingredients in the glass bottle from the surface between the bottles coated with silicon dioxide as described above and uncoated bottles. Thus, each of the bottles, having been subjected to the cleaning treatment by dipping in a 5% hydrochloric acid solution for 2 hours, followed by rinsing with deionized water and drying, was filled with methyl alcohol, acetone or butyl acetate and kept at 25°-27° C. for weeks. Small portions of the solvent were taken periodically and analyzed for the concentration of the sodium ions leached out of the glass surface along with the measurement of the electric conductivity at 25° C. The results are summarized in Table 1 below.
TABLE 1__________________________________________________________________________ After After After After AfterSolvent Glass bottle Initial 3 weeks 6 weeks 9 weeks 12 weeks 15 weeks__________________________________________________________________________MethylConcentration of Uncoated 0.02 0.07 0.08 0.09 0.10 0.4alcoholNa ions, p.p.m. Coated 0.02 0.02 0.02 0.02 0.03Electric conduc- Uncoated 0.6 0.7 0.8 0.9 1.0 2.1tivity, μmho/cm Coated 0.6 0.6 0.6 0.6 0.7AcetoneConcentration of Uncoated 0.03 0.04 0.05 0.07 0.09 0.20Na ions, p.p.m. Coated 0.03 0.03 0.03 0.03 0.03Electric conduc- Uncoated 0.6 0.6 0.6 0.7 0.9 1.3tivity, μmho/cm Coated 0.6 0.6 0.6 0.6 0.6ButylConcentration of Uncoated 0.04 0.06 0.07 0.09 0.14 0.20acetateNa ions, p.p.m. Coated 0.04 0.04 0.04 0.04 0.04Electric conduc- Uncoated 0.4 0.4 0.4 0.5 0.7 1.2tivity, μmho/cm Coated 0.4 0.4 0.4 0.4 0.4__________________________________________________________________________
EXAMPLE 2
Tetraacetoxysilane was prepared by the reaction of 125 g of silicon tetrachloride and 400 g of acetic acid as blended and stirred at room temperature. When the evolution of hydrogen chloride gas had ceased with precipitation of white crystalline tetraacetoxysilane, the unreacted acetic acid was removed by stripping under a reduced pressure and the residue was dissolved in 300 g of ethyl alcohol. The reaction between the tetraacetoxysilane and ethyl alcohol was carried out by heating the above reaction mixture at 60° C. with agitation for 10 hours. The formation of large amounts of ethyl acetate and hydroxy-containing silane compounds was detected in the resultant reaction mixture which had a solid content of 5.9% by weight upon dilution by adding 120 g of ethyl alcohol.
The reaction mixture was further diluted by adding n-butyl alcohol to a solid content of 3.0% and the solution was filtered with a filter having micropores of 0.45 μm diameter to give a coating solution.
A container of 20 liter capacity made of 18-8 stainless steel was coated with the above prepared coating solution on the inner walls by spraying followed by heating treatment at 400° C. for 60 minutes.
The thus coated container was filled with a 5% hydrochloric acid and kept standing at room temperature for 10 days and the hydrochloric acid was analyzed for the concentration of metallic elements to give a result that no noticeable amounts of nickel, chromium and iron were dissolved out of the container.
EXAMPLE 3
Into a mixture composed of 209 g of orthoethylsilicate, 54 g of water and 572 g of ethyl alcohol was added 0.5 g of 35% hydrochloric acid with agitation. The reaction took place and proceeded with evolution of heat. The analysis undertaken with the reaction mixture after standing a room temperature for 3 days indicated formation of large amounts of hydroxy-containing silane compounds.
The reaction mixture containing 9.0% by weight of solid as measured by heating at 140° C. for 3 hours was diluted by adding acetone to a solid content of 8.0% by weight followed by filtration with a filter having micropores of 0.45 μm diameter to give a coating solution.
A glass plate having dimensions of 80 mm×120 mm×0.7 mm was dipped in the thus prepared coating solution and then pulled up at a velocity of 30 cm per minute to be coated with the solution and the coated glass plate was subjected to drying at 100° C. for 15 minutes and then baking at 500° C. for 60 minutes to form a coating film of oxidized silicon having a thickness of 0.15 μm.
Leaching test of sodium ions was undertaken with the thus coated glass plate and a similar glass plate before coating by dipping them separately for 10 minutes in 900 ml of diluted hydrochloric acid of 10% concentration at 60° C. in a beaker of fused quartz glass after washing with 5% hydrochloric acid for 5 minutes.
The concentration of sodium ions in the hydrochloric acid after leaching was determined by atomic absorption spectrophotometry taking the starting hydrochloric acid as the reference to give a result that the concentration or rather the increment of the concentration of sodium ions in the acid in which the coated glass plate was dipped was 0.01 p.p.m. while the value for the uncoated glass plate was 0.34 p.p.m.
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An efficient method is proposed for preventing leaching of contaminants from the surface of a solid, such as sodium ions from the surface of soda glass or nickel, chromium or iron from the surface of stainless steel in order to minimize detrimental contamination of highly pure substances in contact with the solid surface.
The effect is basically obtained by providing a coating film of oxidized silicon on to the solid surface and the coating film is formed by applying a coating solution containing a hydroxysilane compound to the surface followed by baking of the coating layer at a temperature not lower than 150° C., the coating solution being prepared by the equilibration reaction of an alkoxysilane with a carboxylic acid and an alcohol, of an acyloxysilane with an alcohol, or of an alkoxysilane with water in an alcohol where the molar ratios of the individual reactants are in the specified ranges.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This Application is a Continuation-In-Part and claims priority to U.S. Provisional Application No. 62/077,522, entitled “Modular Boat Lift Cover,” filed on Nov. 10, 2014; and U.S. patent application Ser. No. 14/636,409 entitled “Modular Boat Lift Cover,” filed on Mar. 3, 2015.
FIELD OF USE
[0002] The present invention relates to a modular boat lift cover system which is designed for ease of shipping and assembly as well as adjustability as the lift owner changes or modifies their boat. The modular boat lift cover being unique in that it can accommodate all boat lifts that are square, such as lake lifts, as well as tidal lifts which, due to their nature of construction, are seldom square.
BACKGROUND OF THE INVENTION
[0003] A watercraft represents a significant investment. Watercraft owners' who store their boats on lifts understand that a boat lift cover or canopy is needed to minimize the maintenance work required to maintain the appearance of the boat. Watercraft owners need to shelter docked boats from the elements to preserve the life of the boat. While boat houses can provide such shelter, they are expensive, often impractical and, under some circumstances, not allowed by code. Watercraft owners also need to lift their watercraft out of the water for storage and maintenance, and to lower their watercraft into the water for launching or flotation at dock. There are typically two types of boat lifts: lake lifts and tidal lifts. A lake lift is typically manufactured as a complete frame system that is lowered into the water as a single unit and fastened to the lake floor. It remains square due to the calmness of inland water. Tidal lifts are typically constructed on site with a barge pounding long pilings into the sea floor onto which the boat lift mechanism is then mounted. This construction technique is subject to tidal forces during the time that the pilings are being hammered into the sea floor, which can cause the lift to be not perfectly square. Additionally, each boat lift manufacturer has its own design for the lifting I-beam, the cable system and the position of the electric motors making it difficult to design, manufacture and install a boat lift cover for tidal lifts.
[0004] Prior approaches use many different parts, while shipping in multiple boxes, or one large box. They also require complex assembly procedures and are not adjustable depending on the size of the watercraft.
U.S. Pat. No. 5,185,972 (Markiewicz) discloses an all-purpose modular canopy system including a canopy frame formed of a plurality of interconnected sections, the sections being formed of welded tubular elements. The sections are modular in configuration including end and central portions whereby the sections may be selectively assembled to produce the desired length. The canopy frame includes transversely disposed brace elements associated with supporting columns and adjustable fittings to facilitate alignment of the columns and canopy frame, and the canopy frame is covered by a flexible covering using a lacing system between the frame and covering to maintain covering tension. The covering may include a skirt cooperating with skirt stabilizers formed in the canopy frame corners for maintaining the skirt properly oriented. U.S. Publication No. 20050252542 (Basta) discloses a boat lift canopy comprises a truss type framework with a base frame. Joined to the base frame and circumscribed by it is a tie tube frame, which may be discontinuous. A fabric cover, which in preferred embodiments is decorative as well as functional, snugly encloses the outside of the framework, wraps around the base frame and is secured to the tie tube frame. U.S. Pat. No. 5,573,026 (Griffith) discloses a pre-fabricated boat lift canopy constructed of galvanized steel or aluminum tubing. All joints are crimped to a tight, permanent fit by using a special rolling tool. The canopy frame is mounted on “I” beams of existing boat lifts, docks, or pilings. The canopy frame is then covered with a water tight and sunlight resistant decorative canopy. Wind spoilers, in the form of canvas strips, are fastened to the peak of the canopy, a continuous strip, horizontally across the top, a strip at each end, and a third strip at the center. U.S. Pat. No. 6,846,129 (Edson) discloses a boatlift assembly having a boat cradle portion and a canopy portion. The canopy portion and boat cradle portion are movably coupled to cause the canopy portion to be automatically raised when the boat cradle is lowered and to be automatically lowered when the boat cradle is raised. U.S. Pat. No. 8,602,043 (Kaiser) discloses a wakeboard tower canopy which enables wakeboard boats which contain wakeboard towers of various height that protrude above the gunwale, sheer, and/or windshield of the wakeboard boat to gain protection against the elements. By constructing a special frame that incorporates a drive-through curtain system and also a peak in the canopy structure itself, the wakeboard boat being enabled to pull into the normal lift with enough clearance for the tower from the canopy frame. The packaging of boat lift covers and canopies currently being marketed is overly-complicated and costly, and assembly is difficult to explain even with instructions. In order to communicate the intricacies of assembly and disassembly, personal demonstrations are often required. In some cases, multiple training sessions are needed. If the complicated unpacking was not difficult enough, the procedure for layout and assembly of the frame is oftentimes even more complex. In addition to the difficulty of assembly, current boat lift covers cannot be easily adjusted if the lift owner modifies his boat, such as by adding a tower, or replaces his boat with, for example, a larger boat. Current boat lift cover designs have some degree of adjustability but are not adjustable enough to easily accommodate all boat lift mechanisms and the dimensional tolerance variations of tidal lifts.
[0012] In addition, a further limitation of the prior art boat lift canopies, in general, is that they are not designed to maximize the structural inherent in truss type framework structures. Long unsupported overhangs, which are becoming increasingly popular, require that newer canopy configurations require considerable structural strength.
[0013] There is a need for a modular boat lift cover system that is easier to manufacture, package, assemble and disassemble. There is a need for a modular boat lift cover system that has a robust, lightweight design that is compatible and adjustable for width, height and length as the boat owner modifies his existing boat or purchases a new boat of different dimensions, and that will protect the watercraft from the elements and is designed to withstand even the severest of storms, undamaged. There is also a need for an adjustable boat lift cover that will work with any manufacturer's boat lift and will accommodate the variation in build tolerances of tidal lifts.
[0014] The is the primary object of boat lift cover of the present invention is to provide a modular boat lift cover that is comparatively simple to attach around the watercraft both in and outside the water and wherein attachment is possible and ensured that the boat lift cover will withstand even the severest of storms undamaged. It is an object of the present invention to provide a compact, all-weather, temporary shelter designed for both personnel and equipment. It is another object of the present invention to provide a modular boat lift cover that is easy to pack and assemble. All of the straight components are packaged into the main box frame channel for simplicity in packaging as well as quality control, ensuring no components are missing during packaging and shipping. It is yet another object of the present invention to provide a modular boat lift cover that is easy for the user to assemble and adjust, is intuitive and requires little training to adjust the canopy to different widths, lengths and heights both upon initial installation as well as during the life of the lift cover, enabling for the lift owner to accommodate modifications to his existing boat as well as to accommodate new boats of different dimensions. And, it is still yet another object of the present invention to provide a modular boat lift cover that is easy for the user to assemble and adjust, being compatible with square lake style boat lifts, as well as the typically non-square tidal lifts.
SUMMARY OF THE INVENTION
[0015] The modular boat lift cover of the present invention addresses these needs.
[0016] As used herein, a cantilever is a rigid structural element, such as a beam or a plate, anchored at only one end to a (usually vertical) support from which said cantilever is protruding. Cantilever construction enables overhanging structures without external bracing. Cantilever construction is in contrast to constructions supported at both ends with loads applied between the supports. When subjected to a structural load, the cantilever carries the load to the support where it is forced against by a moment and shear stress.
[0017] The modular boat lift cover of the present invention comprises a gable assembly of straight tubes, a canopy, a cantilever, and an adjustable support structure to accommodate the height of various watercraft.
[0018] The gable assembly includes a plurality of peak fittings, a plurality of box frame support members, a plurality of pipe fittings disposed on the box frame support members, and a plurality of tubes, which may be arcuate or straight, securely attaching the peak fittings to the box frame support members enabling for either a straight or curved roof design as well as no overhang or various lengths of overhang, depending on the customer's preference.
[0019] The modular boat lift cover of the present invention is preferably supported by a pair of cantilevers mounted on each by a bracket and secured to a box frame support member, said upper bracket being needed to support the gable assembly, which supports the canopy. It will be noted that the pair of cantilevers secured to each box frame support member are needed to support the modular boat lift cover of the present invention. The cantilevers in combination with the box frame channels have sufficient bulk to store the gable components during transport will protect the watercraft from the elements and withstand even the severest of storms, undamaged. The pair of cantilevers are secured to each box frame with an upper bracket and the pair of cantilevers are secured to the deck assembly with a variable centered bracket. The plurality of peak fittings are positioned on the gable assembly, the peak fittings being connected by at least one peak fitting connector tube.
[0020] The plurality of peak fittings are positioned between the box frames and a peak fitting connector tube of the gable assembly, the peak fitting connector tube being connected by at least one end peak fitting.
[0021] The plurality of box frame support members are preferably two parallel members, although other configurations are also envisioned. Preferably, the plurality of box support members is essentially parallel to the peak fitting connector tube. The peak fittings, the peak fitting connector tube, and additional connectors and fasteners can be stored inside the plurality of box frame support members during shipping. The box frame support members, including but not limited to standard square, rectangular, rhomboidal, trapezoidal, or other polygonal-shaped cross sectional shaped tubing, with either pointed or rounded edges, to round or oval cross sectional shaped tubing, being either regular or irregular in shape, the box frame support members having sufficient bulk to store members of the gable assembly during storage or transport.
[0022] The plurality of tubes are used as needed to attach the peak fittings to the box frame and to lay a foundation for the canopy. The plurality of tubes securely attach the peak fitting connectors to the box frame support members by engaging with the plurality of pipe fittings.
[0023] The canopy covers the gable assembly protecting the watercraft from the sun, rain and storms, the canopy being securely affixed to the gable assembly.
[0024] An adjustable support structure enables elevation and lowering of portions of the gable assembly of the modular boat lift cover of the present invention. The support structure is compatible with a wide variety of modular boat lift covers.
[0025] The gable assembly is supported upon the adjustable support structure which includes a plurality of beam brackets and a plurality of support columns, each support column being disposed within a beam bracket. The adjustable support structure provides a vertical adjustment for portions or all of the gable assembly. The gable assembly is cantilevered out from the support structure depending upon necessary clearance requirements for a particular length watercraft as well as depending upon the configuration of the main piles for the dock.
[0026] All of the length, width and height assemble points are designed to have a wide range of adjustment. This wide range of adjustment is what enables the modular boat lift cover of the present invention to accommodate boat lifts from any manufacturer as well as accommodating square lake lifts and out-of-square tidal lifts. In addition, the range of adjustment enables for easy configuration for different sizes of watercraft.
[0027] The modular boat lift cover of the present invention combines the advantages is a portable structure which in its collapsed state forms a standard shipping container for ease of transport.
[0028] The box frames of the modular boat lift cover of the present invention serves as shipping containers and modular building blocks for expanding the modular boat lift cover of the present invention to adapt to a completely different watercraft purchased by the owner.
[0029] For a complete understanding of the modular boat lift cover of the present invention, reference is made to the accompanying drawings and description in which the presently preferred embodiments of the invention are shown by way of example. As the invention may be embodied in many forms without departing from spirit of essential characteristics thereof, it is expressly understood that the drawings are for purposes of illustration and description only, and are not intended as a definition of the limits of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] FIG. 1 depicts a first preferred embodiment of an assembly side view of the modular boat lift cover of the present invention, including the gable assembly, the support structure, and the cantilever attachment to the piling.
[0031] FIG. 2A depicts an assembly end view of the preferred embodiment of a gable assembly for the modular boat lift cover of the present invention of FIG. 1 .
[0032] FIG. 2B depicts a preferred embodiment of an end view of the gable assembly of FIG. 1 mounted on a pair of support columns and beam brackets.
[0033] FIG. 2C depicts a preferred embodiment of an end view of the gable assembly of FIG. 1 mounted on a pair of upper brackets, centered brackets and variable centered brackets.
[0034] FIG. 2D depicts an exploded view of a preferred embodiment of an end view of the gable assembly of FIG. 1 attached to a pair of support columns with U-bolts, and a pair of beam brackets secured to I-beams with beam clamps.
[0035] FIG. 3 depicts an assembly side view of a second preferred embodiment the modular boat lift cover of the present invention, the tube members being curved under stress, including the gable assembly, the support structure, and the cantilever attachment to the piling.
[0036] FIG. 4A depicts an assembly end view of a gable assembly for the modular boat lift cover of FIG. 3 .
[0037] FIG. 4B depicts a preferred embodiment of an end view of the curved gable assembly of FIG. 4A mounted on a pair of support columns and beam brackets.
[0038] FIG. 4C depicts a preferred embodiment of an end view of the curved gable assembly of FIG. 4A mounted on a pair of upper brackets, centered brackets and variable centered brackets.
[0039] FIG. 4D depicts a preferred embodiment of an end view of the curved gable assembly of FIG. 4A attached to a pair of support columns with U-bolts, and a pair of beam brackets secured to I-beams with beam clamps.
[0040] FIG. 5A depicts a preferred embodiment of the front view of the end peak fitting for the modular boat lift cover of FIGS. 1 and 3 .
[0041] FIG. 5B depicts a preferred embodiment of the front view of the internal peak fitting for the modular boat lift cover of FIGS. 1 and 3 .
[0042] FIG. 5C depicts a preferred embodiment of the side view of the end peak fitting of FIG. 5A .
[0043] FIG. 5D depicts a preferred embodiment of the side view of the internal peak fitting of FIG. 5B .
[0044] FIG. 5E depicts a preferred embodiment of the top view of the end overhang fitting for the modular boat lift cover of FIG. 3 .
[0045] FIG. 5F depicts a preferred embodiment of the top view of the internal overhang fitting for the modular boat lift cover of FIG. 3 .
[0046] FIG. 6A depicts a preferred embodiment of a side view of the box frame of for the modular boat lift cover of FIG. 1 .
[0047] FIG. 6B depicts a preferred embodiment of a simplified end view of the box frame engagement with a pipe fitting of the gable assembly of the modular boat lift of FIGS. 2A, 2B and 2C .
[0048] FIG. 6C depicts a preferred embodiment of a typical exploded front view of the box frame engagement with a pipe fitting of the gable assembly of the modular boat lift cover of FIGS. 2A, 2B and 2C .
[0049] FIG. 6D depicts an isometric view of a preferred embodiment of the box frame splice assembly of the modular boat lift cover of FIG. 1 .
[0050] FIG. 7A depicts a preferred embodiment of a simplified top view of a beam bracket of the modular boat lift cover of FIGS. 1 and 3 .
[0051] FIG. 7B depicts a preferred embodiment of a simplified side view of a beam bracket of the modular boat lift cover of FIGS. 1 and 3 .
[0052] FIG. 7C depicts a preferred embodiment of a simplified front view of a beam bracket of the modular boat lift cover of FIGS. 1 and 3 .
[0053] FIG. 8A depicts a preferred embodiment of a simplified top view of a support column of the modular boat lift cover of FIGS. 1 and 3 .
[0054] FIG. 8B depicts a preferred embodiment of a simplified side view of a support column of the modular boat lift cover of FIGS. 1 and 3 .
[0055] FIG. 8C depicts a preferred embodiment of a simplified front view of a support column of the modular boat lift cover of FIGS. 1 and 3 .
[0056] FIG. 9A depicts a preferred embodiment of the end view of the upper bracket for the centered bracket of FIG. 1 .
[0057] FIG. 9B depicts a preferred embodiment of the side view of the upper bracket for the centered bracket of FIG. 1 .
[0058] FIG. 9C depicts a preferred embodiment of the front view of the upper bracket for the centered bracket of FIG. 1 .
[0059] FIG. 10A depicts a preferred embodiment of the end view of the variable centered bracket for the centered bracket of FIG. 1 .
[0060] FIG. 10B depicts a preferred embodiment of the side view of the variable centered bracket for the centered bracket of FIG. 1 .
[0061] FIG. 10C depicts a preferred embodiment of the front view of the variable centered bracket for the centered bracket of FIG. 1 .
[0062] FIG. 11 depicts a plurality of tubes packaged inside a box frame of the gable assembly for the modular boat lift covers of FIGS. 1 and 3 .
[0063] FIG. 12 depicts an isometric view of a preferred embodiment of the box frame end cap and box frame of the modular boat lift covers of FIGS. 1 and 3 .
[0064] FIG. 13A depicts one preferred embodiment for attaching the canopy to the box frame of the boat lift cover of FIGS. 1 and 2A .
[0065] FIG. 13B depicts one preferred embodiment for attaching the canopy to the box frame of the boat lift cover of FIGS. 3 and 4A .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0066] Referring now to the drawings, FIG. 1 depicts a preferred embodiment of an assembly side view of the modular boat lift cover of the present invention [ 10 A]. The modular boat lift cover of the present invention [ 10 A] comprises a gable assembly [ 13 ], a canopy [ 16 ], and an adjustable support structure [ 20 ] for a watercraft.
[0067] The gable assembly [ 13 ] includes a plurality of end peak fittings [ 14 ] and internal peak fittings [ 15 ], as further depicted in FIGS. 5A, 5B, 5C, 5D , a plurality of box frame support members [ 30 ], and a plurality of tubes [ 18 ] securely attaching the end peak fittings [ 14 ] and the internal peak fittings [ 15 ] to the box frame support members [ 30 ]. The box frame support members [ 30 ] are preferably horizontally mounted in the gable assembly [ 13 ] and cantilevered out from the piling [ 50 ] upon which the beam brackets [ 25 ] are attached if necessary for applications in which the piling [ 50 ] is not arrayed as desired for a given size boat or watercraft. In the cantilevered application, the cantilever [ 32 ] is not needed, or can be moved if required. The second box frame support members [ 30 ] are preferably horizontally disposed within said gable assembly [ 13 ].
[0068] As depicted in FIG. 2 , the modular boat lift cover of the present invention [ 10 A] is preferably supported by a pair of cantilevers [ 32 ] mounted on each by a bracket [ 33 ] and secured to a box frame support member [ 30 ], said upper bracket being needed to support the gable assembly [ 13 ], which supports the canopy. It will be noted that the pair of cantilevers secured to each box frame support member are needed to support the modular boat lift cover of the present invention [ 10 A]. The cantilevers [ 32 ] in combination with the box frame channels [ 30 ] have sufficient bulk to store the gable components during transport will protect the watercraft from the elements and withstand even the severest of storms, undamaged. The pair of cantilevers [ 32 ] are secured to each box frame [ 30 ] with an upper bracket [ 33 ] (see FIGS. 9A, 9B and 9C ) and the pair of cantilevers [ 32 ] are secured to the deck assembly [ 12 ] with a variable centered bracket [ 34 ] (see FIGS. 10A, 10B and 10C ). The plurality of peak fittings [ 14 and 15 ] are positioned on the gable assembly [ 13 ], the peak fittings being connected by at least one peak fitting connector tube [ 17 ].
[0069] In cantilevered applications, the beam is affixed on one end with the other end protruding outwardly. This type of construction is commonly found as an architectural feature in buildings as well as being commonly used in bridge applications. When subjected to a load, the load is transferred down the beam to the point where beam is supported during the moment of force and shear stress. This type of construction enables no external bracing in overhanging structures.
[0070] Cantilevers are good for use in applications for wide spans while not requiring a large number of support members. For example, by using the cantilever design in bride construction, a bridge may span a wide area with a minimum number of supports needed as well as enabling the supports to be further apart, saving in construction costs, as well as easing the construction of the span. In the present application, cantilevering the box frame support members [ 30 ] enables for the boat lift cover of the present invention to be used in applications where there piles [ 50 ] are not spaced properly to enable for the boat lift cover of the present invention [ 10 A and 10 B] to be correctly mounted so as to cover the given boat or water craft. Also, if there is an instance of not having enough piles [ 50 ] necessary for the primary embodiment, the box frame support members may be cantilevered instead. This will also have the effect of enabling for a greater number of lengths of boat to be stored in boat slips which may be meant for shorter craft.
[0071] During construction, the boat lift cover of the present invention [ 10 A and 10 B] can be temporarily cantilevered until assembly is completely. Frequently, during constructions projects, the cantilever is used temporarily, such as when a bridge span is being constructed between supports.
[0072] In other applications, the cantilever is deployed for overhangs, such as in buildings in which the floors are cantilevered so as to provide space for pedestrians to walk at the street level, as well as having the added benefit of providing protection from rain and sun.
[0073] The plurality of box frame support members [ 30 ] are preferably two parallel members, although other configurations are also envisioned. Preferably, the box frame support members [ 30 ] are essentially parallel to the peak fitting connector tube [ 17 ]. The peak fittings [ 14 and 15 ], the peak fitting connector tube [ 17 ], tubes [ 18 ], and additional connectors and fasteners (not shown) can be stored inside the plurality of box frame support members [ 30 ] prior to assembly and during shipping. The box frame support members [ 30 ] can be of any shape, i.e. round, oval, hexagonal, triangular or of any shape which is required for a given application as required. The tubing [ 18 ] can be straight or pre-curved, with even the pre-curved tubing [ 18 ] being storable in the box tubing [ 30 ]. The tubes [ 18 ] may be pre-curved, or straight, while still fitting into the box frame support members [ 30 ] for storage and/or transport.
[0074] Tubes [ 18 ] are used as needed to attach the peak fitting connector tube [ 17 ] to the box frame support members [ 30 ] and to lay a foundation for the canopy [ 16 ]. The tubes [ 18 ] securely attach the peak fittings [ 14 and 15 ] and the peak fitting connector tube [ 17 ] to the box frame support members [ 30 ].
[0075] The canopy [ 16 ] covers the gable assembly [ 13 ] protecting the watercraft from the sun and rain. The canopy [ 16 ] is securely affixed to the gable assembly [ 13 ]. The canopy [ 16 ] can be of any fabric type material which has sufficient wind- and ultraviolet—(UV) resistant properties, with the preferred embodiment being vinyl for its durability and ease of maintenance.
[0076] The adjustable support structure [ 20 ] enables elevation and lowering of portions of the gable assembly [ 13 ] of the modular boat lift cover of the present invention [ 10 A]. The adjustable support structure [ 20 ] is compatible with a wide variety of modular boat lift covers, and can be mounted on any type of boat lift.
[0077] FIG. 2A depicts an assembly end view of a preferred embodiment of a gable assembly [ 13 ] for the modular boat lift cover of the present invention [ 10 A]. FIG. 2B depicts a preferred embodiment of an end view of the gable assembly [ 13 ] of FIG. 2A mounted on an adjustable support structure [ 20 ]. The gable assembly [ 13 ] is supported upon the adjustable support structure [ 20 ] which includes a plurality of beam brackets [ 25 ] and a plurality of support columns [ 28 ], each support column [ 28 ] being disposed within a beam bracket [ 25 ]. The adjustable support structure [ 20 ] provides a vertical adjustment for portions or all of the gable assembly [ 13 ]. The adjustable support structure [ 20 ] enables the bow section of the gable assembly [ 13 ] to be raised or lowered, the stern section of the gable assembly [ 13 ] to be raised or lowered, or their combination to be raised or lowered. Similarly, the port and starboard sections of the gable assembly [ 13 ] can be raised or lowered. The preferred angle between the tubes [ 18 ] of the gable assembly [ 13 ] is 150°.
[0078] FIG. 2C depicts a preferred embodiment of an end view of the gable assembly [ 13 ] of FIG. 2A mounted on a pair of cantilevers [ 32 ] and variable centered brackets [ 34 ]. The cantilevers [ 32 ] are secured to the box frame support members [ 30 ] by a pair of upper brackets [ 33 ].
[0079] FIG. 2D depicts an exploded view of a preferred embodiment of an end view of the gable assembly [ 13 ] and adjustable support structure [ 20 ] of FIG. 2B . Tubes [ 18 ] are inserted into the end peak fitting [ 14 ] and pipe fittings [ 37 ], which are in turn attached to the box frame support members [ 30 ]. The box frame support members [ 30 ] are fastened to the support columns [ 28 ] with U-bolts [ 45 ]. Each support column [ 28 ] is disposed within a beam bracket [ 25 ] and held in place with a clevis pin [ 29 ]. The clevis pin [ 29 ] can be removed to enable vertical adjustment of the support column [ 28 ] within the beam bracket [ 25 ]. The beam brackets [ 25 ] are in turn fastened to I-beams [ 44 ] of the deck assembly [ 12 ] using bolts [ 41 ] and beam clamps [ 42 ].
[0080] FIG. 3 depicts a preferred embodiment of an assembly side view of a curved gable assembly [ 70 ] of the modular boat lift cover of the present invention [ 10 B].
[0081] The curved gable assembly [ 70 ] includes a plurality of end peak fittings [ 14 ] and internal peak fittings [ 15 ], as further depicted in FIGS. 5A, 5B, 5C, 5D , a plurality of box frame support members [ 30 ], and a plurality of bowed tubes [ 62 ] that are initially linear in shape but become bowed under stress are securely attaching the end peak fittings [ 14 ] and the internal peak fittings [ 15 ] to the box frame support members [ 30 ].
[0082] The plurality of peak fittings [ 14 and 15 ] are positioned on the curved gable assembly [ 70 ], the peak fittings being connected by at least one peak fitting connector tube [ 17 ].
[0083] The plurality of box frame support members [ 30 ] are preferably two parallel members, although other configurations are also envisioned. Preferably, the box frame support members [ 30 ] are essentially parallel to the peak fitting connector tube [ 17 ]. The peak fittings [ 14 and 15 ], the peak fitting connector tube [ 17 ], bowed tubes [ 62 ], and additional connectors and fasteners (not shown) can be stored inside the plurality of box frame support members [ 30 ] during shipping.
[0084] The bowed tubes [ 62 ] are used as needed to attach the peak fitting connector tube [ 17 ] to the box frame support members [ 30 ] and to lay a foundation for the canopy [ 16 ]. The bowed tubes [ 62 ] securely attach the peak fittings [ 14 and 15 ] and the peak fitting connector tube [ 17 ] to the box frame support members [ 30 ] using pipes [ 60 ] attached to the box frame support members [ 30 ].
[0085] An advantage of the curved gable assembly [ 70 ] is that it enables the creation of a canopy overhang on either side of the modular boat lift cover of the present invention [ 10 B]. This enables additional protection of the watercraft from sun and rain and provides additional support during storms and high winds.
[0086] The canopy overhang comprises a canopy anchor support bar [ 58 ] which is preferably parallel to the box frame support members [ 30 ] and the peak fitting connector tube [ 17 ]. The canopy anchor support bar is connected to the box frame support member [ 30 ] using a plurality of end canopy overhang fittings [ 55 ] and internal canopy overhang fittings [ 56 ], which are further depicted in FIGS. 5E and 5F .
[0087] The canopy overhang can be adjusted to suit the user's needs. For example, if the modular boat lift cover of the present invention [ 10 A and 10 B] is installed in an east-west orientation, there will be more exposure to the sun throughout the day on the southern side of the watercraft. The canopy overhang can be installed such that the side facing south is longer, thus providing more protection from the sun.
[0088] FIGS. 4A, 4B and 4C depict an assembly end view of a preferred embodiment of a curved gable assembly [ 70 ] for the modular boat lift cover of the present invention [ 10 B], similar to FIGS. 2A, 2B and 2C , with the bowed tubes [ 62 ].
[0089] FIG. 4D depicts an exploded view of a preferred embodiment of an end view of the curved gable assembly [ 70 ] and adjustable support structure [ 20 ] of FIG. 4B . The tubes [ 62 ] are inserted into the end peak fitting [ 14 ] and pipes [ 60 ], which are in turn attached to the box frame support members [ 30 ]. The box frame support members [ 30 ] are fastened to the support columns [ 28 ] with U-bolts [ 45 ]. Each support column [ 28 ] is disposed within a beam bracket [ 25 ] and held in place with a clevis pin [ 29 ]. The clevis pin [ 29 ] can be removed to enable vertical adjustment of the support column [ 28 ] within the beam bracket [ 25 ]. The beam brackets [ 25 ] are in turn fastened to I-beams [ 44 ] of the deck assembly [ 12 ] using bolts [ 41 ] and beam clamps [ 42 ].
[0090] FIG. 6A depicts the box frame support member [ 30 ] as well as pipe fittings [ 37 ] and the upper bracket [ 33 ]. FIG. 6B depicts an end view of the box frame support member [ 30 ] with the attached pipe fitting [ 37 ] and tube [ 18 ], which forms part of the gable assembly [ 13 ]. FIG. 6C depicts a side view of the box frame support member [ 30 ] with the attached pipe fitting [ 37 ]. FIG. 6D depicts an isometric view of two box frame support members [ 30 ] and a splice reinforcement [ 52 ], which is used for connecting the box frame support members [ 30 ] and strengthening the connection juncture. This enables the user to vary the length of the modular boat lift cover of the present invention [ 10 A or 10 B]. For smaller watercraft, the box frames [ 30 ] will not need to be spliced together in the gable assemblies, but rather a single box frame [ 30 ] on each side of the gable assemble will suffice. Only for larger watercraft, will multiple modular gable assemblies be needed, and the splice reinforcements [ 52 ] are needed to strengthen these junctures.
[0091] The preferred embodiment of the beam bracket [ 25 ] of the modular boat lift cover of the present invention [ 10 A or 10 B] is depicted in FIGS. 7A, 7B, and 7C . Holes [ 27 ] for the insertion of a clevis pin [ 29 ] are shown. The bottom plate is adjustable as after said bottom plate is secured to the beam bracket [ 25 ] excess may be cut off after mounting. The beam bracket [ 25 ] can be rotated 180°, on one side or both sides of the lift cover to enable for boat accessories such as outriggers or just to give additional protection from sunlight and rain.
[0092] In one preferred embodiment, the modular boat lift cover of the present invention [ 10 A and 10 B] features a top drive shaft used to raise and lower the boat. Box risers (not shown) may be used to provide raised attachment points for the beam brackets [ 25 ]. A box lift riser is attached to the boat lift frame on both sides of the drive shaft along the longitudinal axis. This enables normal functioning of the drive shaft with no interference from the beam brackets [ 25 ].
[0093] The preferred embodiment of the support column [ 28 ] is depicted in FIGS. 8A, 8B , and 8 C. The support column [ 28 ] is a bit smaller than the beam bracket [ 25 ] and fits inside the beam bracket [ 25 ]. A clevis pin [ 29 ] as shown in FIGS. 2D and 4D enables the relative height of the support column relative to the beam bracket [ 25 ] to be adjusted. Holes for the insertion of a clevis pin [ 29 ] are shown.
[0094] FIG. 11 depicts a plurality of tubes [ 18 ] packaged inside a box frame support member [ 30 ] of the gable assembly [ 13 ] for the modular boat lift cover of the present invention [ 10 A and 10 B]. This packaging method enables for ease of shipping, and ensures no parts are missing.
[0095] FIG. 12 depicts an isometric view of a preferred embodiment of the box frame end cap [ 49 ] and box frame support member [ 30 ] of the modular boat lift cover of the present invention [ 10 A and 10 B]. The box frame end cap [ 49 ] fits securely into one or both ends of a box frame support member [ 30 ] sealing said assembly. During shipping, the end caps [ 49 ] prevent the components stored therein from falling out. Once the modular boat lift cover of the present invention [ 10 A and 10 B] is installed by the user, the box frame end caps [ 49 ] seal the gable assembly and prevent debris and other material from entering the channel of the box frame support member or their combination [ 30 ].
[0096] FIG. 13A depicts one preferred embodiment for attaching the canopy [ 16 ] to the gable assembly [ 13 ] of the modular boat lift cover of the present invention [ 10 A and 10 B]. Knobs [ 47 ] and elastic cords [ 48 ] are used to secure the canopy [ 16 ] in place. In a second preferred embodiment of the modular boat lift cover of the present invention, the canopy [ 16 ] is sold separately and is not included in the assembly.
[0097] The cantilever cover [ 16 ] is deployed in the modular boat lift cover of the present invention [ 10 A and 10 B] for use in covering and protecting a boat moored at a dock or slip, as the cover support and actuating mechanism may be secured to the side of the dock to extend over the boat to the open water side of the slip. It will also be seen that the cantilever cover may be used in other environments, e.g., as a patio cover, carport cover, etc., without a supporting structure opposite the laterally disposed actuating mechanism.
[0098] FIG. 13B depicts another view of a preferred embodiment for attaching the canopy [ 16 ] to the curved gable assembly [ 70 ] of the modular boat lift cover of the present invention. The canopy [ 16 ] is stretched over the curved tubes [ 62 ] which are inserted into the pipes [ 60 ]. The pipes [ 60 ] are attached to the box frame support member [ 30 ]. Knobs [ 47 ] and elastic cords [ 48 ] are used to secure the canopy [ 16 ] in place. The elastic cords [ 48 ] are attached to the canopy anchor support bar [ 58 ].
[0099] The modular boat lift cover of the present invention [ 10 A and 10 B] will be used on any boat lift and will replace the complicated current manufacturing process, complicated design, costly training of the sales force and installation teams, and will be stronger and last longer for the customer. This new design is a boat lift cover or canopy that is adjustable for width, height, length and placement on almost any boat lift.
[0100] The modular boat lift cover of the present invention [ 10 A and 10 B], preferably includes two 3 inch×6 inch aluminum box frame support members [ 30 ] with stainless steel connection bolts covered with a unique vinyl cover. The box frame support members [ 30 ], including but not limited to standard square, rectangular, rhomboidal, trapezoidal, or other polygonal-shaped cross sectional shaped tubing, with either pointed or rounded edges, to round or oval cross sectional shaped tubing, being either regular or irregular in shape, the box frame support members having sufficient bulk to store members of the gable assembly during storage or transport. This design has many fewer parts than current designs and will establish a new standard of strength and flexible and scalable design at a much lower cost. Significant cost savings will also be achieved with the tubes [ 18 ] fitting into the 3 inch×6 inch box frame support members [ 30 ]. In addition, customers will see a significant reduction in installation and service costs. This is only possible because of the simplicity in design and packaging. Also, there is a box frame end cap [ 49 ] which is included which covers the open end of the box frame support members [ 30 ] in order to prevent birds and other animals from taking up residence in the box frame support members [ 30 ].
[0101] Some of the many novel features of the modular boat lift cover of the present invention [ 10 A and 10 B] include that the modular boat lift cover [ 10 A and 10 B] is compatible with and will mount or fit on almost any boat lift, it is adjustable for the width, height and length of most any watercraft. Also, the tubes [ 18 ] and multiple gable components will fit into the box frame support members [ 30 ] for high density packaging, protecting the gable assembly [ 13 ] components, insuring that the kit is complete (no parts are missing), ease of assembly and significant cost savings both in the manufacturing process as well as the installation process. The modular boat lift cover of the present invention [ 10 A and 10 B] is also designed to survive wind speeds of greater than 150 miles per hour, or those found in a Category 5 hurricane. However, the vinyl cover must be and is easily removable by the modular boat lift cover of the present invention [ 10 A and 10 B] owner in event of a hurricane or other high winds.
[0102] Also, the modular boat lift cover of the present invention [ 10 A and 10 B] is designed to withstand winds of up to 180 miles per hour. The structural framing members have been designed in accordance with Florida Building Code Section 3105—Awnings and Canopies—specifically Section 3105.4.2.1 parts 1, 2 and 3, based on a rational analysis using Category 1 hurricane winds and exposure “D” corrosion. The design condition basis is a minimum wind gust velocity of 116 miles per hour (for 3 seconds) when the cover has been removed, and an ultimate sustained wind speed of 150 miles per hour. In the event of a hurricane, the owner will be able to quickly and easily remove the canopy [ 16 ].
[0103] All of the components of the gable assembly [ 13 ] will fit into the channel of one of the 3″×6″ aluminum box frame support members [ 30 ], thereby improving quality control and packaging for the manufacturer, as well as giving the customer peace of mind knowing that everything will be in place without having multiple packages to deal with.
[0104] The preferred embodiment of the modular boat lift cover of the present invention [ 10 A and 10 B] uses aluminum construction in all materials to make the apparatus lighter and easier to use as well as corrosion resistant. However, other lightweight materials may also be used that are corrosion resistant and provide the unit with the necessary strength.
[0105] Accordingly, it will thus be seen from the foregoing description that the modular boat lift cover of the present invention [ 10 A and 10 B] along with the accompanying drawings provides a new and useful modular gable assembly that is expandable and readily modifiable to adapt to changes in the watercraft. In addition, the modular boat lift cover of the present invention [ 10 A and 10 B] can be deployed with a different watercraft having desired advantages and characteristics, enabling the owner of the watercraft to deploy the modular boat lift cover of the present invention [ 10 A and 10 B] as a building block to accommodate other watercraft that he or she may subsequently acquire.
[0106] Throughout this application, various Patents and Applications are referenced by number and inventor. The disclosures of these documents in their entireties are hereby incorporated by reference into this specification in order to more fully describe the state of the art to which this invention pertains.
[0107] It is evident that many alternatives, modifications, and variations of the adjustable modular boat lift cover of the present invention will be apparent to those skilled in the art in light of the disclosure herein. For example, the system can be used for all types of boat lifts as well as other applications, such as a portable event tent. It is intended that the metes and bounds of the present invention be determined by the appended claims rather than by the language of the above specification, and that all such alternatives, modifications, and variations which form a conjointly cooperative equivalent are intended to be included within the spirit and scope of these claims.
PARTS LIST
[0108] 10 A. Modular Boat Lift Cover (with linear tubes)
[0109] 10 B. Modular Boat Lift Cover (with linear tubes that become arcuate when stressed)
[0110] 12 . Deck Assembly
[0111] 13 . Gable Assembly
[0112] 14 . End Peak Fitting
[0113] 15 . Internal Peak Fitting
[0114] 16 . Canopy
[0115] 17 . Peak Fitting Connector Tube
[0116] 18 . Tube
[0117] 20 . Adjustable Support Structure
[0118] 25 . Beam Bracket
[0119] 27 . Fastener Hole
[0120] 28 . Support Column
[0121] 29 . Clevis Pin
[0122] 30 . Box Frame Support Member
[0123] 32 . Cantilever
[0124] 33 . Upper Bracket
[0125] 34 . Variable Centered Bracket
[0126] 37 . Pipe Fitting
[0127] 40 A. Curved Gable Assembly
[0128] 40 B. Curved Gable Assembly
[0129] 41 . Bolt
[0130] 42 . Beam Clamp
[0131] 44 . I-Beam
[0132] 45 . U-Bolt
[0133] 47 . Knob
[0134] 48 . Elastic Cords
[0135] 49 . Box Frame End Cap
[0136] 50 . Piling
[0137] 52 . Splice
[0138] 55 . End Canopy Overhang Fitting
[0139] 56 . Internal Canopy Overhang Fitting
[0140] 58 . Canopy Anchor Support Bar
[0141] 60 . Pipe
[0142] 62 . Bowed Tube
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The modular boat lift cover for a watercraft comprises a gable assembly and an adjustable support structure. All of the straight components are packaged into the main box frame channels for simplicity in packaging as well as quality control, ensuring no components are missing during packaging and shipping. The box frame channels have sufficient bulk to store the gable components during transport. The modular boat lift cover system has a robust, lightweight design that is compatible and adjustable for width, height and length as the boat owner modifies his existing boat or purchases a new boat, and that will protect the watercraft from the elements and will withstand even the severest of storms, undamaged as well as having the ability to be cantilevered. The modular boat lift cover is easy for the user to assemble and adjust on square lake style boat lifts, and the typically non-square tidal lifts.
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CROSS-REFERENCE TO RELATED APPLICATION
This application is generally related in subject matter to the following applications: Ser. No. 08/175,603, filed Dec. 30, 1993 entitled inflatable Packer Device and Method; and Ser. No. 08/175,607, filed Dec. 30, 1993 entitled Inflatable Packer Device Including Limited Initial Travel Means and Method.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to an inflatable packer device, such as a packer, bridge plug, or the like, for use in a subterranean well bore, and a method of using same.
2. Description of the Prior Art
Inflatable packers, bridge plugs, and the like have long been utilized in subterranean wells. Such inflatable tools normally comprise an inflatable elastomeric bladder element concentrically disposed around a central body portion, such as a tube or mandrel. A sheath of reinforcing slats or ribs is typically concentrically disposed around the bladder, with a thick-walled elastomeric packing cover concentrically disposed around at least a portion of the sheath, typically a central portion of the sheath. Pressured fluid is communicated from the top of the well or interior of the well bore to the bore of the body and thence through radial passages, or around the exterior of the body, to the interior of the bladder.
Normally, an upper securing means engages the upper end of the inflatable elastomeric bladder and reinforcing sheath (if included in the design), sealably securing the upper end of the bladder relative to the body, while a lower securing means engages the lower end of the bladder and reinforcing sheath, sealably and slidably securing the lower end of the bladder for slidable and sealable movement on the exterior of the body, in response to the inflation forces.
With inflatable packers of this type, it has been observed that the exposed anchor section of the packer prematurely inflates prior to the other sections of the packer which are reinforced against expansion by an elastomeric packing cover element. When an exposed portion, such as the upper exposed anchor section of the bladder, inflates, the lower end of the bladder moves upwards relative to the body, and the exposed portion inflates until it meets the wall of the well bore, which may be cased or uncased. If well bore is uncased, the well bore will have a wall, and if the well bore is cased, the wall of the well bore will be the interior of the casing.
Although not fully understood, as the inflation begins to propagate downward and the reinforced portions of the bladder begin to inflate, the bladder has a propensity to pinch around the exterior of the body, creating a seal that prevents the effective communication of further fluid to the lower portions of the bladder. As the upper portion of the bladder above the seal continues to inflate, a convoluted fold forms in the bladder at the point of the seal, thus entrenching the seal.
The seal prevents or obstructs passage of the pressured fluid, employed for inflating the inflatable bladder, from reaching the lower portions of the bladder. Further, if the bladder is successfully inflated, the convoluted fold often remains in the bladder. During deflation, this fold can similarly pinch and seal around the body, obstructing the communication of fluid out of the lower portions of the bladder and thereby preventing complete deflation of the bladder. This nonuniform axial inflation of the bladder also causes the ribs in the sheath to cut into the bladder.
Applicant is aware of the following prior art: U.S. Pat. Nos. 4,781,249, 4,897,139, and 4,979,570, which are related in subject matter.
The present invention addresses the nonuniform axial inflation and rib-cutting problems set forth above by providing an inflatable packer device and method of use which provides a series of shape controlling means disposed along the length of the bladder to cause substantially uniform axial inflation of the bladder.
SUMMARY OF THE INVENTION
The present invention provides an inflatable packer device and method of use thereof with the packer being introduceable into a subterranean well bore on a conduit, such packer being inflatable by pressured fluid communicated to the packer from an available source of pressured fluid located at the top of the well, interior of the well bore, or within the packer. The well bore may be cased or uncased. If well bore is uncased, the well bore will have a wall, and if the well bore is cased, the wall of the well bore will be the interior of the casing.
The packer has a body, with means on its upper end for selective engagement to the conduit. An inflatable elastomeric bladder is concentrically disposed around the exterior of the body, which is selectively movable between deflated and inflated positions by the application of pressured fluid applied to the interior of the bladder. The pressured fluid is communicated via a fluid transmission means from the source of pressured fluid, either to the bore of the body and thence through radial passages, or around the exterior of the body, and thence to the interior of the bladder. By the application of this pressured fluid, the bladder may be moved between deflated and inflated positions, so that the inflatable packer device may be moved into or out of sealing engagement with the wall of the well bore.
A first securing means engages one end of the bladder for sealably securing the bladder end to the body, while a second securing means engages the other bladder end of the bladder for sealably securing the other bladder end to the body. At least one of these securing means enables the bladder end to which it is engaged to move slidably relative to the body, in response to the inflation or deflation forces.
Finally, a series of shape-controlling means is disposed along the length of the bladder for causing substantially uniform axial inflation of the bladder, such that the ratio of the greatest circumference of the bladder to the smallest circumference of the bladder at any moment during inflation is always below a pre-determined maximum ratio. Thus, the heretofore mentioned nonuniform axial inflation and rib-cutting problems are eliminated.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a half-sectional elevational view of a preferred inflatable packer device embodying this invention, with the elements of the packer shown inserted in a subterranean well bore in their non-inflated positions, prior to actuation for setting in the well bore.
FIG. 2 is a cross-sectional view of the section of the packer shown in FIG. 1, looking downward through the section indicated by line 2--2 on FIG. 1.
FIG. 3 is a view similar to that of FIG. 2 showing the inflatable packer device during inflation of the packer, prior to sealable engagement with the wall of the well bore.
FIG. 4 is a view similar to that of FIG. 2 showing the inflatable packer device subsequent to inflation and sealably engaged with the wall of the well bore.
FIG. 5 is a half-sectional elevational view of an alternate preferred inflatable packer device embodying this invention, with the elements of the packer shown inserted in a subterranean well bore in their non-inflated positions, prior to actuation for setting in the well bore.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Now referring to FIG. 1, there is shown an inflatable packer device 10. The packer 10 may be provided in the form of a packer, bridge plug, tubing hanger, or the like, depending upon whether or not the bore of the packer 10 is open or closed.
The packer 10 contains a body 15 which may be provided in the form of a tube. The body 15 extends through the full length of the packer 10 and connects to the bottom of a conduit B, such as tubing in the form of a continuous length coiled tubing, or the like, which extends to the well surface (not shown). The conduit B may also be provided in the form of wire or electric line, or sectioned, threaded drill or production pipe, or casing. The body 15 is connected to the bottom of the conduit B by means on its upper end such as a threaded surface 20 engageable with conduit B.
An inflatable elastomeric bladder 40 is concentrically disposed around the body 15. The bladder may be surrounded and secured relative to a reinforcing sheath 70. The sheath 70 may be formed of a plurality of longitudinally extending slats or ribs with each of the longitudinally extending strips circumferentially overlapping an adjacent strip. The width of such strips and their arrangement in forming the sheath 70 is such that each of the strips will overlap the next adjacent strip when the bladder 40 is deflated and each strip will overlap the next adjacent strip when the inflatable bladder 40 is inflated, thus forming a reinforcing sheath 70 for the inflatable bladder 40 at all times.
The exterior of the reinforcing sheath 70 is either partially or completely surrounded and bonded to an outer annular elastomeric packing cover 75.
The first bladder end 50 and sheath 70 are sealably secured to the body 15 by a first securing means, such as a collar 60 mounted to the body. The second bladder end 55 and sheath 70 are sealably secured to the body 15 by a second securing means, such as a collar 65 mounted to the body. The second securing means, which includes the collar 65, is also engaged for movement slidably relative to the body 15, in response to the inflation forces.
The bladder 40 is selectively movable between deflated and inflated positions by the introduction of pressured fluid through a fluid transmission means such as the bore 18 and the radial ports 17 in the body 15. The pressured fluid is communicated in a known and conventional manner from the source of pressured fluid (not shown), through the bore 18 and the radial ports 17 to the interior 45 of the bladder 40. Alternatively, the body 15 may be solid, in which case pressured fluid may be introduced around the exterior 30 of the body 15. By the application of pressured fluid to the interior 45 of the bladder 40, the packer 10 may be inflated whereupon the second bladder end 55 and the second securing means comprised by the collar 65 move relative to the body and towards the first bladder end 50.
A series of shape-controlling means are disposed along substantially the entire length of the bladder 40, to cause substantially uniform inflation of the bladder 40 such that, at any moment during inflation, the ratio of the largest circumference of any section of the bladder 40 to the smallest circumference of any section of the bladder 40 is below a pre-determinable maximum ratio. The term "circumference" widen used herein to refer to the circumference of a portion of the bladder 40 refers to the circumference of the exterior of the portion of the bladder 40. When used to refer to the circumference of a belt 41, the term "circumference" refers to the circumference of the interior of the belt 41. The term "smallest circumference" refers to the smallest circumference of any section of the bladder 40 at a given moment during inflation, excluding the portions of bladder ends 50 and 55 immediately near the collars 60 and 65, which portions retain a relatively small circumference throughout the entire inflation process.
In one embodiment of the invention, the series of shape-controlling means comprise a plurality of circumferential limiters, shown in FIG. 1 as belts 41, which are concentrically disposed between the sheath 70 and the cover 75, except for exposed portions of the sheath 70 which are not covered by the cover 75, in which case the belts 41 are disposed around the sheath 70. The belts 41 may be formed of any suitable material which is substantially nonelastic, and where each belt 41 is formed of the same material having a pre-determinable failing tension at which tension a belt 41 will break. Alternatively, the belts 41 may be formed with different materials, thicknesses, widths, and tensile strengths to achieve the desired pre-determinable failing tension.
The belts 41 have a circumference larger than the circumference of the bladder 40 in its uninflated position, but less than the circumference of the well bore casing wall C. The wall of the well bore A may be cased or uncased, and is shown cased in the figure. When the bladder 40 is in its uninflated position as shown in FIGS. 1 and 2, the belt has an excess length which is folded upon itself as shown in FIG. 2. As the bladder 40 begins to inflate, each belt 41 unfolds its excess length, until the circumference of a portion of the bladder 40 beneath a given belt 41 is equal to the circumference of that belt 41, at which point the belt is fully extended, as illustrated in FIG. 3.
The tensile strength of the belts 41 is selected such that all belts 41 must be fully extended before the pressured fluid introduced into the interior 45 of the bladder 40 causes enough tension to break or fail any of the belts 41. In this manner the belts 41 will become fully extended one by one as the bladder 40 inflates, so that if any belt 41 is not yet fully extended, the inflation pressure will be strong enough to inflate the relatively uninflated portions of the bladder 40 near the unextended belts 41 but not strong enough to break any of the fully extended belts 41. In this manner the bladder 40 inflates along its entire length out to an intermediate circumference, being the circumference of the fully extended belts 41. During inflation to this intermediate circumference, the largest circumference of any portion of the bladder 40 is substantially limited to the circumference of the belts 41, and the smallest circumference of the bladder is the circumference of the bladder 40 in its uninflated position. The length of the belts 41 is selected so that tile ratio of these circumferences is less than the maximum pre-determined ratio, to prevent formation of the aforementioned pinch and seal and to prevent the ribs in the sheath 70 from cutting into the bladder 40.
After the bladder 40 has inflated such that each belt 41 has been fully extended, the inflation pressures increase and reach a point where the tension on some of the belts 41 becomes high enough so that the belts 41 break or fail. Thus the belts 41 fall, one by one, until each has failed and the bladder 40 may thus fully inflate along its entire length, moving the cover 75 and the exposed section of the sheath 70 into sealing engagement with the casing C of the well bore A, as illustrated in FIG. 4.
During inflation from the intermediate circumference to the circumference of the well bore casing wall C, the largest circumference of any portion of the exterior 46 of the bladder 40 is limited to the circumference of the well bore casing C, and the smallest circumference of the bladder is the circumference of the belts 41. The length of the belts 41 is such that the ratio of these circumferences is less than the maximum pre-determined ratio, to prevent to formation of the aforementioned pinch and seal and to prevent the ribs in the sheath 70 from cutting into the bladder 40.
In a second embodiment of the invention, as shown in FIG. 5, the series of shape-controlling means comprise a plurality of variably inflation-resistant modules 43, which are integral components of the cover 75, concentrically disposed around the sheath 70. As illustrated in FIG. 5, some of the modules 43 are formed from a relatively thicker piece of elastomer and are called "high modulus modules," an example of which is module 43H, while others of the modules 43 are formed of relatively thinner pieces of elastomer, and are called "low modulus modules," an example of which is module 43L. The low modulus modules such as module 43L have less resistance to stretching and thus to inflation forces since they are formed of a thinner piece of elastomer, while the high modulus modules such as module 43H require a higher tension to stretch and thus inflate, since they are formed of relatively thicker pieces of elastomer. The modules 43, while acting as shape-controlling means, also continue to act as a packing cover 75 to provide a means for a pressure-tight hydraulic seal against the casing C.
Preferably, each module 43 will have a length equal to one to two times the diameter of the cover 75 in its uninflated position, typically three to six inches in axial length, but may be of different lengths depending upon the non-uniform inflation characteristics sought to be controlled in the bladder 40. The modules 43 are shown disposed axially along the length of the bladder 40, alternating between high and low modulus modules, with an area of the sheath 70 left uncovered by any module 43. With these variably-inflation resistant modules 43 suitably and alternatingly axially arranged along the length of the bladder 40, an overall substantial uniformity of resistance to inflation pressures is achieved, such that the bladder 40 inflates substantially uniformly along its axial length, from its run-in position until its fully-expanded position whereby the packer 10 is moved into sealing engagement with the well bore casing wall C. Since the inflation of the bladder 40 is substantially uniform along its length, the ratio of the circumferences of any more-expanded portions to that of less-expanded portions is less than the maximum pre-determined ratio, thereby preventing the formation of the aforementioned pinch and seal and preventing the ribs in the sheath 70 from cutting into the bladder 40.
It will be appreciated that the low and high modulus modules 43 may also have a uniform thickness but be formed of different elastomeric composites with different resistivities to stretching. Additionally, the low and high modulus modules 43 may be formed from a single tube of elastomer or from separate sections of elastomer situated contiguously along the sheath, and the separate sections may further be bonded to each other. Alternatively, the low modulus modules 43L may comprise sections of elastomer or other suitable material that break after an initial amount of inflation and fall off of the packer 10, still allowing the desired programmed shape control and also exposing multiple sections of the sheath 70 to provide multiple anchoring segments to anchor against the casing wall C.
With any embodiment of the invention, the packer 10 is lowered into the top (not shown) of the well bore A on the conduit B to a pre-determinable position. At this position the packer 10 may be moved into sealing engagement with the well bore casing wall C by the introduction of pressured fluid communicated to the packer 10 from a source of pressured fluid (not shown) located at the top of or within the well bore A. Alternatively, the source of pressured fluid may be located within the packer 10 or within its setting tool (not shown).
After actuation of the packer 10, the packer 10 may be deflated and thereupon removed from the well bore A or moved to a new pre-determinable position within the well bore A for subsequent actuation.
Although the invention has been described in terms of specified embodiments which are set forth in detail, it should be understood that this is by illustration only and that the invention is not necessarily limited thereto, since alternative embodiments and operating techniques will become apparent to those skilled in the art in view of the disclosure. Accordingly, modifications are contemplated which can be made without departing from the spirit of the described invention.
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An inflatable packer and a method for its use are provided for introduction into a subterranean well bore on a conduit. A pinch can form in the inflatable elastomeric bladder of the packer during inflation or deflation, forming a seal which obstructs the effective passage of pressured fluid, thereby obstructing inflation and deflation of the bladder. Additionally, ribs on the exterior of the bladder can cut into the bladder during nonuniform inflation or deflation of the bladder. The packer provides a series of shape-controlling means to cause uniform inflation along the length of the bladder to eliminate these problems.
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BACKGROUND OF THE INVENTION
Substances and compounds containing fibers of different characteristics are of special interest. For disintegrating such materials and compounds numerous devices are known such as crushers, granulators, defibrators and so on. Apart from knife ring flakers in the first instance, wing beater mills, hammer mills, shredders and derivations thereof must be mentioned.
Wing beater mills, cross stream mills and double stream mills have as a main characteristic a rotor and, as a functional counterpart, a screen or friction ring or a combination of both encircling the rotor as a whole. The raw material to be disintegrated is fed axially to the rotor and centrifugally accelerated by the rotor blades towards the surrounding screen or friction ring. Wear plates fixed to the ends of the rotor blades drag the material to be milled along the surrounding screen oror friction ring, until it is disintegrated to an extent that it is able to pass through the screen perforations. The screen perforations are the bottle neck of the system. The smaller they are, the more often the material has to be dragged by the rotor along the surrounding screen or friction ring, until it is sufficiently disintegrated to be able to pass through the perforations. The smaller the perforation, the more times the material to be ground has to be dragged along the screen ring, until it is sufficiently disintegrated and can finally pass through the screen holes. The output drops correspondingly and the energy consumption increases. If friction rings are employed instead of screen rings, the sufficiently disintegrated material has to leave the milling zone via the lateral slots between the rotor blades and the friction ring. They are bottle necks, too. Their negative effects are the more serious, the more finely that the material is to be disintegrated and the higher its moisture content.
With very moist or even sticky materials, the machines mentioned above fail entirely since the screen holes or lateral slots get plugged and the function of the machines breaks down. As a result, these machines are generally only used for disintegrating materials having a moisture content between 1 and 5 %, referred to dry matter, for example as chip disintegrators in particleboard manufacture. But dry wood flakes with 1 to 5% moisture content, are extraordinary brittle. When being disintegrated to fine flakes or even micro flakes, as required for good surface layers in particleboard manufacture, they do not break as desired in the longitudinal sense parallel to the main axis, but because of their high brittleness they break several times in an unfavourable manner transversely, resulting in a poor ratio of slenderness (length:cross-section). A poor ratio of slenderness again results in poor values for bending strength and poor homogeneity of the board surface. In contrast, moist wood is flexible and tough. It breaks preferably at points of natural weakness, for example in the vascular vessels or in the soft spring wood. The number of undesired transversal ruptures drops sizeably. A flake of favourable dimensions and high ratio of slenderness, i.e. a long and thin flake, emerges, as required for boards of high bending strength and good surface quality.
SUMMARY OF THE INVENTION
It is the aim of the invention to separate materials as well as waste materials consisting of at least two or more physically sufficiently different components into their individual components. It is also an aim to disintegrate structures as for example pulp fibers in a paper sheet to their original components, which means into pulp fibers. It is also an aim to execute such disintegration as carefully as possible in order to preserve the original sizes of particles, length of fiber and so on, in order to be able to repeat recycling operations as often as possible. An additional aim is to execute such disintegrating operations in all ranges of moisture and even in fluid suspensions or with sticky materials or when adding sticky additives. Furthermore, heat development shall be kept as low as possible in order to avoid evaporation of volatile materials.
EMBODIMENTS
The basic idea of the invention consists in a combination of several measures. In contrast to all machines according the state of the art, the tool ring according invention has a distinctly “open circumference”. This has to be understood as the ratio of gaps between the tools referred to the total circumference of the tool ring. This is the basic precondition for avoiding plugging even with moist and sticky materials.
Example
The total of all gaps between the tools is 4.100 mm. The total circumference is 5.100 mm. Then the “open circumference” is 80,4 %. That means that 80,4% of the circumference is entirely open, so that material can pass through without any hindrance.
Machines corresponding to the state of the art have an “open circumference” of only 25 to 45%.
Another important feature of machines according to the invention is the “large clear span” between one tool to the next being 15 to 25 times larger than with any comparable machine of the state of the art. Screen perforations with machines according the state of the art range between 1,5 to 3,0 mm for so-called “Conidur screens”. “Slot screens”, as employed for example for producing micro flake surfaces in particleboard manufacture have slots in the range of 1,5×15 mm to 3,0×30,0 mm. In contrast, the free spaces of the machine according to the invention range between 40×400 mm to 55×500 mm, depending on the size of machine. That means that the size of particles of material fed into machines according the state of the art is a multiple of the size of screen perforations and therefore the material has to stay on the screen until it is entirely disintegrated. Even the disintegrated material is still larger than the screen perforations, so that the danger of plugging remains persistent, especially with moist material.
The situation is entirely different with the machine according to the invention: Here the free span from tool to tool is in general larger than the lengths of the input material. At a free span between the tools of for example 40 to 50 mm, no piece of the input is able to set and rest on the tools. Even with material of greater length such risk does not exist, as the high centrifugal force effects that long pieces sag and are flung through the gap between the tools. Last but not least, the machine according to the invention is constructed with shearing knives fixed to the rotor with the objective to shear off any build up of material on the tools greater then about 2 mm.
The principle of operation of the machine according the state of the art as well as the one according the invention is based on the radial acceleration of the input material. The tools according to the invention are rotated with a relative speed preferably between 30 and 100 m/sec around the rotor. The working edges ( 3 . 5 ) of the tools ( 3 . 3 . . . 3 . 6 ) intercept the radially accelerated material in flight more or less at a right angle and effect that the material bends around the working edges. Thereby, in each piece of input material, impulse-like bending and shearing strain are produced, which effects that the material is disintegrated at its weakest point or layer. Such weak points are for example spring wood, vascular vessels and parenchymatic tissue of the wood as well as natural tension and drying fissures, but also jointing points of elements of the same material, like particles in particleboard.
Machines of the state of the art are fixed by the supplier to a certain rotation speed in accordance with trials executed to determinate the optimal speed before delivery. Normally such speed is not subsequently changed. The determining parameters for the degree of disintegration are in the first instance the size of the screen perforations, the distance between the wear plates of the rotor and the screen or friction ring, the profile of the friction ring and its orientation. The output of the machine is a function of the selected screen or friction ring without a further possibility of adjustment or control.
The machine according invention is entirely different in design, control and possibilities of adjustment: Here the main adjusting parameters are the circumferential speeds of rotor ( 2 ) and tool ring ( 3 ) or of the working edge ( 3 . 5 ) of the tools ( 3 . 4 . . . 3 . 6 ). That's why the motors of both rotor ( 2 ) and tool ring ( 3 ) are normally equipped with frequency converters enabling to adjust the speed continuously.
High speed effects a high degree of disintegration and a high output. Low speed means a low degree of disintegration and lower output.
Further means of control are modulating the speed of the rotor ( 2 ) or the speed of the tool ring ( 3 ) independently from each other. In general rotor ( 2 ) and tool ring ( 3 ) are rotated in opposite directions. But for certain applications rotating in the same direction at different speeds can yield favorable effects.
Another control parameter of the machine according invention is the quantity and speed of air passing through the machine. Both rotor ( 2 ) and tool ring ( 3 ) act as radial fans and generate about 3 to 6 times as much air as machines according to the state of the art. The reason for this is the large “open circumference” of the tool ring ( 3 ), which does not throttle the air generated by the rotor ( 2 ).
Huge quantities of air passing through the machine at high speed result in scavenging the machine of disintegrated material within fractions of a second.
A special throttling device ( 6 ) at the inlet of the machine serves to adjust the quantity of air entering the machine over a continuous range. The throttle consists of at least one pull in belt ( 6 . 1 ) and a cross section adjustment plate ( 6 . 2 ), which can be replaced by a second pull in belt. This does not only limit the intake of air, but also reduces the speed of air and consequently the dwell time of the material in the machine. That again determines the throughput.
Another control parameter is the height of the tool ( 3 . 4 ) in the tool ring ( 3 ). There is a minimum of tools ( 3 . 6 ) of about ¼ to ⅙ that must have a large height in order to guaranty a high transversal stiffness of the tool ring ( 3 ). They must be welded to the ring ( 3 ). The rest of the tools ( 3 . 4 ) are executed as interchangeable ones. Their height is selected in accordance with the technical requirements of the individual application. Tools ( 3 . 4 ) with a large height act like blower blades. The more of them that are installed in the tool ring ( 3 ), the greater the generation of air and the air velocity. If less air shall be generated, interchangeable tools ( 3 . 4 ) of low height must be installed.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 shows a longitudinal section through a plane perpendicular to the plane of FIG. 2 .
FIG. 2 shows a cross-section through a plane perpendicular to the plane of FIG. 1
DETAILED DESCRIPTION OF THE INVENTION
The device according to the invention that is shown in FIGS. 1 and 2 includes a housing that is preferably made of parts that are welded together. A front door ( 1 . 1 ) serves to open the machine for changing the tools, for taking out rotor ( 2 ) and tool ring ( 3 ) for repair work and for installing a friction ring ( 4 ) when required for special applications. A material feeding chute ( 1 . 2 ) is integrated into the front door ( 1 . 1 ). A heavy pillow block ( 1 . 3 ) for the drive shaft of the rotor ( 2 . 2 ) and the tool ring ( 3 . 3 ) is situated at the rear side of the machine ( 2 . 3 ) represents a V-belt disc sitting on the shaft ( 2 . 2 ) of the rotor ( 2 ). The rotor ( 2 ) consists of a multiple of rotor blades ( 2 . 1 ) the function of which is to give a high radial acceleration to the material to be disintegrated. Before touching the rotor blades ( 2 . 1 ) the input material crashes first against the distributing cone or disc ( 2 . 4 ) which distributes it equally over the whole circumference. Wear blades ( 2 . 5 ) are fixed to the ends of the rotor blades ( 2 . 1 ). They act at the same time to prolong the acceleration path. In order to avoid that long pieces of input material twist around the tools and build up, at least one shear off or cleaning knife ( 2 . 6 ) is fixed to the end of one rotor blade instead of a wear blade. In order to avoid that material enters the narrow gap between rear side of the rotor ( 2 ) and base disc of the tool ring ( 3 ), where it could produce friction and cause fire, radially arranged ribs ( 2 . 7 ) produce scavenging air, which is centrifugally accelerated. This air keeps the gap clean.
Tool ring ( 3 ) consists of a base disc ( 3 . 1 ), a hollow wheel for the drive ( 3 . 2 ), a mechanical or hydraulic drive ( 3 . 3 ) and two types of tools. The first type is an interchangeable tool ( 3 . 4 ) which can be executed in any suitable geometry and height. The second type of tool or large tool carrier is not interchangeable but welded in between base disc ( 3 . 1 ) and counter ring ( 3 . 9 ) in order to give the necessary transversal stabilty to the tool ring ( 3 ). The working edges of the large tool carriers ( 3 . 6 ) are always replaceable. The exchangeable tools ( 3 . 4 ) are provided in two executions, one with replaceable working edges ( 3 . 5 ) and another without. Here the tool carrier incorporates the working edge and is replaced as a whole after being worn out.
At the rear side of the large tool carriers ( 3 . 6 ) upset and wear plates are installed when working with the friction ring ( 4 ).
One of the main characteristics of the machine according invention is the extremely wide “open circumference”, which means a large free passage between two adjacent tools in relation to the distance between their center lines. This feature explains why the machine cannot get plugged either with wet material or with sticky material.
When changing tools or executing repair work, the tool ring ( 3 ) is taken out of the machine as a whole. For easy connection with the base disc ( 3 . 1 ) a connecting ring ( 3 . 10 ) is provided, which is connected with the base disc ( 3 . 1 ) by heavy screws.
Ribs ( 3 . 11 ) at the rear side of the base disc ( 3 . 1 ) are provided to produce scavenging air to keep the space between the machine housing and base disc ( 3 . 1 ) clean.
If further disintegration is desired, friction ring ( 4 . 1 ) can be installed in the machine housing. The already disintegrated material flung through the open circumference ( 3 . 8 ) lands on the friction ring ( 4 ). The friction ring ( 4 ) consists preferably of cast iron profile elements to exert friction when the material is drawn along it. For this purpose the wear plates ( 3 . 7 ) must be installed on the large tool carriers ( 3 . 6 ) to move the material along the friction ring and effect the further disintegration.
A channel system ( 4 . 2 ) serves to feed fluids, additives, and cooling or drying medium through the friction ring ( 4 ) into the material being milled. For this purpose perforations are provided in the friction ring ( 4 ) as continuations of the channel system ( 4 . 2 ).
If additives shall be added to the input material while being disintegrated, special devices are provided for liquid additives ( 5 . 1 ) and dry matter/powder additives ( 5 . 2 ).
Air quantity and air velocity belong to the essential regulating parameters. They are controlled by the air throttle ( 6 ). The throttle consists of an upper pull in belt ( 6 . 1 ) and a counter plate ( 6 . 2 ) or upper and lower pull in belts with adjustable cross sections and pull in speeds.
Last but not least a tool cleaning device ( 7 . 1 ) is provided to clean the tools by pressurized air or pressurized liquid.
The material is aspirated by the high draft of air generated by rotor ( 2 ) and tool ring ( 3 ) through the inlet chute ( 1 . 2 ) and flung against the distribution cone or disc ( 2 . 4 ), which again accelerates and distributes it radially to cross the orbit of the tools ( 3 . 4 . . . 3 . 6 ) so that an intensive impact can take place. The rotor blades are equipped at their end with wear plates ( 2 . 5 ). At least one wear plate is replaced by one shear off or cleaning knife ( 2 . 6 ) in order to keep the tools ( 3 . 4 . . . 3 . 6 ) clean and cut or shear off long pieces of material twisting around the tools.
The tool ring shown in FIG. 2 consists in this case of 12 welded in large tool carriers ( 3 . 6 ) with round working edges ( 3 . 5 ) The number of large tool carriers depends on the size of the machine. The geometry of the working edges ( 3 . 5 ) depends on the type of material and application.
The interchangeable tools ( 3 . 4 ) as shown in the FIG. 2 are of simple execution consisting of round iron bars, only. As soon as they are worn out, they are replaced by new ones. If a more sophisticated geometry with more expensive tools is required the interchangeable tools are also executed in two parts, i.e. tool carrier ( 3 . 4 ) is exchangeable working edge ( 3 . 5 ).
The elements of the friction ring ( 4 . 1 ) are available in many profiles for intensive disintegration as well as for preserving disintegration. The channel system ( 4 . 2 ) behind the friction ring serves to cool the friction ring ( 4 . 1 ) when the necessity arises for example when processing materials with volatile ingredients. The channel system can also serve to add additives via the perforations ( 4 . 3 ) directly into the material being processed. Cooling air or hot air for drying can also be injected.
With the injecting devices 7 . 1 pressure air or pressurized fluids can be injected to clean the tools or to add additives.
The disintegrated material has to be discharged and transported by pneumatic conveying. The material is more or less radially flung into the pneumatic duct underneath the outlet ( 1 . 5 ) of the machine to be conveyed to the cyclone or similar air separator.
In the mill like machine housing ( 1 ) two main aggregates are incorporated, namely rotor ( 2 ) and tool ring ( 3 ). The function of the machine is performed in the first instance by the tool ring ( 3 ). Tool carriers ( 3 . 6 ) are welded between the base disc ( 3 . 1 ) of the tool ring and the counter ring ( 3 . 9 ). They have a large height in order to guarantee a high moment of resistance and sufficient stiffness of the tool ring even at high rotation speed. The welded in tools are made preferably wedge shaped at their outside edge, in order to provide a slim working edge necessary to perform an effective function with respect to disintegrating the input material and to guarantee at the same time by the broader outer edge of the tools a high stiffness of the tool ring over the tangent.
The majority of the tools or tool carriers ( 3 . 4 ) is interchangeable. They are plugged or screwed in. They can be made with or without interchangeable working edge or wear piece ( 3 . 5 ). By the possibility of interchanging, a very high degree of versatility and flexibilty is achieved with respect to the different fields of application. If, for example, a high degree of disintegration with dry input material is to be achieved, for which a high throughput of air is not required, then the interchangeable tools ( 3 . 4 ) can consist of simple round bars with a small radius of 5mm, for example The small radius effects a high deflection of the input material when being intercepted by the rotating tool resulting in high bending and shear strain which again effect the disintegration. Due to their low specific surface, the round bars do not produce a high ventilation effect in the machine. The quantity of air produced by the round bars is sufficient when disintegrating dry material since this is easily discharged from the machine. If, in contrast, moist or even sticky material shall be disintegrated or mixed, then a high air generation of the machine is required, in order to support the centrifugal force for discharging the material from the machine and avoiding caking. For such purpose tools ( 3 . 4 ) having a large height are plugged or screwed in. They act as blower blades and produce the required large quantity of air. The higher the quantity of air and the higher the air velocity, the more thorough the discharging of the disintegrated material even if humid or sticky. The machine is literally blown clean.
The tool carriers ( 3 . 4 ) and ( 3 . 6 ) can be equipped with interchangeable elements ( 3 . 5 ) with different working edges. This also aims to provide the machine according invention with a maximum of versatility with respect to being adapted to the different fields of application. As described already, a small radius of the tools produces high bending and shear strain in the material, which results in an intensive disintegration. Increasing the diameter of the radius results in a less intensive and more material preserving disintegration, as may be preferred when working with very dry and brittle input material. Thus, undesired shortening of the material can be avoided. The other extreme is sharp edged knife like tools as applicable for the recycling of composites containing reinforcing fibers or the like. The possibility to replace the working edges ( 3 . 5 ) is furthermore necessary since they are subject to wear and must be replaced from time to time by new ones.
The input material is fed into the machine via the feeding chute ( 1 . 2 ) in the front door ( 1 . 1 ) of the machine more or less centrally to the distributing cone/disc ( 2 . 4 ) of the rotor 2 which distributes the material centrifugally to the rotor blades ( 2 . 1 ). The rotor blades have the essential function to enhance the acceleration and to propel the material against the working edges ( 3 . 5 ) of the tools.
Rotor ( 2 ) and tool ring ( 3 ) rotate preferably in opposite directions. The rotation of the rotor ( 2 ) covers the range of 400 to 4.000 rpm, preferably 400 to 1,500 rpm. The tool ring ( 3 ) rotates in the range from 0 rpm to 4,000 rpm, preferably between 200 and 2,000 rpm. But rotor ( 2 ) and tool ring ( 3 ) can also operate in the same direction. Rotor ( 2 ) propels the input material with high speed radially. Thereby it has to cross the orbit of the tools ( 3 . 4 and 3 . 6 ) at a right angle. In correspondence with the rotation speed it is more or less completely intercepted by the working edges ( 3 . 5 ) and subject to highly intensive bending and shear strain resulting in disintegration by rupture in the weak zones, as for example spring wood. High rotation speed yields almost complete intercepting of material at extremely high energy induction. As result, an almost complete and very intensive disintegration is achieved. In contrast, low rotation speed of the tool ring yields an incomplete disintegration and a low degree of disintegration as desired for several applications. Mentioned effects can be adjusted continuously by adjusting the rotation speed of rotor ( 2 ) or tool ring ( 3 ) or of both. For applications, where an extraordinarily high degeree of disintegration/ defibration is aimed for, as for example micro particle surface layers in particleboard manufacture, the integration of a friction ring ( 4 ) encircling the tool ring ( 3 ) is provided as an option. In general it encircles the tool ring ( 3 ) by around 3/4 of its circumference. In contrast to machines according the state of the art, such friction ring is not responsible for the intrinsic disintegration. Furthermore, in contrast to machines of the state of the art, the material does not effect as many revolutions as necessary to be able to pass through the slot between wear plates of the rotor and friction ring, but about ¾ revolution only. If further disintegration is desired, the friction ring can also be executed as a {fraction (1/1)} ring in order to allow to perform several revolutions. Then the discharge of material is effected laterally of the friction ring ( 4 ) in the section of the outlet of the machine ( 1 . 5 ), while with machines according the state of the art the discharge is done over the full circumference.
As the machine according invention cannot get plugged due to its large “open circumference” and due to the large quantity of air passing through, dry and liquid additives can be added to be homogeneously mixed with the material. Feeding devices for liquid additives ( 5 . 1 ) and solid ones ( 5 . 2 ) are provided.
Examples of Fields of Application
The subsequent examples shall demonstrate the wide range of applications of the machine according invention without limiting it.
The examples cover the fields of “defibration”, “disintegration” and “blending/ mixing” referring to specific materials as input.
The examples shall serve specially the purpose to show to the professional how to adjust or to modify the machine in accordance with details shown by FIGS. 1 and 2 in order to achieve the desired results and advantages.
Disintegration of Wood Flakes
It has been mentioned already that for particleboard manufacture, long, slender fine or microfine flakes are desired for surface layers which cannot be produced until now under economic conditions. Flake disintegrators according the state of the art can only disintegrate dry flakes. At elevated moisture content they get plugged. Furthermore dry flakes/chips are brittle and therefore break while being disintegrated transversally, thus resulting in unfavorably short lengths.
The machine according invention is not sensitive at all to moisture due to the large “open circumference”. It has no problems to disintegrate flakes/chips having a moisture content of 40% after flaking or even more. As the disintegration is effected by high bending and shear strain at zones of natural weakness and due to the fact that moist flakes are plastic and flexible, transversal ruptures do not prevail. As a result, long and slender fine or micro flakes are achieved being ideal for the manufacture of particleboard with very homogenous surfaces and high bending strength.
If a fine particle with a high ratio of slenderness is to be achieved, the bending strain at the working edge ( 3 . 5 ) of the tools ( 3 . 4 . . . 3 . 6 ) has to be kept moderate, since elevated strain provokes transversal ruptures. For such purpose tools with large radius must be plugged in, since a large radius produces a more moderate bending strain. The rotation speed of the rotor ( 2 ) and tool ring ( 3 ) have to be adjusted to 600 to 800 rpm, both rotating in opposite directions. If, in contrast, a very intensive disintegration is desired even at the sacrifice of less favorable lengths, a working edge ( 3 . 5 ) with small radius or even knife like geometry has to be employed, in order to achieve high bending and shear strain resulting in ruptures at the weak points, preferably in the sense of fiber. The degree of disintegration can further be boosted by increasing the rotation speed of rotor ( 2 ) and tool ring ( 3 ) to about 1000 to 1,500 rpm, each. Further increases in the degree of disintegration are possible by throttling the air throttle ( 6 ) in order to reduce the flow of air in the machine and thus increase the dwell time of the material in the machine. For ultimate intensification of disintegration the friction ring ( 4 ) can be installed into the machine. A series of friction profiles permits a large choice of disintegration intensities up to almost powder.
Recycling of Particleboard
According the state of the art, waste particleboard is chopped or shredded and then fed to a digester to be treated by steam in order to weaken the glue joints. Then the flakes can be recycled for particleboard manufacture. However, the method can only be applied for boards made with resins, which dissolve or weaken under the influence of moisture. It does not work with phenolic resins, for example. The process is furthermore expensive.
The machine according to the present invention simplifies particleboard recycling considerably by making the digesting operation unnecessary. Thus particleboard recycling becomes more economical. According to the invention chopping or shredding prior to applying simply cold water is all that is needed as preparation for recycling. Preference should be given to chopping machines which produce tension fissures in the material so that the capillary system produced can suck the water into the inner parts of the chips in order to soften the wood particles and weaken the glue joints. The swelling of the individual wood particles initiated by the cold water produces swelling strain in the composite which again loosens the structure of the board. If the chips are now passed through the machine according to the invention and it produces intensive impulses, the chips dissolve to individual wood flakes. An additional support in dissolving the material into individual flakes is rendered by the friction ring ( 4 ).
When recycling macerated and therefore plastified particleboard it is necessary to differentiate between board made with resins that are able to swell under the influence of water and those that have moisture resistant characteristics.
If particleboard to be recycled is made with resins that are able to swell when moisture is added, tools ( 3 . 4 . . . 3 . 6 ) with a large radius at their working edge are sufficient to produce a good disintegration. The large radius produces a moderate bending strain and consequently a careful preservation of the original lengths of the flakes. The air throttle is widened for this purpose in order to render an intensive air rinsing of the inner parts of the machine. This is necessary and it is an advantage of the machine according to the invention since the slightly water soluble resins produce a smear film at the inner parts of the machine if not continuously blown out by the intensive air stream.
With particleboard made with water resistant resins all options of the machine have to be exhausted. The tools ( 3 . 4 . . . 3 . 6 ) must have a small radius as high strains only can break up the glue joints. The rotation speeds of both rotor ( 2 ) and tool ring ( 3 ) must be adjusted in their upper range in order to produce high impulses. The wear plates ( 3 . 7 ) must be adjusted close to the friction ring ( 4 . 1 ) to give a small gap and execute an intensive friction.
Recycling of Automotive Composites
Composites to line the inner parts of motor cars consist mainly of fibers and a duroplastic matrix. The matrix is often foamed. After chopping -similar to that which is done with particleboard—the material is fed to the machine according to the invention. Here the duroplastic matter is pulverized due to its brittleness while the elastic or flexible fibers and other matter get separated and can be recovered by a subsequent screening or sifting operation. For this application, the friction ring ( 4 ) represents a valuable help to loosen brittle components from flexible ones.
Depithing of Sugar Cane Bagasse
Sugar cane bagasse is an excellent raw material for the manufacture of particleboard, MDF-board, pulp and paper, furfural and others. The fibers are embedded in a matrix of parenchymatic tissue. For board and pulp only the fiber can be used. For furfural the parenchymatic tissue, socalled “pith” gives the better yield. Separating fibers from pith is done in two steps according the state of the art, namley pre-depithing when still wet, then drying and subsequent defibration by wing beater mills, double stream mills or similar. As with wood flakes, the bagasse becomes brittle after drying.
When being defibrated in the mentioned mills, the fibers break transversally. Long and slender fibers cannot be achieved.
The machine according to the invention can work with any moisture content. It pulverizes the pith without breaking the fibers, if they are moist and correspondingly flexible and tough. Instead of two operations, only one is required according to the invention. And as an additional great advantage, a long fiber with good ratio of slenderness is achieved rendering much better strength properties in board manufacture.
When “depithing” (separating the parenchymatic tissue) bagasse and comparable plants, the choice of adjusting parameters depends on whether the input is dry, humid or moist or even in water suspension. For dry material, working edges ( 3 . 4 . . . 3 . 6 ) with large radius shall be employed. The rotations shall be in the order of magnitude of 500 rpm for the rotor and the tool ring. The friction ring should not be used. If, however, humid material or material in water suspension shall be processed, tools ( 3 . 4 . . . 3 . 6 ) with small radius and high rotation speeds are to be preferred. As interchangeable tools ( 3 . 4 ) those of large height are the better choice in order to get a high fan effect for keeping the machine housing clean. For very intensive defibration, friction ring ( 4 . 1 ) should be installed.
Disintegration of Cereal- and Rice Straw as well as Giant Grasses
Cereal straw and rice straw are monocotyledons like sugar cane, where the fibers are embedded in a parenchymatic matrix. The same is true of sugar cane fibers; they are brittle when dry. Their fibers are already short by nature. With machines according the state of the art, short fibers only can be produced. In contrast, with the machine according to the invention, long fibers are achieved, since the machine is able to cope with any moisture content, the same as when disintegrating bagasse. The parameters to be adjusted are basically also the same as with bagasse.
Recycling Waste Paper
According to the state of the art of gipsum-fiberboard manufacture, waste paper is first pre-disintegrated by hammer mills or their derivates and then defibered by wing beater mills, double stream mills or the like as dry matter. Both hammer mills and wing beater/ double stream mills are not able to cope with moist material. As a consequence, the length of the paper fibers is broken down due to its brittleness. Much dust is also produced and must be disposed of. With the machine according to the invention, wet waste paper can be dissolved without any risk of getting plugged.
It is well known that ordinary paper loses its strength when being wetted. It is easy to dissolve wet paper. Consequently, it suggests itself to moisten the paper after having been pre-disintegrated in order to soften the system and to execute the final defibration by the machine according to the invention at a sufficiently high moisture content required to make the fibers flexible and plastic. Thus, transversal ruptures are reduced to a minimum. Most of the fibers are separated from the paper composite without being damaged, preserving the original fiber length. Moisture is no disadvantage for the further process, since for the manufacture of recycling paper as well as for gipsum board moisture is required anyhow.
In a similar manner chemical pulp as well as mechanical pulp can be dissolved for further processing.
Moistened and thereby softened paper does not require special considerations with respect to adjusting the parameters of the machine according to the invention. The fibers are short anyhow. Due to the moisture they are flexible and do not tend to rupture. That means that any geometry of the tools or working edges ( 3 . 5 ) can be employed. However the throttle ( 6 ) should be opened wide to get a strong air stream for keeping the machine free from caking. Papers contain a series of additives, most of them being water soluble and producing a smeary film in the machine, ending as incrustation, if not blown out while moist.
For dissolving chemical and mechanical pulp the friction ring ( 4 ) is a useful option to intensify the disintegration.
Mixing Fibers
For the manufacture of composites it is necessary to mix fibers of different types with each other. Fiber mixing installations according to the state of the art face problems in mixing fine polymer fibers being cut to defined length. The ends of the fiber bundles are micell like comressed by the cutting knife. A normal mixer is not able to dissolve such compressions properly. In contrast, with the machine according to the invention, the compressed ends of the polymer fiber bundles are dissolved in an explosive manner by the impact of the tools and the high impulse directed into the fiber bundle. The high speed of air and the turbulences in the machine result in an extraordinarily homogenous mixing of the different types of fibers. The friction ring ( 4 ) contributes further to homgeneity.
The degree of homogeneity increases with the rotation speed of rotor ( 2 ) and tool ring ( 3 ) as well as with lower air speed and consequently longer dwell time.
Blending with Liquid and Dry Additive
Due to the fact that the machine according to the invention is not sensitive to moisture at all due to the very open circumference in combination with the high centrifugal acceleration, liquid as well as dry additives can be added with the input material to be blended together. When doing so, the liquid additive has to be added first or simultaneously, so that the solid matter can stick to the fibers.
The additive can be added by feeding it to the machine together with the main material via inlet ( 1 . 2 ) or via the injection for liquids ( 5 . 1 ) and infeed for dry additives ( 5 . 2 ). A third possibility exists via the channel system ( 4 . 2 / 4 . 3 ).
Cottonizing Raw Fibers
Disintegrating raw, thick, coarse natural fiber bundles to fine elementary fibers for spinning yarns is another field of application for the machine according invention. According to the state of the art, cottonizing is done by means of drums equipped with hundreds or thousands of fine needles or serrated saw belts on rotating drums. Such methods are damaging to the fibers. Another method is to subject the raw fibers to a chemical treatment dissolving the pectins gluing the elementary fibers together to create fiber bundles. After that the fibers are fed to a pressure vessel and exposed to steam pressure. By opening a quick action valve, the fiber bundles expand almost explosively and are disintegrated to elementary fibers. This process was first applied in the USA for fiber board manufacture and is known there as the “steam explosion process” or “Mason process”. The process suffers from high cost and is therefore regressing in the USA.
Further efforts are directed to defibrating digested raw fibers by supersonic waves. The system is still in the laboratory stage.
Digested raw fibers can also be thoroughly disintegrated by means of the machine according to the invention. As mentioned, the machine can cope with any moisture content and even with materials in water suspension. So, if digested, raw fibers are passed through the machine and high impulses are applied to the material, an easy disintegration down to elementary cells is achieved at lower cost and lower energy consumption than with the steam explosion or supersonic technology.
For this purpose high rotation speeds for rotor 2 and tool ring 3 are to be adjusted. The higher the speeds, the higher the impulse applied to the material and the more complete the disintegration. Since slimy substances are produced as a result of the digestion prior to the mechanical treatment, the throttle ( 6 . 1 / 6 . 2 ) must be kept wide open to pass a large amount of air through the machine for keeping it clean.
Defibrating Digested Wood Chips and Chips of Renewable Raw Materials
According to the state of the art, fibers for cardboard, fiberboard, MDF-board and other products based on natural fibers are produced by chopping the material first, digesting it under steam pressure and defibrating it still under pressure by means of mills with dented discs, so-called “defibrators”. But less uniform and less disintegrated fibers can also be produced with the machine according to the invention after cold chemical digestion.
No doubt, fibers produced under steam pressure with defibrators have a higher quality, but they are expensive and not very ecological due to the high energy consumption.
Fibers produced after cold chemical digestion by means of the machine according to the invention are less uniform and coarser, but they are much cheaper and more ecological, as the energy consumption is only a fraction. The quality is sufficient for composites for the outfitting of motor cars, for cardboard for packing purposes and for low density fiberboard as employed for heat insulation in construction.
Granulating and Pulverizing
Granulating or pulverizing solid fuel makes burning in boilers easier and aids combustion. Therefore, already today friction mills are employed for this purpose to serve dust fired boilers. The physical principle of such mills is shear and friction on friction elements. The material is many times recirculated along the friction ring or disc until the size is reduced sufficiently that the material can pass through screen perforations or lateral slots.
Recycling the material several times over friction elements involves a high risk of fire and even explosions, if hard foreign matter enters the machine and generates sparks. Furthermore with machines according to the state of the art, the wear of friction elements and tools is very costly. Last but not least, friction always means high energy consumption.
The entirely different working principle of the machine according invention avoids most mentioned disadvantages. Disintegration is not done by friction, but by high impulses. No friction or shear is applied in the basic machine. Consequently the energy consumption is much lower. No friction heat is generated.
The dwell time of the material in the machine according to the invention is a fraction of a second only, compared to seconds or sometimes minutes in machines according to the state of the art. There is basically only one short but very powerful impact on the material by the working edge ( 3 . 5 ) of the tool. Sparks can hardly be generated by foreign matter, since the impact is not accompanied by friction. Correspondingly, with the machine according to the invention, fire or explosion can hardly occur.
Granulating and pulverizing can also be done with limestone, gipsum stone, plastics and waste materials. By deep freezing, even rubber like or soft materials can be disintegrated.
The machine can also be employed for premilling of cereals, maize, seeds, or fruits. For such purposes, working edges ( 3 . 5 ) with small radius are to be preferred as well as high rotation speeds of rotor ( 2 ) and tool ring ( 3 ). Long dwell time helps to achieve small grain or powder like sizes, depending on material.
Cold Milling
A series of materials, especially food stuffs, pharmaceuticals, raw material with volatile and fragile ingredients lose flavor or similar characteristics when becoming hot by friction.
With the machine according to the invention, heat generation is very low due to the fact that there is no friction involved. If the friction ring ( 4 . 1 ) must be employed for more intensive disintegration, a cooling channel system ( 4 . 2 / 4 . 3 ) is provided to be installed behind the friction ring ( 4 . 1 ).
When disintegrating materials with sensitive flavor or fragile ingredients or similar are to be processed, the air throttle ( 6 ) should be kept wide open to take advantage of the cooling effect of the air passing through the machine. The degree of disintegration depends in the first instance on the speeds of rotor ( 2 ) and tool ring ( 3 ). The geometry of the tools is another influencing factor. For dry herbs for example a large radius will favor an explosion-like disintegration. For cereals and hard seeds a small radius and high rotation speeds are the better choice. If the resulting grain is still too coarse, the friction ring ( 4 ) should be installed to effect a subsequent milling.
List of reference numerals=
1 =machine housing
1 . 1 =front door of machine
1 . 2 =material feeding chute
1 . 3 =pillow block for drives
1 . 4 =scavenging air inlet hole
1 . 5 =material discharge
1 . 6 =stationary shear off knife/toll
2 =rotor
2 . 1 =rotor blades
2 . 2 =drive shaft of rotor
2 . 3 =V-belt disc for rotor
2 . 4 =distributing cone/disc
2 . 5 =wear blades
2 . 6 =shear off/cleaning knife
2 . 7 =scavenging air generator ribb
3 =tool ring
3 . 1 =base disc
3 . 2 =hollow wheel as drive of the tool ring 3
3 . 3 =drive of tool ring, hydraulically or mechanically
3 . 4 interchangeable tool, variabale in height and geometry
3 . 5 =interchangeable working edge, changeable in geometry
3 . 6 =large tool carrier, welded in
3 . 7 =upset and wear plate, replaceable
3 . 8 =“open circumference” in %=ratio of free passage between 2 tools and distance between the center lines of the 2 tools
3 . 9 =counter ring of tool ring
3 . 10 =connecting ring to base disc 3 . 1
3 . 11 scavenging air generator ribb at base disc 3 . 1
4 =upset an friction ring, stationary
4 . 1 =friction ring
4 . 2 =channel system for pressure air, cooling or drying air
4 . 3 =perforations in friction ring as continuation of the channel system 4 . 2
5 =feeding systems for additives
5 . 1 =feeding system for liquid additives
5 . 2 =feeding system for solid/powder additives
6 =air throttle
6 . 1 =pull in belt, upper or lower
6 . 2 =cross section adjustment, upper or lower
7 =toll pressure cleaning
7 . 1 =device for toll cleaning by pressure air or liquid
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A device to treat or process and especially to disintegrate materials and compounds characterized by a rotor, to which mentioned materials are fed axially. The rotor centrifugally accelerates the input material to a tool ring rotating around the rotor preferably in opposite direction, in which the tools are arranged radially. The tools of the tool ring intercept the highly accelerated material in flight and induce an extrem shear and bending strain effecting that the material disintegrates at it's natural weak point. The tools are arranged at the circumference at such distances that a laregely open circumference is established. That effects that the disintegrated components of the material can be discharged from the device after the impact without any hindrance even if the material is wet or sticky. The degree of impact of the tools on the material can be adjusted by the regulating parameters. That offers a large field of applications to disintegrate and separate raw materials and waste materials consisting of physically sufficiently different components into their individual components.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a domain wall displacement readout type magneto-optical disc and a manufacturing method thereof and, more in particular, to a method for annealing anneal tracks that exist at both sides of an information recording track.
2. Related Background Art
As a rewritable high density recording system, there is a system available wherein, by using thermal energy of a semiconductor laser, a magnetic domain is written in a magnetic thin film to record information and, by using a magneto-optical effect, this information is read. Further, in recent years, there has been an increasing demand for further increasing the recording density of the magneto-optical disc of this system so as to make it as a large-capacity recording medium. By the way, a line recording density of the magneto-optical disc and the like largely depends on a laser wave length λ of a reproduction optical system and a numerical aperture NA of an objective lens. In other words, when the laser wave length λ of the reproduction optical system and the numerical aperture NA of the objective lens are decided, the diameter of a beam waist is decided and, therefore, a spatial frequency at the time of reproducing a recorded domain has a detectable limit only at about 2 NA/λ.
Accordingly, in order to realize high density by the conventional magneto-optical disc, it is necessary to shorten the laser wave length of the reproduction optical system and enlarge the NA of the objective lens. However, there is a limit to improvement of the laser wave length and the numerical aperture of the objective lens. For this reason, a technology to think out a constitution of the recording medium and a reading method and improve recording density is being developed.
For example, in Japanese Patent Application Laid-Open No. 06-290496, the magneto-optical disc and its manufacturing method are disclosed, the disc using a perpendicular magnetic anisotropy multi-layer film having at least s domain wall displacement layer magnetically linked, a switching layer and a memory layer.
This method uses an ingenious mechanism, wherein, at the time of reproduction, a thermal gradient to be generated by irradiation of an optical beam is used and the domain wall of a recorded mark of the domain wall displacement layer is displaced without changing recorded data in the memory layer, and the domain wall displacement layer is magnetized so that a part of an optical beam spot area is uniformly magnetized and a change of the polarization plane of the reflected light of the optical beam is detected, thereby reproducing a recorded domain of the cycle below a diffraction limit.
By using this reproduction system, a reproduction signal becomes rectangular (FIG. 11 D), and it is possible to reproduce the recorded mark of the cycle below the diffraction limit of a light without lowering the reproduction signal amplitude by depending on an optical resolving power, and the magneto-optical disc capable of considerably improving the recording density and a transfer velocity becomes possible.
Note that, in this type of magneto-optical disc, in order to utilize the temperature gradient by irradiation of the light beam so as to easily cause the displacement of the domain wall of recorded mark of the domain wall displacement layer, a laser beam of high power is irradiated at the portion of adjacent two pieces of the anneal tracks (guide grooves) which make the information recording track of the magneto-optical disc exist between them, and a magnetic layer of the anneal track (guide groove) is annealed at high temperature and subjected to an annealing process which degenerates a magnetic layer of the portion of the anneal track (guide groove). By this annealing process, a switched connection between the information recording tracks is disconnected and the domain wall is not formed along the side portion of the information domain track of the recorded mark. As a result, the action of a domain wall coercivity is reduced, and more stabilized displacement of the domain wall becomes possible. This annealing process can obtain a good reproduction signal.
The reproducing action of the domain wall replacement type magneto-optical disc will be described by using FIGS. 11A to 11 D. Here will be dealt with the constitutions of three layers: a memory layer which governs the storing of the recorded mark; the domain wall displacement layer where the domain wall displaces and directly contributes to the reproduction signal; and a switching layer which switches a link status between the memory layer and the domain wall displacement layer.
FIG. 11A is a typical view which shows a magnetic domain reproducing state. A thick line 111 shows a domain wall of the domain wall displacement layer, and a narrow line 112 shows the domain wall of the memory layer only. FIG. 11B shows a state graph of a recording film, FIG. 11C a temperature state graph of a medium and FIG. 11D the reproduction signal. Note that the two pieces of the anneal tracks (guide grooves) which make the information recording track exist between them, as described above, subjected to the annealing process where a magnetic layer is degenerated by irradiation of high powered laser beam. At the time of reproduction, the anneal track is heated until a Ts temperature condition (FIG. 11A) where the domain wall of the domain wall displacement layer of a domain wall displacement medium is displaced by irradiation of a light beam 116 . Here, the Ts is the Curie point of the matter which constitutes the switching layer, and the switching layer 22 (FIG. 11B) is in a link state with the memory layer 21 and the domain wall displacement layer 23 by the switched connection in a low temperature area. When the magneto-optical disc displaces in the direction shown by an arrow mark 114 and is heated more than the Ts temperature by irradiation of the light beam, the link between the domain wall displacement layer and the memory layer is put into a disconnected state (inside of a Ts constant temperature line shown by the Ts of FIG. 11 A. For this reason, as soon as the domain wall of the recorded mark arrives at this Ts temperature area, an effect of the annealing process (annealing process portion by laser is shown by reference numeral 113 in FIGS. 11A to 11 D) of the two pieces of the anneal tracks (guide grooves) adjacent to the information recording track also takes place, and the domain wall of the domain wall displacement layer instantaneously displaces to the position where the domain wall can stably exist energy-wise in relation to the temperature gradient of the domain wall displacement layer, that is, to the direction of an arrow mark 115 so that the domain wall can cross the information recording track at the highest temperature of the line density direction of the temperature rise by the light beam irradiation. In this way, a large portion of magnetic state of an area S which is covered by the reproduction light beam becomes the same and, therefore, in the usual light beam reproduction principle, even if it is a minute recorded mark which is not possible to reproduce, a reproduction signal nearly in a rectangular shape as shown in the drawing can be obtained.
SUMMARY OF THE INVENTION
The present invention provides a domain wall displacement type magneto-optical disc where an error rate and a jitter of a reproduction signal are improved, and a manufacturing method of the disc.
According to an aspect of the present invention, there is provided a manufacturing method of a domain wall displacement type magneto-optical recording medium comprising the steps of:
depositing a magnetic layer on a substrate to prepare a disc; and
irradiating the magnetic layer with a converged light beam while applying a magnetic field and annealing the magnetic layer a converged light beam between information tracks.
According to another aspect of the present invention, there is provided a domain wall displacement type magneto-optical disc comprising:
a domain wall displacement layer in which a domain wall displaces;
a memory layer that holds a recording magnetic domain according to information;
a switching layer that is provided between the domain wall displacement layer and the memory layer and has a Curie temperature lower than that of those layers; and
a disconnecting area that is provided in the domain wall displacement layer and disconnects a switching connection between information tracks;
wherein the polarity of a residual magnetization at a boundary between the information track and the disconnection area is oriented in a certain direction.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a view to explain a manufacturing method of the present invention;
FIG. 2 shows an annealing device to be used in the manufacturing method of the present invention;
FIGS. 3A, 3 B, 3 C and 3 D show a timing chart to show the action of a first embodiment of the present invention;
FIG. 4 shows an example of an application of an annealing magnetic field;
FIG. 5 shows another example of the application of the annealing magnetic field;
FIG. 6 shows a jitter property graph of the first embodiment of the present invention;
FIG. 7 shows a pulse width fluctuation property graph by a second embodiment of the present invention;
FIG. 8 shows another example of an annealing device to be used in the manufacturing method of the present invention;
FIG. 9 shows a case where an annealing magnetic field parallel to a light beam scanning direction inside the disc surface is applied;
FIG. 10 shows a case where the annealing magnetic field perpendicular to the light beam scanning direction inside the disc surface is applied; and
FIGS. 11A, 11 B, 11 C and 11 D are a view to explain the reproducing method of a domain wall displacement type magneto-optical recording medium.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a schematic diagram to show a property of an annealing method of a magneto-optical disc of the present invention. It shows a sectional view of a magneto-optical disc 3 at the stage where a step of laying on a magneto-optical disc substrate 1 comprising glass or plastic as a material a magnetic layer 2 which includes at least a domain wall displacement layer where the domain wall displaces, a memory layer which holds information as a recording magnetic domain and a switching layer provided between the domain wall displacement layer and the memory layer and having Curie temperature lower than those layers has been completed. While any protective layer is still not formed at the stage of FIG. 1, it does not matter whether the protective layer exists when annealing the disc. Here, a character d denotes one of the information recording tracks, and the information track is an area which forms a recording magnetic domain to hold the information such as a user data etc. In general, this convex portion provided on the substrate is referred to as a land. Magneto-optical disc of FIG. 1 has a constitution in which the light beam for use of forming an anneal track enters from the back side of the substrate where the magnetic layer 2 is not formed. Characters a and a′ which make an information recording track d exist between them denote anneal tracks, which are formed by a laser annealing with a higher light intensity than that at writing an information on the information recording track d.
In the present drawing, the anneal tracks a and a′ serve also as the guide grooves to control the light beam at the center of the information recording track d in the reproduction step. In general, the concave portion provided on the substrate is referred to as a groove.
In the present embodiment, the lands (convex portions) on the substrate 1 are taken as information recording tracks and the grooves (concave portions) as the anneal tracks, but the constitution of the magneto-optical disc is not limited to this. For example, a constitution wherein the lands (convex portions) are taken as the anneal tracks and the grooves (concaves) are taken as the information recording tracks is also allowable.
The laser spots denoted by characters b and b′ show the converged light beams when annealing anneal tracks a and a′, which enter from the back of the substrate.
In the drawing, the laser spots of b and b′ are illustrated as if the two points were irradiated at the same time. This is to clarify that the directions of annealing magnetic fields applied to the two anneal tracks which are adjacent to the information recording track are different.
Characters c and c′ show the polarities of applied magnetic fields in the case where the anneal tracks a and a′ are annealed. In the present embodiment, the direction of the applied magnetic field is from one side of the substrate on which the magnetic layer 2 is provided to the other side of the substrate (i.e., the back side of the substrate) when anneal track a is annealed, and the direction of the applied magnetic field is from the back side of the substrate to the side on which the magnetic layer 2 is provided when anneal track a′ is annealed. In addition, the annealing magnetic fields at the adjacent anneal tracks with the information recording track d made to exist between them have opposed polarities.
In order to form the anneal tracks by applying thus annealing magnetic fields perpendicular to the substrate surface, a device as shown in FIG. 2 is suitable.
A magneto-optical disc 100 , wherein a magnetic layer 2 is formed on a magneto-optical disc substrate 1 made of glass or plastic and further a protective layer 3 is formed, is held on a spindle motor with a magnetic chucking and the like, and is constituted such that it is rotatable against an axis of rotation.
A laser light for forming the anneal track generated from a semiconductor laser light source 7 is changed to a parallel ray by a collimator lens 8 and passes through a beam splitter 9 and is converged by a condenser lens 6 . Then a predetermined position of the magneto-optical disc 100 is irradiated with the converged laser light as a beam from the back. Note that the condenser lens 6 is driven by a drive actuator 5 .
On this occasion, the condenser lens 6 is constituted such that it is controlled by actuator 5 to move in a focusing direction and a tracking direction so that the laser light successively places a focus on the magnetic layer 2 . The condenser lens 6 also moves along the guide groove engraved on the magneto-optical disc.
On the other hand, the reflected light which reflected from the surface of magneto-optical disc surface passes through a route in reverse to the incident light and arrives at the beam splitter 11 and is reflected at a right angle and passes through a λ/2 plate 10 . This λ/2 plate is a filter to rotate a the reflected light at 90° in the polarizing direction of the incident light.
Further, the reflected light enters the polarized beam splitter 11 and is put into two condenser lenses 12 by the polarity of the magneto-optical disc magnetization of the magneto-optical disc 100 . Two pieces of photo sensors 13 detect the intensities of the incident lights which enter the sensors respectively. The detected resultants are amplified respectively by a differential amplification circuit 14 which differentially amplifies the signal converged and detected respectively according to the polarization direction and by a summing amplification circuit 15 which summing-amplifies the signal converged and detected respectively according to the polarization direction. A light magnetic signal and by a summing signal from the differential amplification circuit 14 and the summing amplification circuit 15 are synthesized and binarized by a digital circuit 200 and outputted to a controller 17 . In addition, the number of rotations of the magneto-optical disc, an annealing radius, an annealing sector information and so forth are inputted to controller 17 , and a signal to control an annealing power is outputted to a LD driver 16 . The LD driver 16 irradiates a laser to a substrate 1 under a predetermined condition according to that signal.
Further, the controller also controls a magnetic head driver 19 at the same time, and outputs a signal which controls the polarity of the annealing magnetization and the like.
Reference numeral 18 denotes a magnetic head to apply a magnetic field to a laser-irradiated portion of magneto-optical disc 1 when forming an anneal track, and sandwiches the magneto-optical disc 100 and is arranged in a manner that opposes to condenser lens 6 . Magnetic head 18 is used to record information and to reproduce it. In the annealing, a semiconductor laser 7 irradiates the LD driver 16 with an anneal laser power and, at the same time, the magnetic head 18 is allowed to generate a perpendicular magnetic field of a polarity corresponding to a polarity signal of a magnetic field applied for annealing an anneal track (hereinafter referred to as “annealing applied magnetic field”) by magnetic head driver 19 . The magnetic head 18 is constituted such that, coupled with an optical head, it moves in the radial direction of the magneto-optical disc 1 and, at the annealing step, applies a magnetic field successively to the laser-irradiated portion of the magneto-optical disc 3 to perform a desired annealing.
However, means which reproduces the information from the reflected light from the magneto-optical disc is not necessarily required. Such a means is utilized as means to detect a pre-format and the like and to reproduce a magneto-optical signal when controlling a timing to switch the polarity of the annealing applied magnetic field by the reflected light from the magneto-optical disc, or when checking whether a desired property develops in the information recording track or not after the annealing of the anneal track. In the case, a construction where a parameter such as a laser power according to the annealing, an applied magnetic field or the like is changed into a value relative to the recording or reproduction by the controller 17 is required.
In the idea of the above described annealing method and the annealing means, the action of annealing the anneal track will be described by using FIGS. 3A to 3 D. FIG. 3A shows an annealing power ON/OFF signal which shows the start of the annealing, FIG. 3B shows an applied magnetic field polarity change timing signal which shows a timing to change the polarity of the applied magnetic field, FIG. 3C shows an applied magnetic field polarity control signal which controller 17 outputs to magnetic head driver 19 , and FIG. 3D shows a generated magnetic field of magnetic head 18 . An irradiating power of the laser is set to a desired annealing power by an annealing start command from controller 17 . Although the annealing power is different depending on a property of the magneto-optical disc, but it is typically about two times that of the recording power. At the same time of the irradiation of the laser power, the annealing magnetic field is applied by the magnetic head 18 . On this occasion, the polarity of the applied annealing magnetic field is allowed to generate the magnetic field of the polarity corresponding to a polarity of the applied magnetic field control signal from the controller 17 . As described below, the absolute value of the magnetic field intensity is preferable to be larger than about 50 Oe. In order to execute the property of the present invention, it is necessary to switch the polarity of the applied magnetic field at least more than one time for one cycle, and this switching timing is controlled by an applied magnetic field polarity change timing signal from the controller 17 . The applied magnetic field polarity change timing signal can be formed by counting a clock for rotation control of the spindle and can be also formed by detecting the reflected light such as a phase pit which causes a change of reflectivity embedded in advance in the anneal track of the magneto-optical disc as an applied magnetic field change timing. The later makes it possible to control the magneto-optical disc by higher position accuracy.
Since the switched portion of the polarity of the annealing applied magnetic field is considered to have adverse effect on the information recording track, the area where the polarity of the annealing applied magnetic field is switched is preferably the area where the adjacent information recording track is not an user data area, for example, preferably a header area which shows a sector position information and the like. Further, an applied magnetic field polarity switching area may be specially provided. By these means and processes, it is possible to control the applied magnetic field to a predetermined magnitude and polarity in annealing the anneal tracks adjacent to both sides of the information recording track.
Examples of the applied magnetic field polarity change timing in a case where the magneto-optical disc is annealed by these means are shown in FIGS. 4 and 5. In FIGS. 4 and 5, reference numeral 41 denotes the anneal track, and reference numeral 42 denotes the information recording track. Among the anneal tracks, the hatching portion shown by T has the applied magnetic field at the time of annealing in the upward direction to the plane of the drawing, and among the anneal tracks, the hatching portion shown by F has the applied magnetic field at the time of annealing in the downward direction to the plane of the drawing. In FIG. 4, switching of the polarity of the annealing magnetic field is performed only when the magnetic field-applying means moves to the next anneal track and the switching is one time for one cycle of the anneal track. In contrast to this, in FIG. 5, since the anneal track of one cycle is divided into four continuous magnetic areas, the switching of the polarity of the applied magnetic field is performed five times. The white portion 42 indicates the information recording track in FIG. 5 . The figure shows that the polarities of the annealing magnetic fields in adjacent portions T and F of the recording tracks are reversed.
The timing of switching the applied magnetic field is not limited to the above. The gist of the switching is adaptable not only to CAV but also to format, of zone CAV, CLV and zone CLV, assuming that the applied magnetic fields at the time of annealing anneal tracks adjacent to both sides of an information track have opposite polarities.
(Embodiment 1)
The present invention was executed by the device described in FIG. 2 . The device of FIG. 2 applies an annealing magnetic field perpendicular to the magneto-optical disc surface.
FIGS. 6 and 7 show properties in embodiments of the present invention and the comparative examples, as explained below.
After completing the formation of the magnetic layer, the annealing of the anneal track was conducted by laser beam under various conditions.
In FIG. 6, the ordinate shows a jitter property. The jitter property is better as the value of the jitter property is smaller. The abscissas of FIG. 6 shows applying methods of the magnetic field at the time of annealing the anneal track.
Described in order from the left side on the axis of the abscissa are the methods
(1) wherein, as comparative example 1, the applied magnetic fields at both of the anneal tracks adjacent to the information recording track were taken as −300 Oe and were applied to all the anneal tracks the annealing magnetic field of the same polarity at the same magnitude.
(2) wherein, as comparative example 2, the applied magnetic fields at both of the anneal tracks adjacent to the information recording track were taken as +300 Oe, which was the same as (1) in annealing magnetic field.
(3) wherein, as comparative example 3, the applied magnetic fields at both of the anneal tracks adjacent to the information recording track were taken as 0 Oe, and the annealing magnetic field was not applied at the time of forming the anneal track.
(4) wherein, as example 1, the applied magnetic fields at both of the anneal tracks adjacent to the information recording track were inversed in polarity by one cycle interval, and the generated magnetic field was taken as ±300 Oe, which corresponds to FIG. 4 .
FIG. 7 is the same as FIG. 6 in axis of abscissas, and the axis of ordinates shows a aberration amount of the reproduction signal pulse width in relation to the regular pulse width in the reproduction signal. If the pulse width is near to “0”, it shows that it is near to the desired pulse width.
Table 1 shows annealing magnetic field applied conditions and reproduction properties.
TABLE 1
Table: Annealing magnetic field (magnetic field
applied in the direction perpendicular to the disc
surface) and reproduction property.
Comparative
Comparative
Comparative
Example 1
Example 2
Example 3
Example 1
Condition
Annealing
available
available
not available
available
of
Magnetization
Annealing
Applied
Magnet-
Reversal of
not available
not available
not available
available
ization
Polarity
Applying
Intensity of
+300
−300
0
±300
Annealing
Magnetization
Length of
one cycle
one cycle
—
one cycle
Continuous
Magnetization
Area
Reproduc-
Jitter
good
good
bad
good
tion
Property
Property
Estimation
Pulse Width
bad
Bad
a little
good
Property
bad
Estimation
Overall
bad
bad
bad
very good
Estimation
Regarding jitter property, example 1 shows that a jitter value is low. (FIG. 6, Table 1)
The pulse widths regarding the three types of the method for applying the annealing magnetic field were estimated. Comparative examples 1 and 2 have large aberrations in the reproduction signal pulse width (FIG. 7, Table 1). Embodiment 1 has the most excellent performance among the four experiments even in pulse width.
From the result of these experiments, it is evident that, in the case where the applied magnetic fields at both of the anneal tracks adjacent to the information recording track are inversed at intervals of every one cycle and the generated magnetic field is taken as ±300 Oe, the jitter property is excellent and the pulse width fluctuation is not generated, and it is the most suitable annealing condition among the above described conditions.
In this way, the remanent magnetization at the boundary between the anneal track, where, though there is a deterioration of the magnetic property due to the laser annealing of the present invention, the magnetic property is not lost completely, and the information recording track is taken as a predetermined polarity by both of the adjacent anneal tracks which make the information recording track exist between them, so that the influence for the magnetic recording track in the information recording track is offset and the influence can be equalized. In this way, it is possible to provide the magneto-optical disc, which can obtain the reproduction signal of high quality, and further improve the recording density.
The remanent magnetization at the time of the above described annealing has been confirmed not to be inversed by a recording power usually used and a recording magnetic field usually used.
(Embodiment 2)
In FIG. 8 is shown a schematic diagram to show a property of the second embodiment of the annealing method of a magneto-optical disc of the present invention. In the drawing, what is different from embodiment 1 is that a ring head is used, where the magnetic disc 18 , which applies the magnetic field at the time of annealing, can apply the annealing magnetic field in the in-plane direction of the face of the disc to a heated area on the recording medium. In this way, the magnetic field which is parallel to the magneto-optical disc surface can be applied to a heated annealing portion. In the case where the magnetic field is applied to the inside of the magneto-optical disc surface, there exist two directions parallel and perpendicular to the scanning direction of the light beam. In FIG. 9, an example of the annealing applied magnetic field was shown, where the annealing applied magnetic field is in the in-plane direction to the face of the magneto-optical disc and parallel to the light beam scanning direction. In the case where the annealing magnetic field is applied in this direction, it is not necessary to consider the polarity of the magnetic field and it does not matter whether it is the same polarity or different. In FIG. 10, an example of the annealing applied magnetic field, where the annealing magnetic field is perpendicular in the plane of the face of magneto-optical disc, is shown. In the case of FIG. 10, when the annealing magnetic field of the reverse polarity is applied, it is necessary to certainly apply the annealing magnetic field of the same polarity since there is a risk of the magnetic field line loop of the remanent magnetization owned by the adjacent anneal tracks being multiplied on the information recording track.
As shown in FIGS. 9 and 10, in order to change the polarity of the generated magnetic field to the scanning direction of the light beam, the direction of the ring head of FIG. 8 may be changed 90°. As already described as above, in FIG. 10, although the annealing applied magnetic fields have the same polarity, the polarity of the applied magnetic field does not cause any specific problem in the case where the annealing applied magnetic fields are parallel to the light beam scanning direction. Further, in the present embodiment, though the ring head was used in order to generate the magnetic field parallel to the magneto-optical disc surface, there is no limit to this, but it does not matter specifically whatever shape it has, provided the magnetic field parallel to the magneto-optical disc surface can be applied to the laser irradiated portion at the time of annealing.
In this way, the remanent magnetization at the boundary between the anneal track, where, though there is a deterioration of the magnetic property due to the laser annealing of the present invention, the magnetic property is not lost completely, and the information recording track is directed to the direction of the inside of the magneto-optical disc surface, so that the influence can be reduced for the magnetic area of the perpendicular direction recorded in the information recording track, and it is further possible to equalize the influence.
Note that the remanent magnetization at the time of the above described annealing is confirmed not to be inversed by the usually used recording power and the recording magnetic field.
As described above, the remanent magnetization at the boundary between the anneal track, where, though there is a deterioration of the magnetic property due to the laser annealing of the present invention, the magnetic property is not lost completely, and the information recording track is equalized and the influence of the remanent magnetization is taken as a predetermined polarity by both of the anneal tracks which make the information recording tracks exist between them, so that a bad influence on the information recording track can be offset, and the jitter property and the pulse width fluctuation can be improved. Further, the remanent magnetization at the boundary between the anneal track and the information recording track is directed to the direction of the inside of the magneto-optical disc surface, so that the influence for the magnetic area in the perpendicular direction recorded in the information recording track can be equalized. In this way, the reproduction signal having higher quality than that of the conventional method can be obtained. Furthermore, since the information recording track width can be made narrower than that of the conventional method, it is possible to further improve the recording density of the magneto-optical disc.
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A manufacturing method of a domain wall displacement type magneto-optical recording medium comprises the steps of depositing a magnetic layer on a substrate to prepare a disc, and irradiating the magnetic layer with a converged light beam while applying a magnetic field and annealing the magnetic layer a converged light beam between information tracks. A domain wall displacement type magneto-optical disc comprises a domain wall displacement layer in which a domain wall displaces, a memory layer that holds a recording magnetic domain according to information, a switching layer that is provided between the domain wall displacement layer and the memory layer and has a Curie temperature lower than that of those layers, and a disconnecting area that is provided in the domain wall displacement layer and disconnects a switching connection between information tracks, wherein the polarity of a residual magnetization at a boundary between the information track and the disconnection area is oriented in a certain direction.
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RELATED APPLICATIONS
[0001] This application claims priority to and is a continuation-in-part application of U.S. patent application Ser. No. 12/439,957, entitled Blade Assembly for Excavating Apparatus, Filed on Sep. 2, 2009, which is a national stage application of and claims priority to International Application No. PCT/AU2007/001297, filed Sep. 4, 2007, which designates the U.S., which application claims priority to Australian Application No. 2006904874, filed on Sep. 4, 2006. Each of the above-identified applications are expressly incorporated herein by this reference.
FIELD OF THE INVENTION
[0002] The present invention relates to a blade to be mounted to an excavating machine. Excavating machines comprise but not limited to bulldozers, tractor shovels, graders, drag line apparatuses and compacting machines.
[0003] In the context of the invention a blade is intended to cover any type of working tool with an edge which is intended to contact material so that it can be moved. Thus a blade includes but not limited to a bucket, collector and spreader.
[0004] By way of example the present invention will be described in relation to a bulldozer blade.
BACKGROUND OF THE INVENTION
[0005] A bulldozer can be used on a variety of working sites. The blade can be used for a variety of different operations including digging, carrying of soil or other material, banking, compacting and levelling. The design of the blade and how it is used determines the efficiency of the bulldozer in a working situation. It is advantageous to maximise working efficiency by designing a blade which is easier to use and can perform at least one function better than an existing blade.
[0006] The ability of a blade to dig into the ground depends on the shape of the front edge, force for pressing the blade into the ground as well as the angle of the blade when it contacts the earth. U.S. Pat. No. 6,938,701 discloses one type of bulldozer blade in which the front edge of the blade has a width which is larger than the width between the tracks of the bulldozer which carries it. This front edge is straight and perpendicular to the direction of movement of the vehicle in a forward direction. On either side of the central section the blade is angled rearwardly and then forwardly to provide three separate sections of cutting edges. The side and end sections are connected in a V-type configuration which is completely behind the front edge of the central section.
[0007] In operation the blade must be tilted downwardly with respect to its non-operative position in order to engage a ground surface.
[0008] The blade described in this patent suffers a number of drawbacks which reduces overall operating efficiency. One of the disadvantages with the blade design is that the blade must be tilted upwardly in order retain material effectively on its surface. Furthermore, the blade must be tilted downwardly to engage a ground surface. Furthermore, the ability of the blade to cut through a ground surface is inferior to blades which have a point. As well material which is contacted by the front edge moves up the front face of the blade but interferes with excavation of further material in front of the blade. Any material which moves to the side of the front edge of the blade generally escapes beyond each edge of the blade if the blade moves too far forward without being tilted upwardly.
[0009] Other disadvantages arise from the shape of the front face and difficulties associated with effectively cutting into a ground surface.
[0010] For existing bulldozers, present practices when loading material onto a blade that is tight is to use the corner tips to achieve penetration and roll the blade back when loaded. This has a tendency to turn the dozer towards the corner tip as the load is now off centre. If the operator is not very experienced he will use the steering clutches in an attempt to keep the dozer moving straight. As well the existing blades do not fill to full capacity when in operation.
OBJECT OF THE INVENTION
[0011] It is an object of the present invention to provide an alternate blade that overcomes at least in part one or more of the above mentioned disadvantages.
SUMMARY OF THE INVENTION
[0012] In one aspect the invention broadly resides in a blade for an excavating apparatus comprising
[0013] a substantially concave front face with a side wall on each side of the front face, said front face has a raised substantially concave centre section at a substantially central and lower position on the front face, said front face has a side gusset portion on each side of the centre section, side gusset portions slope from the centre section, said front face has a centre forward edge portion, a side forward edge portion on each side of the centre forward edge portion and an end forward edge portion on each distal side of the side forward edge portion;
[0014] wherein the angular position of the centre forward edge portion is discontinuous with the concave arc of the centre section and the concave arc of the centre section is discontinuous with the concave arc of a front face section above the centre section to form three adjacent discontinuous sections which cooperate with the side gusset portions to direct excavated material outwardly from the centre section towards the side walls.
[0015] Preferably the present invention provides a blade that can use its centre for penetration assisting the bulldozer's ability to use both tracks to push the blade and reduce the loading time then roll back after loaded.
[0016] Preferably a blade in accordance with the present invention has a centre for penetration which results in power being applied to the centre of the blade when loading and not the corners.
[0017] In one embodiment the end forward edge bottom edges are lower than the bottom edges of the side forward edges. The bottom corners of distal edges of the end forward edge are preferably the lowest point of the blade.
[0018] It is preferred that the angle β is less than θ where β is the angle between the end forward edge and a line perpendicular to the centre forward edge and θ is the angle between the side forward edge and a line perpendicular to the centre forward edge.
[0019] The centre forward edge preferably extends perpendicular to the forward direction of the blade.
[0020] Preferably the side forward edges are each angled rearwardly with respect to the centre forward edge.
[0021] At least one of the forward edge portions is attachable to the front face.
[0022] At least one of the forward edge portions is removably attachable to the front face or other part of the blade.
[0023] At least one forward edge is made separately from the rest of the blade.
[0024] The side edges may extend forward from either side of the front face.
[0025] According to one embodiment the side edges extend outwardly from either side of the front face.
[0026] Each forward edge may comprise a metal plate or plate of other impact resistant material.
[0027] Preferably the blade is described on the basis it is resting on a ground surface or in a neutral position.
[0028] According to one embodiment the end forward edge has a forward most end edge which is behind the centre front edge.
[0029] According to another aspect of the present invention there is provided a blade for an excavating apparatus comprising a front face, side walls on each side of the front face, a centre forward edge portion, a side forward edge portion at each side of the centre forward edge portion and an end forward edge portion at each distal side of the side forward edge portion; wherein each side wall has a front edge which is behind the forward most edge of the end forward edges and in front of the rearmost portion of the side forward edge portions.
[0030] Each side wall may have a lower edge portion which is slanted rearwardly.
[0031] The lower front edge of the side walls may be in front of the rearmost portion of the end forward edges.
[0032] Each upper portion of each side wall preferably extends over the end forward edges.
[0033] Each end forward edge may be disposed inwardly of an outer portion of each end forward edge.
[0034] It is preferred that each side wall has a front edge which is located behind the centre forward edge portion.
[0035] Preferably the rearmost point of the side forward edge portions is located behind the front edge of the side walls.
[0036] According to one embodiment the corner portion located between the end forward edges and the side forward edges is located behind the front edge of the side walls.
[0037] According to one embodiment the centre forward edge portion comprises a lower edge which extends rearwardly below the front face in a generally horizontal orientation.
[0038] According to another aspect of the present invention there is provided a blade for an excavating apparatus comprising a front face, side walls on each side of the front face, a centre forward edge portion on each side of the centre forward edge portion and an end forward edge portion on each distal side of the side forward edge portion;
[0039] wherein the front face comprises a substantially concave centre section and side gusset portion on each side thereof for directing material outwardly toward the side walls.
[0040] Preferably each gusset portion comprises a curved plate section curved towards respective side walls.
[0041] Each gusset portion may comprise a generally triangular surface portion.
[0042] Each centre section preferably has substantially the same width as the centre forward edge portion.
[0043] The centre section may be aligned behind the centre forward edge portion.
[0044] Each gusset portion may extend at a slant forwardly to an outer mid section of the side forward edge.
[0045] Preferably the front face is contoured so that material slides off it when the blade is oriented in a neutral position (tilted neither up or down).
[0046] Alternatively or in conjunction the front face is contoured so that the material slides off it when the side walls top edge is parallel to the ground.
[0047] According to one embodiment the width of the centre forward edge portion is less than the width between tracks of a vehicle or wheels of a vehicle to which the blade is connected/attached.
[0048] The blade may be adapted to be tilted forward and back/down and up.
[0049] Preferably the width W of the centre forward section is less than the width of the side forward edge portions M.
[0050] The width of the end forward edge portions is preferably less than the width of the side forward edge portions.
[0051] Preferably the width of the end forward edge portions is less than the width of the centre forward edge portion.
[0052] According to one embodiment of the invention the side walls are straight/vertical in a neutral position of the blade.
[0053] Preferably each optional feature of the invention can be used in any aspect of the invention.
[0054] Each edge may be inclined forward between 70° and 30° when the blade is in a neutral position.
[0055] Preferably the side forward edge is at an obtuse angle with respect to the centre forward edge.
[0056] According to one embodiment the blade is attached to a controlling machine through a lower pivot and an upper pivot connected to an actuable piston, which is adapted to tilt the blade upwardly or downwardly with respect to the lower pivot.
[0057] According to another aspect of the present invention each of the forward edge portions may be made separately as removably attachable plates.
[0058] It is preferred that the end forward edges have pointed lower end edges, which are configured to engage a ground surface before any part of the centre forward edge portion.
[0059] It is preferred that the front face comprises a concave surface from a lower end portion to an upper end portion.
[0060] Preferably the whole of the front face is concave.
[0061] According to one embodiment the front face comprises two concave portions, the lower concave portion being configured to allow retention of material thereon if the blade is tilted upwardly from its neutral position.
[0062] According to one aspect of the present invention anyone of the blades hereinbefore described is part of a blade assembly including attachment portions to enable the blade to be attached to an excavation apparatus such as a bulldozer, backhoe, or any other vehicle which utilises an excavation bucket.
[0063] It is to be understood that reference to “blade” is to be interpreted broadly to cover an excavation bucket, a digging implement which collects material and any other device which engages a ground surface or material deposited on a ground surface or equivalent and is able to cut or dig through the material and collect it on its upper surface.
[0064] According to another embodiment of the present invention there is provided a blade assembly comprising a blade according to any one of the above defined embodiments.
[0065] It is preferred that a blade assembly in accordance with one of the above defined embodiments includes one or more attachment portions for attachment to controlling rams for tilting the blade.
[0066] According to another embodiment of the present invention a blade according to any one of the previously described embodiments includes an attachment portion for attachment to a lifting ram.
[0067] According to a further embodiment of the present invention there is provided a blade assembly including a blade according to any one of the previously defined embodiments and an attachment portion which is configured to be attached to a lifting arm of a vehicle such as a bulldozer or grader.
[0068] According to another aspect of the present invention there is provided a method of controlling a blade according to any one aspect of the invention previously defined, the method comprising moving the blade downwardly, forcing the lowermost edge of the blade below a ground surface and tilting the blade upwardly while the lowermost edge is below the ground surface.
[0069] It is preferred that the lowermost edge comprises the centre forward edge portion.
[0070] Preferably the blade is tilted to a generally horizontal disposition.
[0071] It is preferred that the blade is tilted upwardly so front edges of the side walls are substantially in a vertical orientation.
[0072] According to another aspect of the present invention there is provided a controller for controlling operation of a blade assembly comprising a blade according to any one of the aspects of the invention previously defined, lifting pistons, tilting pistons and support arms, wherein the blade is able to be controlled by the pistons and support arms to engage a ground surface and roll back/tilt upwardly once the blade cuts into the ground surface.
[0073] According to a further aspect of the present invention there is provided a controller for controlling operation of a blade as defined in any one of the previous aspects of the present invention, the controller comprising a first module for controlling operation of tilting pistons, a second module for controlling lifting pistons and a third module for controlling blade support arms, wherein based on data relating to the material which is to be engaged by the blade, the first module is operated to control the lifting piston to drop the blade, the second module is operated to control the tilting piston to tilt the blade downwardly and wherein when the centre forward edge portion has cut into the ground surface/material module is operated to control the tilting piston to tilt the blade upwardly while maintaining the lowermost edge of the centre forward edge portion below the ground surface/material surface.
[0074] It is preferred that the third module maintains the blade in a substantially constant position relative to the ground surface. In this respect it is to be understood that the supporting arms are preferred to be in a horizontal disposition when the blade is tilted downwardly and the centre forward edge portion engages the ground surface/material.
[0075] According to the preferred embodiment of the present invention the support arms are pivotally connected to a rearward back portion of the blade through an attachment portion.
[0076] It is to be understood that the blade in accordance with one or more embodiments of the invention is connected to a machine such as a bulldozer through mountings including rams/pistons and supporting arms in a configuration consistent with conventional bulldozers.
[0077] According to one embodiment each module comprises a sub program of a computer program.
[0078] According to one embodiment of the present invention the controller includes one or more sensors for sensing the orientation of the blade.
[0079] According to another embodiment of the present invention each mounting (piston, arm, etc. includes a sensor for sensing the position/length of extension or contraction of a mounting.
[0080] According to one embodiment of the invention the tilting piston comprises a cylinder and rod and a position sensor for sensing the relative position of the rod and the cylinder.
[0081] According to another embodiment the lifting piston comprises a cylinder, rod and sensor for sensing the relative position of the rod and cylinder.
[0082] According to another embodiment of the present invention the support arms comprise a sensor for sensing the orientation of the arms with respect to a horizontal and/or vertical axis.
[0083] According to a further aspect of the present invention there is provided a method of controlling a blade in accordance with the present invention as defined in any one of the previous aspects, comprising collecting material on a front face of the blade, lifting the blade upwardly by operating the lifting pistons, tilting the blade upwardly by operating the tilting pistons whereby lowermost edges of the blade disengage from a ground surface.
[0084] It is preferred that the method includes moving the blade forward once it has disengaged from a ground surface.
[0085] In another aspect the invention broadly resides in a blade for an excavating apparatus comprising
[0086] a substantially concave front wall with a side wall on each side of the front wall, said front wall has a front face that has a raised substantially concave centre section at a substantially central and lower position on the front face, said front face has a side gusset portion on each side of the centre section, side gusset portions slope from the centre section, said front face has a centre forward edge portion, a side forward edge portion on each side of the centre forward edge portion and an end forward edge portion on each distal side of the side forward edge portion;
[0087] wherein the angular position of the centre forward edge portion is discontinuous with the concave arc of the centre section and the concave arc of the centre section is discontinuous with the concave arc of a front face section above the centre section to form three adjacent discontinuous sections which cooperate with the side gusset portions to direct excavated material outwardly from the centre section towards the side walls.
[0088] Preferably the side gusset portions extend from the centre section to the side forward edge portion adjacent the end forward position. Each side gusset portion preferably forms a substantially triangular shaped sloping section.
[0089] Preferably each of the side gusset portions extend from the centre section to a position where the side forward edge portion is adjacent to the end forward edge portion and forms a substantially triangular shaped sloping section either side of the centre section.
[0090] Preferably the centre forward edge portion and the side forward edge portions are substantially in line providing a substantially continuous edge portion.
[0091] Preferably the end forward edge portion is substantially in line with the side forward edge portion. Preferably the end forward edge portions provide a substantially continuous edge portion section with the side forward edge portions and the centre forward edge portion. Preferably the end forward edge portions are substantially aligned along a horizontal axis with the side forward edge portions and the centre forward edge portion.
[0092] In a preferred embodiment the centre forward edge portion is lower than the other edge portions so that it contacts the ground first and excavated material consequently moves up the centre forward edge portion and centre section.
[0093] In an alternate embodiment the end forward edge portion forms a v-shape with the adjacent side forward edge portion.
[0094] Preferably the end forward edge portions are substantially in line with the side forward edge portions and the centre forward edge portion and the centre forward edge portion is orientated lower than the other edge portions so that it contacts the ground first and excavated material consequently moves up the centre forward edge portion and centre section. Preferably the end forward edge portions provide a substantially continuous edge portion section with the side forward edge portions and the centre forward edge portion and the centre forward edge portion is orientated lower than the other edge portions so that it contacts the ground first and excavated material consequently moves up the centre forward edge portion and centre section. Preferably the end forward edge portions are substantially aligned along a horizontal axis with the side forward edge portions and the centre forward portion and the centre forward edge portion is disposed vertically lower than the end forward edge portions and the side forward edge portions.
[0095] Preferably a top section of the front wall adjacent the side walls curves over towards the front of the blade. Preferably the top section of the blade adjacent the side walls curves over by several degrees. Preferably the top section of the front wall adjacent the side walls bends towards the front of the blade by several degrees.
[0096] The side walls preferably extend higher than the front wall. More preferably the side walls extend higher and rearward of the front wall.
[0097] A corner formed by the front wall and the side wall is preferably supported by a bracket and without a boxed gusset.
[0098] A blade with an upper corner formed by the front wall and the side walls with the curved top section of the front wall and with the side walls that extend above the front wall preferably enables an increased volume of excavated material to be retained on the blade.
[0099] Preferably the top section of the blade has a plurality apertures for an operator to view in front of the blade. Preferably the plurality of apertures are spaced along a central and side sections of the top section of the blade.
[0100] Preferably there is an upper attachment point located on each of the side walls above and preferably behind the front face of the blade. Preferably the upper attachment point is used by cranes to lift the blade. The position of the upper attachment point is preferably a balanced position for a crane to lift the blade without swinging crooked.
[0101] Preferably there are a plurality of mountings on the back wall of the blade. The plurality of mountings preferably provides connection to one or more lifting arms and one or more rams. More preferably the plurality of mountings are positioned adjacent the back wall of the blade to have the centre of gravity of the blade closer to the associated vehicle thereby providing more control over the blade and helping balance the vehicle with the blade.
[0102] The attachment of the lifting arms and rams to the blade preferably orientates the blade in a manner so that substantially all of the carried excavated material can be discharged when the blade is in a forward tilt position.
[0103] The one or more rams attached to the mountings can preferably tilt the blade forward at an angle between 89 and 70 degrees relative to the ground level. Preferably the blade can tilt forward to a maximum of approximately 75.8 degrees relative to the ground level. Preferably the blade can tilt forward to an extent that allows the blade to unload substantially all of the carried excavated material.
[0104] The one or more rams attached to the mountings can preferably tilt the blade backwards at an angle between 91 and 100 degrees relative to the ground level. Preferably the blade can tilt backwards to a maximum of approximately 92.3 degrees relative to the ground level.
[0105] The degree of forward and rearward tilt is preferably achieved with rams that have longer piston strokes.
BRIEF DESCRIPTION OF THE DRAWINGS
[0106] Preferred embodiments of the present invention will now be described by way of example only with reference to the accompanying drawings in which:
[0107] FIG. 1 shows a diagrammatic plan view of a blade according to a first preferred embodiment of the present invention;
[0108] FIG. 2 shows a diagrammatic front view of the blade shown in FIG. 1 ;
[0109] FIG. 3 shows a diagrammatic cross-sectional side view of the blade shown in FIG. 1 ;
[0110] FIG. 4 shows another diagrammatic cross-sectional view of the blade shown in FIG. 1 ;
[0111] FIG. 5 shows a diagrammatic side view of the blade shown in FIG. 1 at cross section A;
[0112] FIG. 6 shows a diagrammatic side view of a bulldozer with a blade in accordance with the first preferred embodiment of the present invention in a neutral position;
[0113] FIG. 7 shows the bulldozer shown in FIG. 6 with the blade raised;
[0114] FIG. 8 shows the blade and bulldozer shown in FIG. 7 with the blade pitched forward;
[0115] FIG. 9 shows a bulldozer and blade in accordance with a first preferred embodiment of the invention on a horizontal ground surface;
[0116] FIG. 10 shows the bulldozer and blade shown in FIG. 9 with the blade tilted downwardly;
[0117] FIG. 11 shows the bulldozer and blade shown in FIG. 10 with the blade lowered below the horizontal ground surface;
[0118] FIG. 12 shows the bulldozer and blade shown in FIG. 9 moving down an inclined surface;
[0119] FIG. 13 shows the bulldozer and blade of FIG. 9 with the blade tilting upwardly prior to entering a second horizontal ground surface;
[0120] FIG. 14 shows the bulldozer and blade shown in FIG. 9 with the bulldozer about to enter the lower horizontal ground surface;
[0121] FIG. 15 shows the bulldozer and blade of FIG. 9 moving along a lower horizontal ground surface;
[0122] FIG. 16 shows a blade according to a first preferred embodiment of the invention attached to a bulldozer with the blade oriented downwardly to engage a horizontal ground surface;
[0123] FIG. 17 shows the blade and bulldozer of FIG. 16 with the blade tilted upwardly after engaging the ground surface;
[0124] FIG. 18 shows the bulldozer and blade of FIGS. 16 and 17 with the blade tilted upwardly and rolled back after collecting material in the blade;
[0125] FIG. 19 shows a diagrammatic view of a second preferred embodiment of the blade attached to a bulldozer wherein the blade is in a level position at ground level;
[0126] FIG. 20 shows diagrammatic view of a second preferred embodiment of the blade attached to a bulldozer wherein the blade is at full tilt back at ground level;
[0127] FIG. 21 shows a diagrammatic view of a second preferred embodiment of the blade attached to a bulldozer wherein the blade is at full tilt forward at ground level;
[0128] FIG. 22 shows a diagrammatic view of a second preferred embodiment of the blade attached to a bulldozer wherein the blade is at a full tilt forward at ground level on an incline;
[0129] FIG. 23 is a diagrammatic front view of a second preferred embodiment of the blade;
[0130] FIG. 24 is a diagrammatic front view of a second preferred embodiment of a section of the side of the blade marked C in FIG. 23 ;
[0131] FIG. 25 is a diagrammatic side view of a second preferred embodiment of the blade;
[0132] FIG. 26 is a diagrammatic view of a mounting portion of the blade marked K in FIG. 25 ;
[0133] FIG. 27 is a diagrammatic view of another mounting portion of the blade marked L in FIG. 25 ;
[0134] FIG. 28 is a diagrammatic front view of the blade similar to FIG. 23 ; and
[0135] FIG. 29 is a diagrammatic view of a side top section of the blade marked A in FIG. 28 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0136] In accordance with the preferred embodiments of the present invention, a blade will be described that can use its centre forward edge for penetration. The blade attached to a bulldozer will be described and the ability to use the centre forward edge of the blade for penetration will assist the dozer's to use both tracks to push the blade and reduce the loading time and then roll back after being loaded.
[0137] FIGS. 1 to 18 show a first preferred embodiment of the blade whereas FIGS. 19 to 29 show a second preferred embodiment of the blade.
[0138] With reference to the first preferred embodiment of the blade, FIGS. 1 and 2 shows a blade 10 having a front face 11 , a centre edge 12 , middle edges 13 and 14 on either side of the centre edge 12 and end edges 15 and 16 on each end of the side edges 13 , 14 .
[0139] Each of the front edges 12 , 13 , 14 , 15 and 16 are preferably separately made from the rest of the blade and are removably attachable thereto. Thus in FIGS. 1 , 2 and 5 , there is a series of holes 17 which serve as attachment points.
[0140] Rearward of each edge 12 , 13 , 14 , 15 , and 16 , the front face 11 is specially shaped to enhance cutting by the blade as well as distribution of cut material away from the centre of the blade and furthermore retaining of excavated material on the blade when it is tilted upwardly from its cutting position.
[0141] The centre edge 12 of the blade extends rearwardly in a generally concave arc which preferably constitutes a rolled section of constant width and of the same width as the centre edge 12 . This rearward centre section 18 extends approximately half way along the front face 11 as shown in FIG. 4 . In FIG. 2 the central front section 18 appears rectangular.
[0142] It is preferred that the central front section 18 is a separately formed metal plate which is formed on the front face 11 .
[0143] Left and right side gussets 19 , 20 curve to each side from the left and right side 21 , 22 of the central front section 18 . In FIG. 2 these gussets 19 , 20 look triangular and extend forwardly from the rearmost end of the central front section 18 to middle blades 13 and 14 respectively to a point closer to their outer ends than their inner ends.
[0144] In effect both the central front section 18 and side gussets 19 and 20 appear as a raised section in the centre of the front face 11 .
[0145] The centre edge 12 is essentially straight and perpendicular to the direction of movement of the blade in the forward direction. Each of the middle edges 13 , 14 slant rearwardly at a angle of approximately 25° with respect to the centre edge 12 . Each of the middle edges 13 and 14 are approximately twice as long as the centre edge 12 and at their outer ends 22 , 23 form a V-shaped angle with the end edges 15 and 16 respectively.
[0146] The thickness of each of the front edges 12 to 16 is generally the same and each of them may be in the form of a metal plate.
[0147] The end edges 15 and 16 are angled forwardly and laterally from the middle edges 13 and 14 . They form an angle of approximately 110° with respect to each of the middle edges 13 , 14 .
[0148] As shown in FIG. 1 , each end edge 15 , 16 has a lower front corner 25 , 26 which is located behind the centre edge 12 . It is also noted that the front edge 27 , 28 of the end edges 15 , 16 are slanted slightly forwardly to form a slightly pointed corner 25 and 26 respectively.
[0149] As shown in FIG. 2 the horizontal level of the centre edge 12 and middle edges 13 and 14 is approximately the same. However the end edges 15 and 16 are angled slightly downwardly and forwardly from the ends 23 and 24 .
[0150] The front face 11 which is generally a concave shaped shovel has a general curvature on either side of the central front section 18 to each side 29 , 30 . These sides 29 , 30 are represented as vertical crease lines which form corner sections with outer wall sections 31 , 32 which extend laterally and forwardly at a similar angle to the end edges 15 and 16 with respect to the middle edges 13 and 14 . Side plates 33 and 34 extend from these walls 31 and 32 generally in a forward direction and thus perpendicular to the centre edge 12 .
[0151] The side walls 33 , 34 are typically in the form of large metal plates extending from the top of the front face 11 forwardly in a straight line then vertically downwardly to a slanted section 35 approximately three quarters of the length from the top corner edge 36 and inwardly to a point on the front face behind the end edges 15 , 16 .
[0152] As shown in FIG. 1 , front end 37 of the side walls 33 , 34 extend over part of the end edges 15 and 16 to a forward position approximately half way across them. The front edges 27 and 28 of the end edges 15 and 16 are the lateral most parts of the front face 11 and extend beyond the side walls 33 , 34 in a lateral direction. It is also noted that the corners 25 and 26 are both in front of and further to the side of the side walls 33 , 34 than their front edges 37 .
[0153] It is preferred that the overall concave curvature of the front face 11 with the raised central sections 18 , 19 and 20 is such that when the blade is connected to the bulldozer and is in a neutral position, that is it is not tilted forward or backward, any material on the front face of the blade is able to slide off it. Furthermore, only a slight tilting upwardly of the blade results in retention of a significant amount of material on the front face of the blade.
[0154] As shown in FIGS. 3 and 4 , the centre edge 12 and middle edges 13 and 14 are generally flat and straight. In FIG. 5 the rear face of the middle edge 14 is shown and this is also generally flat and straight and each of the edges appears as a thick metal plate.
[0155] Behind the blade 10 connection points 50 and 51 are provided at the lower end and close to the top end. The lower end is connected through a pivotal support part through connecting arms to a bulldozer and the point 51 is connected to a pivotal piston arm of the bulldozer. As a result tilting of the blade 10 occurs by movement of the piston and hence pivoting of the blade with respect to the connection point 50 .
[0156] A blade having the features described above when connected to a bulldozer is able to be tilted slightly downwardly so that the centre edge 12 is able to engage a ground surface or material on a ground surface. Initially the corners 25 and 26 of the end edges 15 and 16 contact the ground because they are lower. This also has the result that they wear more quickly than the centre edge and provide a barrier to help capture material within the confines of the blade.
[0157] As the blade moves forward, material moves up the centre edge 12 onto the central front section 18 and is distributed by side gussets 19 and 20 outwardly in a lateral direction. This directs material towards the side walls 33 , 34 . These walls act as a barrier which helps retain material within the confines of the blade. This retention is enhanced by the front edge 37 being located in front of the rearward edge of the end edges 15 and 16 .
[0158] Because the material is directed outwardly to the sides of the blade, cutting/grading by the centre edge 12 is enhanced because material is moved away from the central region. This movement to the sides may be enhanced by increasing the size of each of the gussets 19 and 20 and reducing the width of the section 11 . For example the section 11 may be made triangular with an apex at a rearward most point, thus having a triangular appearance with the apex of the triangle at a rearward point and the sides of the triangle leading into each of the gussets 19 , 20 .
[0159] Some of the noteworthy features of the first preferred embodiment include the following:
[0160] the centre cutting edges forward of the corner tips;
[0161] the centre cutting edge is at the same level as the corner tips when the blade is in the central or carry position;
[0162] the corner tips are lower than the centre cutting edge when the blade is in the central or carry position;
[0163] the centre cutting edge is lower than the corner tips when the blade is rotated forward or down into the digging position;
[0164] the centre cutting edge is higher than the corner tips when the blade is rotated back;
[0165] the blade has larger side plates to carry more material; and
[0166] the side plates are forward of the back edge of the corner tip.
[0167] When the blade is used on a dozer it provides the dozer with a number of operational features which are not available to dozers with existing blades.
[0168] Thus according to one embodiment, larger dozers with the blade according to the present invention have a function that allows the on board processor of the dozer to pitch the blade forward to dump material from the blade when the blade is raised past a preselected position. This function can be expanded to control the pitch of the blade when a digging operation is undertaken.
[0169] In accordance with the first preferred embodiment of the invention when the dozer is in the neutral position the cutting edges of the blades are all level with the ground except for the corner tips or outside cutting edges which may be lower. As shown in FIG. 6 the supporting arms 61 of dozer 60 are generally horizontal with tilting pistons 62 at approximately 45° with the control arms 61 and lifting pistons 63 also approximately at 45° with respect to the arms 61 . In this position the blade 64 is able to push material to a dump site. As shown the side plates 65 generally have their front edges 65 vertical and their top edges 66 horizontal.
[0170] After the blade 64 is raised by pivoting the arm 61 upwardly using the lifting piston 63 , as shown in FIG. 7 , the onboard processor may be operated to pitch the blade 64 forward as shown in FIG. 8 . This is achieved by operation of the tilting pistons 62 .
[0171] As shown in FIGS. 7 and 8 when the blade 64 is raised, edges 65 and 66 effectively pivot clockwise whereas in FIG. 8 they pivot anticlockwise. The result is the edges 65 and 66 are no longer in the vertical and horizontal disposition shown in FIG. 6 .
[0172] With the blade pitched forward, material collected on the blade is able to flow down from the blade and hence reduce any material from sticking to the blade and being carried back to the dig position.
[0173] It is preferred that the onboard processor is programmed for an autopitch step involving the raising and lowering of the blade as shown in FIGS. 7 and 8 . Alternatively an operator can perform these steps manually.
[0174] It is preferred that this function is part of a normal digging cycle involving loading, dumping and clearing/dislodging material on the blade.
[0175] According to one embodiment it may be an advantage to set the dig or pitch forward auto operation in an aggressive setting for hard material. This would start the pitching of the blade when the blade is lowered a short distance from the neutral position. It may also be an advantage to set the auto pitch in a less aggressive setting when digging softer material. This less aggressive setting would allow the blade to be lowered a larger distance from the neutral position before the blade is pitched forward.
[0176] The dump auto settings may be set in the same manner outlined above.
[0177] In the operation described above a bulldozer is able to be used to push material to a dump site. According to another operational task a bulldozer may be required to operate on a downwardly or upwardly inclined slope. FIGS. 9 , 10 , 11 , 12 , 13 , 14 and 15 show how a bulldozer with a bucket according to the first preferred embodiment may be operated so as to control the orientation of the bucket as the bulldozer moves forward. Thus as shown in FIG. 9 , the bulldozer 70 with a bucket 71 is operated so that the onboard processor uses the auto pitch feature to follow the contour of the ground surface. Thus in FIG. 10 the blade 71 is pitched/tilted forwardly using tilting pistons 72 after a slight lifting of the blade 71 by operation of arms 73 and lifting pistons 74 .
[0178] In FIG. 11 the bulldozer 70 moves forward and the blade moves downwardly first under operation of pistons 74 and 72 and arms 73 . As a result the blade 71 has an initial forward pitch as the dozer starts to dig and after the dozer follows the blade into the inclined area as shown in FIG. 12 , the blade is returned to its neutral position again by operation of pistons 72 to 74 and arms 73 .
[0179] After the dozer is following the incline downwardly, the blade 71 is loaded with material and the blade is then required to pitch backwardly so that the dozer can start pushing the material to the dump site.
[0180] Thus in FIGS. 13 and 14 it is shown how operation of pistons 72 and 74 results in an upward tilt of blade 71 as the dozer moves from the incline to the flat surface and then once on the flat surface or as the dozer completes movement to the flat surface, the blade is again tilted back to the neutral position as shown in FIG. 15 .
[0181] Although the example given above relates to movement of the dozer from a level to a downwardly inclined slope and back to a level surface, the operations involved with regard to movement of piston arms and blade 71 are simply reversed if the dozer moves in the opposite direction. As a result it is clear that there are movements of the blade which are effectively repeated and can be stored in the data processor for automated operation depending upon the type of terrain on which the dozer is to work. Thus the onboard data processor or even a remote data processor which has information relayed to it from the bulldozer can be programmed to tilt the blade in accordance with the operation shown in FIGS. 9 to 11 to the neutral position shown in FIG. 12 and then again tilt the blade in the manner shown and described in relation to FIGS. 13 and 14 with the result that it again ends in the neutral position as shown in FIG. 15 . For an upwardly inclining movement of the bulldozer the tilting movement of the blade is simply reversed.
[0182] It is to be understood that tilting of the blade is controlled by the tilting and lift pistons and the control arms of the bulldozer. Accordingly a data processor effectively through sensors located on each of these components can determine the orientation of the blade and can automatically control these components to tilt the blade as the bulldozer moves. Likewise sensors can be located on the blade.
[0183] In accordance with another mode of operation of a dozer utilising the blade of the preferred embodiment of the invention, it is noted that if the blade 81 as shown in FIG. 16 is tilted forwardly to cut into a ground surface there is a tendency because of the design of the blade to cut deeper into the ground surface. This causes the blades cutting edges and/or corner tips to dip lower than the ground level and adjustments need to be made with the lift mechanism to keep the blade at the same height. Accordingly it is preferable that after the forwardmost cutting edges of the blade cut into the ground, there is a rollback operation involving tilting the blade upwardly as shown in FIG. 17 back to a neutral position. As shown in FIG. 18 a final slight tilting upwardly can be initiated to collect material on to the blade and enable it to be carried to a dumping location.
[0184] The data processor can be programmed to operate the lifting and tilting pistons in conjunction with the supporting arms to initially tilt the blade 81 forward so that the forward most edge cuts into a ground surface and then to operate these components to tilt the blade 81 to a neutral position so the bottom edge of the front edge of the blade is able to travel in a horizontal orientation. Finally material collected within the confines of the blade 81 is able to be transferred to another location by a slight further tilting of the blade upwardly so that the forward most edge of the blade is not engaging with the ground surface.
[0185] Alternatively a data processor on board the bulldozer or remote from the bulldozer is programmed to adjust the blade to keep the nominated cutting edges or corner tips at a constant height. The actual height selected will be dependent upon a number of factors such as the hardness of the ground surface, the size of the bucket, the size of the dozer, the angle of the ground surface etc.
[0186] The use of the blade reduces the dependency of the steering clutches and brakes to keep a bulldozer moving straight when loading the blade. As the majority of the load will be centrally located on the blade, the operator has comparatively improved steering and a greater control of the blade.
[0187] FIGS. 19 to 29 describe a second embodiment of the blade. With reference to FIGS. 19 to 22 , blade 100 is attached to dozer 101 . The lifting arms 102 of the dozer 101 are attached to arm mountings 103 on the back of the blade 100 . Horizontal rams 104 and vertical rams 109 of the dozer 101 are attached to ram mountings 105 on the back of the blade 100 . The arm mountings 103 and ram mountings 105 are described more fully with reference to FIGS. 25 , 26 and 27 . The arm mountings 103 and ram mountings 105 are located adjacent the back wall 107 of the blade 100 thereby positioning the blade 100 as close as possible to the dozer 101 . By reducing the space between the dozer 101 and blade 100 , the centre of gravity is brought back towards the dozer 101 and consequently provides the dozer 101 with a comparatively greater control and balance when using the blade 100 . As a consequence of the attachment of the blade 100 to the lifting arms 102 , horizontal rams 104 and vertical rams 109 , the orientation of the blade 100 is such that there is approximately 43 degrees between an axis formed between the forward edge portions 110 and the forward edge portions 110 and the mounting 105 that connects with the horizontal rams 104 when the forward edge portions 110 are in a level position at ground level.
[0188] With reference to FIG. 20 , the blade 100 can be tilted back approximately 92.3 degrees between the blade 100 and the ground level when in a level position at ground level. The degree of backward tilt enables the carried excavated material to be retained on the blade 100 .
[0189] With reference to FIG. 21 , the blade 100 can be tilted forward approximately 75.8 degrees between the blade 100 and the ground level when in a level position at ground level. The degree of forward tilt enables substantially all of the carried excavated material to be discharged from the blade 100 .
[0190] With reference to FIG. 22 , the blade 100 can be tilted forward at approximately 43 degrees when moving along and incline with a gradient of 14 degrees.
[0191] With reference to FIGS. 23 and 24 , the blade 100 has forward edge portions 110 , side walls 111 and front wall 112 . The forward edge portions 110 include centre forward edge portion 115 , side forward edge portions 116 and end forward edge portions 117 . The forward edge portions 110 are substantially aligned in a horizontal axis with the centre forward edge portion 115 inclined downwardly relative to the side forward edge portions 116 and end forward edge portions 117 .
[0192] The front wall 112 generally has a concave shape. The front wall 112 has a raised substantially concave centre section 119 . The centre section 119 has a substantially central and low position on the front wall 112 . The angular position of the centre forward edge portion 115 is different to the concave arc of the centre section 119 which is different to the arc of the concave front wall 112 above the centre section 119 . There is a discontinuity in the shape of the front face from the centre forward edge portion 115 through the centre section 119 to the front wall 112 above the centre section 119 .
[0193] On either side of the centre section 119 there is a side gusset portion 121 that slope downwardly from the centre section 119 to the outer sections of the front wall 112 . Each of the side gusset portions 121 extends from the raised centre section 119 to the side forward edge portions 116 adjacent the end forward end portions 117 .
[0194] Material such as dirt is picked up by the centre forward edge portion 115 , moved towards the centre section 119 and directed outwardly from the centre section 119 via the side gusset portions 121 towards the side walls 111 .
[0195] The top section 123 of the front wall 112 is curved or bent over towards the front wall 112 by a few degrees to maintain a concave shape and assist in retaining excavated material. The side walls 111 extend above the top of the front wall 112 and cooperate with the front wall 112 to retain excavated material. The bracket 124 is positioned between the top section 123 and the side walls 111 to strengthen the integrity of the blade 100 . There is an attachment point 125 on the side wall 111 positioned above and behind the front wall 112 . The position of the attachment point 125 above and behind the front wall 112 enables a crane to lift the blade 100 without being unbalanced and swinging crookedly.
[0196] In the first preferred embodiment, there is shown a boxed gusset in the corner formed between the side wall and the front wall. In the second preferred embodiment, there is no need for the boxed gusset as the side wall 111 extends above the front wall 112 and the attachment point 125 for lifting the blade 100 is above and behind the front wall 112 .
[0197] With reference to FIGS. 25 , 26 and 27 , mountings 103 and 105 located on the back face 132 of the blade 100 allow attachment of lifting arms 102 and rams 104 , 109 respectively. The mountings 103 , 105 are located close to the back face 132 in order that the centre of gravity is moved back towards the dozer 101 thereby providing the dozer 101 with greater control and balance with respect to operation of the blade 100 .
[0198] With reference to FIGS. 28 and 29 , there is shown apertures 127 in the top section 123 . These apertures 127 are located in the centre and sides of the top section 123 . These apertures 127 provide the operator with a view of what is in front of the blade 100 . The second preferred embodiment has apertures 127 on both sides of the top section 123 .
[0199] It is to be understood that, if any prior art publication is referred to herein, such reference does not constitute an admission that the publication forms a part of the common general knowledge in the art, in Australia or in any other country.
[0200] In the claims which follow and in the preceding description of the invention, except where the context requires otherwise due to express language or necessary implication, the word “comprise” or variations such as “comprises” or “comprising” is used in an inclusive sense, i.e. to specify the presence of the stated features but not to preclude the presence or addition of further features in various embodiments of the invention.
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An improved blade assembly for an excavating apparatus having a front wall with a raised concave centre section with sloping side gussets on each side of the centre section for directing excavated material from the centre to the side of the blade is described. There are improvements to the side gussets to further assist in directing excavated material, improvements to the shape of the front wall of the blade to retain excavated material and improved mountings to the dozer to improve blade control and balance and discharging of excavated material.
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This application is a continuation-in-part of U.S. patent application Ser. No. 09/546,424 filed Apr. 10, 2000 entitled “Metal Forming Apparatus”, now U.S. Pat. No. 6,282,935.
FIELD OF THE INVENTION
The present invention relates to equipment for the on-site fabrication of metal roofing flashing and the like and more particularly to portable such equipment that is easily transported from site to site.
BACKGROUND OF THE INVENTION
The fabrication of metallic flashing and the like for use in the installation of roofs is largely a custom operation generally necessitating that fabrication be performed on site. As a rule, such fabrication is done by hand using small metal bending equipment such as portable metal breaks or the like using metal cut from a coil or in sheet form that is carried to the job site. Often the width of a suitable section of, for example flashing must be cut from an oversized coil or sheet marketed to meet the needs of a broad range of customers, but not specifically meeting the needs just described. Such on site fabrication for common shapes in custom lengths is therefore often very time consuming and therefore costly for the installer and ultimately the customer.
While there exists a large number of metal forming devices most are very large and cumbersome, often requiring independent power sources and therefore very costly or requiring a dedicated vehicle for their transportation. The use of such large devices is therefore not practical for the average roofer, even one performing a large number of roofing jobs that require the on site fabrication of a number of commonly shaped, but custom length flashing parts.
The availability of a compact, inexpensive and readily hand operated metal former capable of forming metal flashing and the like in custom lengths that can be transported in, for example, an ordinary pick-up truck without occupying an undue amount of cargo space would, therefore, be of significant value to the roofing community.
OBJECT OF THE INVENTION
It is therefore an object of the present invention to provide a compact, low cost and preferably hand operated metal forming device that meets the needs of the roofing community for the on-site, custom fabrication of metal flashing and the like.
SUMMARY OF THE INVENTION
The present invention provides a compact, portable metal forming device comprising: 1) a frame having entry and exit ends; 2) guide means adjacent the entry end for guiding a sheet of metal to be formed to a hand operated drive assembly supported within the frame that engages the metal sheet and drives it, through the operation of a series of gear linked separately journaled forming roll pairs mounted in the frame, 3) adjacent the exit end an adjustable cam wheel that engages one edge of the metal sheet and forms that edge just prior to the metal sheet reaching the exit end, and 4) forming the exit end, a guillotine cutter including a shaped exit aperture for cutting the formed metal sheet to any selected length.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of the complete metal forming device of the present invention.
FIG. 1 a is a side view of the complete metal forming apparatus of the present invention showing an alternative payoff device at the entry end.
FIG. 1 b is a blown apart perspective view showing a preferred pivoting spool payoff of the metal forming apparatus of the present invention.
FIG. 1 c is a partially cutaway view of the pivoting spool payoff of the metal forming apparatus of the present invention.
FIG. 2 is a partially phantom side view of the metal forming device of the present invention.
FIG. 3 is a partially phantom top view of the metal forming device of the present invention.
FIG. 4 is a partially phantom exit end view of the metal forming device of the present invention.
FIG. 5 is a partially phantom entry end view of the metal forming device of the present invention.
FIG. 6 is a partially phantom exit end view of the metal forming device of the present invention showing the guillotine cutter in the protected or operating position at the exit end.
FIG. 7 is a partially phantom exit end view of the metal forming device of the present invention showing the guillotine cutter in the cutting position.
FIG. 8 is a partially phantom, cutaway view showing the final metal edge, forming wheel in a first position.
FIG. 9 is a partially phantom, cutaway view showing the final metal edge, forming wheel in a second forming or bending position.
FIG. 10 is a partially phantom view of the metal forming apparatus of the present invention showing the final metal edge forming wheel in the down or metal forming position.
DETAILED DESCRIPTION
Referring now to FIG. 1, the complete metal forming system 10 of the present invention includes a platform 12 , a payoff 14 , and where necessary for mounting, for example, on the side rail of a pick-up truck, adjustable jacks 16 for that side of platform 12 that is not supported by the side rail, and metal forming apparatus 18 that is the core of the present invention. Platform 12 may be fabricated from any suitable material such as aluminum or steel and for appearance may be of so-called “diamond plate” high brilliance aluminum. The purpose of platform 12 is simply to provide a convenient co-location for payoff 14 and metal forming apparatus 18 . According to a preferred embodiment, platform 12 , as best shown in FIG. 4, has a slanted flange 20 and an orthogonal flange 22 extending downward therefrom. Orthogonal flange 22 serves as the location of jacks 16 that can be secured to platform 12 in any suitable fashion (bolts, screws brackets, etc.) and support that side of platform 12 by bearing against the bed of a pick-up truck (not shown) and the bottom surface 24 of platform 12 when slanted flange 20 is laid over the pick-up truck side rail (not shown).
Sheet metal forming apparatus 18 may be permanently or removably attached to platform 12 in any suitable fashion such as with bolts or otherwise. One preferred method of attachment best shown in FIG. 2 utilizes a cut out block 13 removably bolted to platform 12 that engages bottom 15 of frame 28 .
Payoff 14 can be of any suitable design that permits support of a coil 26 of metal and allows the controlled extraction of sheet metal therefrom. Thus, it is highly desirable that payoff 14 be equipped with some type of friction or brake mechanism to inhibit uncoiling of the sheet metal in an uncontrolled fashion. A specifically preferred alternative payoff is described below.
As will be obvious to the skilled artisan, metal forming apparatus 18 as described hereinafter can be used independently of any platform 12 , if otherwise securely located or without payoff 14 , if discrete sheets of metal to be formed are introduced thereto.
As previously stated, the core of the present invention is metal forming apparatus 18 . As shown in the various Figures, metal forming apparatus 18 comprises a frame 28 having an entry end 30 , a discharge or exit end 32 , a top 87 , opposing sides 68 and 70 and a bottom 15 . Extending outward from entry end 30 is a pair of parallel offset guide bars 34 and 36 having grooves 38 and 40 respectively therein. Grooves 38 and 40 begin the forming process by engaging the edges of an inserted piece of sheet metal (not shown) and, as the sheet is pushed or advanced therein, because of their offset, aligning the sheet for engagement with the initial set of forming rolls 42 and 44 described hereinafter. For purposes of convenience hereinafter, the metal sheet will be referred to as having a left and a right side, the left side being that which engages groove 38 and the right side being that which engages groove 40 . Insertion of the metal sheet into grooves 38 and 40 as just described causes the metal sheet to assume a general U-shape between grooves 38 and 40 . The presence of this U-shape ease entry of the metal sheet into metal forming apparatus 18 . In the absence of the formation of this general U-shape caused by insertion of the metal sheet edges as just described, the metal sheet will tend to buckle. Such buckling could alternatively be inhibited by the inclusion of additional forming rolls, but the use of grooves 38 and 40 in offset guide bars 34 and 36 obviates the need for such additional forming rolls thereby permitting minimization of the length of metal forming apparatus 18 .
In the embodiment depicted in FIGS. 1, 2 , and 3 , a stiffener assembly 60 is shown. Stiffener assembly 60 comprises a brace 62 mounted to brackets 64 that are in turn attached to frame 28 . An adjustment bolt 66 is threaded through brace 62 to permit stiffening or fine adjustment of frame 28 when frame 28 undergoes deflection due to the thickness of the metal being formed in metal forming apparatus 18 or otherwise. If frame 28 is constructed from sufficiently heavy metal, or metal forming apparatus 18 is used to form only very light metal sheet, stiffener assembly 60 may be eliminated entirely. Metal forming apparatus 18 in its depicted configuration is capable of forming, for example, aluminum flashing and the like up to a thickness of about 0.030″ and the presence of stiffening assembly 60 permits loosening or tightening of the forming rolls to accommodate varying thicknesses of metal sheet.
Each of forming rolls 42 , 52 and 56 is mounted on its own independent shaft (shafts 63 , 65 and 66 ) that are separately journaled in sides 68 and 70 of frame 28 . Shaft 63 is extended beyond side 68 to permit attachment of crank or handle 72 that serves as the driving means for metal forming apparatus 18 . Crank 72 is preferably removably mounted on shaft 63 by provision of engagement portion 74 on handle 72 that slips over shaft 63 and is fixed in place by the insertion of a pin 76 or other similar fastener that penetrates an aperture 78 in shaft 63 and engagement portion 74 . Turning of handle 72 in a clockwise direction thus turns shaft 63 and attached forming roll 42 .
Each of drive rolls 44 , 54 and 58 that are mounted above and parallel to each of corresponding forming rolls 42 , 52 and 56 also has a shaft 80 , 82 and 84 journaled in side 70 of frame 28 at one end thereof and in side 86 of internal frame 88 at the other end thereof. Internal frame 28 is formed by the addition of downward extending flange 26 from the top 27 of internal frame 28 . Attached to the ends of shafts 20 , 22 and 24 are gears 25 , 29 and 20 .
Attached to extremity 22 of shaft 23 is a principal drive gear 24 that is also turned when handle 22 is turned in a clockwise direction by virtue of its connection to shaft 62 . Similarly, shafts 84 and 86 have gears 96 and 98 attached to their extremities that penetrate side 70 of frame 28 . Each of gear sets 94 and 85 , 89 and 96 and 90 and 98 are in engaging relationship with each other. Between each of the above-described gear sets, is a transfer gear 100 and 102 respectively that serves to transfer rotary motion from gear 85 to gear 89 and from gear 89 to gear 90 . Thus, when handle 72 is rotated in a clockwise direction, rotary motion is transferred from gear 94 to gear 85 , from gear 85 to transfer gear 100 , from transfer gear 100 to gear 89 , from gear 89 to gears 96 and 102 , from gear 102 to gear 90 and from gear 90 to gear 98 . Thus, turning of handle 72 causes all of the various gears, shafts and their attached rolls to advance in unison and a piece of sheet metal introduced into grooves 38 and 40 and brought into engagement with roll pair 42 and 44 is caused to advance through metal forming apparatus 18 .
Forming rolls 42 , 52 and 56 include at their extremities opposing those journaled in side wall 70 and beyond side wall 86 of inner frame 88 enlarged forming portions 104 , 106 and 108 respectively that include tapered portions 110 , 112 and 114 that are tapered upward toward these extremities at progressively larger angles so as to progressively form sheet metal inserted between roll pairs 42 and 44 , 52 and 54 and 56 and 58 . Lower edge 116 of side or flange 86 is similarly tapered to accommodate such metal during deformation or forming.
As will be apparent to the skilled artisan, both guide or drive rolls 44 , 54 and 58 and forming rolls 42 , 52 and 56 should be coated or surfaced with some appropriate material. In the case of drive rolls 44 , 54 , and 58 , an adherent material such as polyethylene or polypropylene that provides a gripping surface that “grabs” the sheet metal surface as it advances is highly desirable. It may further be desirable to coat the extremities 118 , 120 and 122 of drive rolls 44 , 54 and 56 near or at the points where they meet tapered regions 110 , 112 and 114 with a “tougher” material such as Deirin, a nylon material commonly used for rollers and the like, that presents a tough but “slick” or slippery surface to the metal sheet passing thereover. Delrin or some such similar tough but slippery material is similarly useful as the surface of forming rolls 42 , 52 ands 56 as well as previously described guide roll 48 .
As will further be apparent to the skilled artisan, while forming apparatus 18 depicted herein is shown as having three progressive forming rolls, a preferred configuration, a system that utilizes as few as two forming rolls or more than three forming rolls may also be considered effective.
Downstream of final forming roll 56 and adjacent to side wall 70 of frame 28 is adjustable edge forming assembly 124 . Edge forming assembly 124 , best seen in FIGS. 8 and 9, comprises an angularly oriented cam wheel 126 rotatably attached to an indexable slide arm 128 capable of moving up and down (being indexed) within channel bracket 130 . Positioning of indexable slide arm 128 and attached cam or forming wheel 126 is preferably achieved through location of set bolt 132 in predrilled apertures 134 and 136 in slide arm 128 . Addressing cam wheel 126 is guide roll 138 . The right edge of sheet metal engaging cam wheel 126 is forced between cam wheel 126 and guide roll 138 causing the edge to bend downward when slide arm 128 is in the down position as shown in FIG. 9, or to pass unformed when cam wheel 126 is in the up position as depicted in FIG. 8 . The particular location of cam wheel 126 will be dependent upon whether or not the final downward bend of the right sheet metal edge imparted by edge follower assembly 124 is required in the flashing installation for which the metal is being fabricated. Both cam wheel 126 and guide roll 138 are preferably coated with or fabricated from Delrin or some similar “tough” and “slick” coating.
Referring now to FIGS. 4 and 5, although it is not critical to the successful practice of the present invention, in order to render the free end, i.e. that end not contacting forming roll 126 , more rigid and therefore easier to manage and feed through guillotine cutter assembly 148 , it is preferred to incorporate a pencil beading assembly 194 just upstream from guillotine cutter assembly 148 . Pencil beading assembly 194 comprises a barbell shaped forming roll 196 that faces a beading roll 198 such that when sheet metal enters between these two rolls, a longitudinal pencil bead of the type well known in the art is formed near the outer edge of the sheet metal thereby making that edge more rigid. Barbell shaped forming roll 196 and beading roll 198 lie facing each other on either side of a slot 193 formed in beading block 195 . Barbell shaped forming roll 196 and beading roll 198 are both freely rotating and mounted on shafts threaded or otherwise secured in beading block 195 . Slot 193 which provides access for the sheet to engage barbell shaped forming roll 196 and beading roll 198 is preferably oriented at an angle of about 60° from horizontal so as to engage the edge of the sheet metal being formed and guide it between the aforementioned two pencil bead forming rolls.
The final element of the metal forming apparatus 18 of the present invention comprises guillotine cutter assembly 148 . Guillotine cutter assembly 148 comprises a cutting arm 150 rotatably attached to frame 28 at point 152 and rotatably to connector 154 at a point 156 intermediate the ends of cutting arm 150 . Connector 154 is in turn rotatably connected to cutting blade 158 at point 160 . Cutting blade 158 is slideably located between a pair of guide plates 162 and 164 that form the end wall of the exit end of frame 28 . Each of guide plates 162 and 164 include an exit slot 166 that registers with a similar, but oversized cutting slot 168 in cutting blade 158 . Exit slots 166 are configured to the shape of the formed sheet metal that will exit metal forming apparatus 18 . If cam wheel 126 is in the down position, as depicted in FIG. 9, the right metal edge will be bent downward and will exit through arm 170 of exit slots 166 . The right metal edge will exit through arm 172 of exit slot 166 if cam wheel 126 is in the up position as depicted in FIG. 8 and the right sheet metal edge is not finally formed or bent. Thus, during fabrication of sheet metal, cutting arm 150 is retained in the up position as shown in FIG. 6 until the appropriate length of metal is formed and advanced through slots 166 and 168 . Cutting arm 150 is then pushed downward as shown in FIG. 7 and the appropriate length of formed sheet metal is cut or sheared at the desired location.
To retain cutting arm 150 in the “up” position during fabrication and as a safety measure, rotating support arm 174 is provided. During fabrication, rotating support arm 174 is in the position shown in FIG. 6 with portion 178 thereof supporting cutting arm 150 . To cut, cutting arm 150 is lifted slightly, support arm 174 rotated 90° to the position shown in FIG. 7 and cutting arm 150 depressed as shown in FIG. 7 to cut metal that has exited slots 166 .
The metal forming apparatus 10 of the instant invention is generally designed to fabricate sheet metal at a width of about 8 inches, but it will be readily understood that both wider and narrower such devices can be similarly manufactured for the fabrication of narrower and wider sheet metal.
Payoff 14 has been depicted in FIG. 1 as a roll core having sides. While such a payoff has been found to provide adequate results, in use it has been determined that the use of such a structure for payoff 14 can result in binding of sheet metal to be formed as the metal transitions from the horizontal orientation on payoff 14 to the vertically offset position required for proper entry into grooves 38 and 40 in vertically offset guide bars 34 and 36 . In order to eliminate this transitional stress and the resultant deformation or binding of the sheet metal, the use of a novel self adjusting payoff device 200 as depicted in FIGS. 1 a and 1 b is preferred.
Referring now to FIGS. 1 a and 1 b , the preferred payoff 200 comprises a supporting frame 212 and a pivoting spool 214 . Supporting frame 212 may be of any design so long as it provides controlled payout of strip from a coil 224 mounted on pivoting spool 214 . Supporting frame 212 depicted in FIG. 1 b , comprises a base 216 and a pair of vertically extending parallel arms 218 . Atop each of parallel arms 218 is a bearing 220 . In the case depicted in FIG. 1 b , bearing 220 is a simple polymeric arch sized to receive an axle 219 placed therein and to permit low speed rotation thereof. In order to assure that axle 219 does not inadvertently extricate itself from bearing 220 , some type of locking or securing mechanism 222 is preferably provided. Locking mechanism 222 , in addition to securing axle 219 in place atop parallel arms 218 also serves as a brake, controlling the rotation of axle 219 thereby preventing a coil 224 of, for example metal, mounted on pivoting spool 214 from “springing” or expanding as such configurations of metal strip are prone to do when left unconstrained or secured.
In the embodiment depicted in FIG. 1 b , locking mechanisms 222 each comprise rotating latches 226 and 228 . When depressed, i.e. rotated downward, recesses 230 in latches 226 engage the extremities of axle 219 . Upward rotation of latches 228 then permits engagement of threaded shafts 232 with slots 234 in latches 226 by rotation of threaded shafts 232 about axles 236 through which they are threaded. Turning of threaded shaft heads 238 then permits tightening of locking/braking mechanisms 222 and adjustment of the amount of tension placed on axle 219 and concomittantly coil 224 mounted on pivoting spool 214 .
The core of the improved payoff of the present invention is pivoting spool 214 . As shown in the various Figures, but initially, FIG. 1, pivoting spool 214 comprises an axle 219 having extremities 240 and 242 . Inboard of extremities 240 and 242 are threaded portions 244 and 246 located adjacent each of extremities 240 and 242 . Threaded over threaded portions 244 and 246 are adjustment wheels 248 and 250 that move laterally along axle 219 when they are turned and threads 252 and 254 at the interior of adjustment wheels 248 and 250 engage threaded portions 244 and 246 . According to the particular embodiment depicted in the drawings, adjustment wheels 248 and 250 also include attached annular grooves 256 and 258 integral with adjustment wheels 248 and 250 .
Inboard of adjustment wheels 248 and 250 are annular collars 260 and 262 having at least three flanges 264 a , 264 b and 264 c extending radially at angles of about 120° therefrom. Annular collars 260 and 262 slide axially and freely along the surface of axle 219 . The axial motion of annular collars 260 and 262 is controlled by the presence of tabs 266 and 268 that extend axially and outwardly from annular collars 260 and 262 and ends 270 and 272 of tabs 266 and 268 engage annular grooves 256 and 258 that form parts of adjustment wheels 248 and 250 . Tabs 266 and 268 can be welded to annular collars 260 and 262 or formed integrally therewith as machined or cast parts. Thus, as adjustment wheels 248 and 250 are turned and threads 252 and 254 advance or retreat over engaging threads 244 and 246 on axle 219 , annular collars 260 and 262 are caused to move axially along axle 219 through the engagement of ends 270 and 272 with annular grooves 256 and 258 . Annular collars 260 and 262 are also preferably provided with slots 274 and 276 that engage stops 278 and 280 that extend axially from axle 219 . The combination of stops 278 and 280 in slots 274 and 276 respectively limit the axial travel of collars 260 and 262 assuring that they cannot be removed, even accidentally, from axle 219 .
As will be obvious to the skilled artisan, more than three flanges may be extended from annular collars 260 and 262 to provide the coil support required. Whatever number of such elements are utilized the structure should be such as to not interfere with the operation of the pivoting spool as described herein.
Extending generally radially from and attached rotatably to flanges 264 a , 264 b and 264 c are arm pairs 282 a , 282 b and 282 c . All of arm pairs 282 a , 282 b and 282 c are of equal length. According to the embodiment depicted in the drawings, arm pairs 282 a , 282 b , and 282 c are attached to flanges 264 a , 264 b and 264 c by the simple expedient of penetrating pins 284 a , 284 b and 284 c that pass through flanges 264 a , 64 b and 264 c and arm pairs 282 a , 282 b and 282 c allowing arm pairs 282 a , 282 b and 282 c to freely rotate about penetrating pins 284 a , 284 b and 284 c . Although in the embodiment depicted in the Figures, each of arm pairs 282 a , 282 b and 282 c is shown as comprising two arms located on either side of flanges 264 a , 264 b and 264 c a single member may be substituted for the two arm structure so long as appropriate rotational freedom is retained.
At the outer extremities 286 a , 286 b and 286 c of arm pairs 282 a , 282 b and 282 c are coil supports 288 a , 288 b and 288 c that are similarly rotatably attached to arm pairs 282 a , 282 b and 282 c by penetrating pins 290 a , 290 b and 290 c . In their fully extended position from axle 219 as shown in FIG. 1 c , or their most closed position (not shown), coil supports 288 a , 288 b and 288 c lie parallel to axle 219 , but as will be explained below, they may, depending upon the location of adjustment of adjustment wheels 248 and 250 , assume positions angularly disposed to axle 219 . Coil supports 288 a , 288 b and 288 c also preferably incorporate stop pairs 292 a , 292 b and 292 c . These elements inhibit excessive rotation and consequent collapse of coil supports 288 a , 288 b and 288 c against axle 219 . As will be apparent to the skilled artisan, a number of other similar expedients may be utilized to accomplish the same result. For example, similar stops (not shown) could be incorporated in flanges 264 a , 264 b and 264 c at the base of arm airs 282 a , 282 b and 282 c to similarly inhibit excessive travel and hence collapse of coil supports 288 a , 288 b and 288 c against axle 219 . Coil supports 288 a , 288 b and 288 c are preferably sized to fit the width of the particular coil 224 applied thereto.
It is this capability of payoff apparatus 2000 to assume angularly disposed relationships with respect to axle 219 that provides the flexibility needed to permit applied coil 224 to assume an angular position relative to axle 219 . This flexibility allows strip material removed from coil 224 to enter parallel but vertically offset grooves 38 and 40 without buckling or otherwise deflecting. The flexibility of payoff 200 imparted by the rotatable attachment of arm pairs 282 a , 282 b and 282 c to flanges 264 a , 264 b and 264 c and coil supports 288 a , 288 b and 288 c permits payoff 200 to self adjust to orient coil 224 at the optimum angle to permit removal of strip from coil 224 with minimum resistance and buckling or bending.
In use, the payoff apparatus of the present invention is utilized by locating frame 212 at the entry end of a suitable metal strip forming device. Pivoting spool 214 is inserted into the center of a suitable coil of metal after adjustment wheels 248 and 250 have been threaded inward as far as they can travel against stops 278 and 280 , which presents the narrowest diameter of extension for pivoting spool 214 . Coil 224 is then centered upon coil supports 288 a , 288 b and 288 c and adjustment wheels 248 and 250 then screwed outwardly, preferably in unison until coil supports 288 a , 288 b , and 288 c push securely against the inner surface of coil 224 . Pivoting spool 214 with coil 24 mounted thereon is then inserted into frame 212 as shown in FIG. 1 a and locking/braking mechanisms 222 tightened as described hereinabove to the appropriate tightness to allow controlled removal of strip from coil 224 . Because of the free rotational structure of arm pairs 282 a , 282 b , and 282 c with respect to flanges 264 a , 264 b and 264 c and coil supports 288 a , 288 b , and 288 c pivoting spool 214 self adjusts to the appropriate angle relative to axle 219 to permit non-binding removal of metal strip from coil 224 into parallel but vertically offset guides 34 and 36 . The self adjusting capability of pivoting spool 214 allows coil 224 to be controllably angularly displaced with respect to axle 219 . In this fashion, metal strip can be drawn from coil 224 with no tendency for the metal to be distorted by lateral forces normally be applied to the metal from coil 224 as it is pulled from a true horizontal position to a somewhat tilted toward the vertical position as is required to properly enter parallel but vertically offset edge guides 34 and 36 .
There has thus been described a compact portable and easily hand operated sheet metal forming device suitable for mounting on the side rail of a pick-up truck and that is capable of producing custom lengths of at least two discrete commonly used flashing shapes.
As the invention has been described, it will be apparent to those skilled in the art that the same may be varied in many ways without departing from the spirit and scope of the invention. Any and all such modifications are intended to be included within the scope f the appended claims.
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The combination of a self-adjusting payoff and a compact, portable metal forming device comprising: 1) a frame having entry and exit ends; 2) guide means adjacent the entry end for guiding a sheet of metal to be formed to a hand operated drive assembly supported within the frame that engages the metal sheet and drives it, through the operation of a series of gear linked separately journaled forming roll pairs mounted in the frame, 3) adjacent the exit end an adjustable cam wheel that engages one edge of the metal sheet and forms that edge just prior to the metal sheet reaching the exit end, and 4) forming the exit end, a guillotine cutter including a shaped exit aperture for cutting the formed metal sheet to any selected length.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No. 61/867,925 filed Aug. 20, 2013, which is herein incorporated by reference.
BACKGROUND
[0002] Audio storage devices may include prompts meant to elicit an audible response from a user. The audible response is recorded and may be transferred to other devices via a USB cord or other method. Existing storage devices typically include several individual single-function buttons. For example, pressing a first button may cause a sound to be played, pressing a second button causes a new recording to be made, a third button causes a file to be transferred, a fourth button is used to delete a file, and so on.
SUMMARY
[0003] This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the detailed description. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used in isolation as an aid in determining the scope of the claimed subject matter.
[0004] Aspects of the present invention enable a storage device (e.g., a recordable book, toy, computing device) to be controlled with a single control button that performs multiple functions. In one aspect, the storage device is an audio recording device that can record, lock, unlock, transfer to a separate storage device, or play back one or more audio recordings. These five functions (i.e., recording, locking, unlocking, transferring, and playing back) are initiated or facilitated by depressing a single button located on the audio storage device for different lengths of time or in different patterns. Audio recordings may be played in response to user interactions with the button to help the user interact with the button properly and warn the user of an action that is about to be taken. Different interactions with the button include tapping the button once, tapping the button multiple times (e.g., twice, three times, five times), holding the button down for a first duration and then releasing, and holding the button down for a second duration and then releasing.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] Aspects of the invention are described in detail below with reference to the attached drawing figures, wherein:
[0006] FIG. 1 is a block diagram of an exemplary computing environment suitable for implementing aspects of the invention;
[0007] FIG. 2 is a diagram of a storage device having a multifunction button that is tapped once to initiate a first function, in accordance with an aspect of the present invention;
[0008] FIG. 3 is a diagram of a storage device having a multifunction button that is tapped twice to initiate a second function, in accordance with an aspect of the present invention;
[0009] FIG. 4 is a diagram of a storage device having a multifunction button that is held down for a short duration threshold to initiate a third function, in accordance with an aspect of the present invention;
[0010] FIG. 5 is a diagram of a storage device having a multifunction button that is held down for a long duration threshold to initiate a fourth function, in accordance with an aspect of the present invention;
[0011] FIG. 6 is a diagram of a flow chart showing a method of performing multiple functions through a single button, in accordance with an aspect of the present invention; and
[0012] FIG. 7 is a diagram of a flow chart showing a method of controlling audio or visual functions in a media storage device through a single multifunction button, in accordance with an aspect of the present invention.
DETAILED DESCRIPTION
[0013] The subject matter of aspects of the invention is described with specificity herein to meet statutory requirements. However, the description itself is not intended to limit the scope of this patent. Rather, the inventors have contemplated that the claimed subject matter might also be embodied in other ways, to include different steps or combinations of steps similar to the ones described in this document, in conjunction with other present or future technologies. Moreover, although the terms “step” and/or “block” may be used herein to connote different elements of methods employed, the terms should not be interpreted as implying any particular order among or between various steps herein disclosed unless and except when the order of individual steps is explicitly described.
[0014] In one aspect, the audio storage device (e.g., a recordable book, toy, computing device) records a few seconds of audio or video in response to a user double-clicking the single button. When a user depresses then releases the single button, the device may initiate playback of the recorded audio. To transfer the audio recording and associated metadata to another computing device, the button may be held down for a first threshold amount of time. Once the button has been held down for a first threshold of time (e.g., two seconds), the device may play the following message (or similar): “release to transfer message, continue holding to lock.” If the user releases the single button, then the message will be transferred.
[0015] If the user continues to depress and hold down the single button for a second threshold amount of time that is longer than the first threshold, the user may have the option to lock or unlock a previously recorded message. To lock the message, the user may depress the single button for the second threshold amount of time (e.g., ten seconds). Upon doing so, the device will play the following message (or similar): “release to lock message.” If the user releases the single button after hearing the message, the audio storage device locks the message. When the recorded audio is locked, re-recording over a message is not possible. To unlock the message, the user may depress the single button for the second threshold amount of time. When depressed for the second threshold amount of time, the following message (or similar) will be played: “release to unlock the message.” If the user releases the single button, then the device will unlock the message and the message may be recorded over.
[0016] Having briefly described an overview of aspects of the invention, an exemplary operating environment suitable for use in implementing aspects of the invention is described below.
Exemplary Operating Environment
[0017] Turning now to FIG. 1 , an exemplary computing environment 100 is shown, in accordance with an aspect of the present invention. The computing environment 100 includes a storage device 110 , a computing device 130 , a network 140 , and a remote server 150 . The computing device 130 is connected to the server 150 through network 140 . The network 140 may be a wide area network, such as the Internet. The computing system environment 100 shown in FIG. 1 is merely an example of one suitable computing system environment and is not intended to suggest any limitation as to the scope of use or functionality of aspects of the present invention. Neither should the computing system environment 100 be interpreted as having any dependency or requirement related to any single module/component or combination of modules/components illustrated therein.
[0018] The server 150 may provide a storage service for users. The storage service may store audio recordings, images, and other content for the user to retrieve when convenient. The service provided by the server 150 may be associated with one or more storage devices that prompt users to respond to a question. The response to the prompt may be recorded and stored in an audio file.
[0019] The storage device 110 comprises an audio speaker 112 , a microphone 114 , computer memory 116 , a controller 118 , a power supply 120 , and a multifunction button 122 . The storage device 110 may take the form of a toy, a recordable storybook, or some other computing device capable of recording audio, storing audio files, and transferring audio files to another device. Both the storage device 110 and computing device 130 may be capable of wireless or wired communications.
[0020] In aspects, storage devices may include multiple speakers. The speaker 112 is used to play audio files stored on the storage device. The speaker 112 may also be used to provide an audible prompt to which a user responds. For example, the prompt could ask a child what the child wants for Christmas. The child's response could be recorded in an audio file.
[0021] The microphone 114 may be used to record a user's response to a prompt. The memory 116 is used to record audio files, which store sounds captured by the microphone 114 . The memory 116 may also store computer instructions that enable recording, prompting, file transfers, and otherwise enable operation of the storage device. The memory 116 may include a software that defines responses to different inputs provided by the multifunction button 122 . Though not shown, the storage device may also include a camera capable of capturing pictures or video. Additionally, the storage device may include a touch pad or touchscreen capable of receiving user handwriting, drawings, and other user created animations that may be stored and transferred. For the sake of simplicity, aspects of the present invention are primarily described in terms of audio files and audio content. However, content such as videos, pictures, digital drawings, and user created animations are contemplated to be within the scope of aspects of the present invention.
[0022] The controller 118 may be a computer processor or other hardware and software capable of controlling the storage device 110 . The controller 118 may access or run programs stored in the memory 116 . The controller 118 may respond to user inputs and generate outputs in response.
[0023] The power supply 120 may be a battery, AC supply, DC supply, or other suitable power supply for the storage device.
[0024] The multifunction button 122 may comprise both a physical button apparatus and coding that initiates different functions based on different interactions with the button. As used herein, the term “button” refers to an apparatus that is able to transition between only two positions. Specifically, the button is able to transition between an open position and a closed position. Further, the button automatically transitions to the open position when pressure is removed from the button (e.g., when a user's finger is removed). When the button is in the process of transitioning between positions, it is still considered in the open position until contact is made with a sensor indicating the button has reached the closed position. The closed position may correspond to a pressed button.
[0025] The button may include a spring or other apparatus that applies tension to the button and maintains the button in an open position absent a force applied to the button. The button transitions from the open position to the closed position upon receiving a mechanical pressure large enough to overcome the tension provided by the spring apparatus. Upon the removal or lessening of the mechanical pressure, the button returns to an open position automatically.
[0026] Aspects of the invention also contemplate a touch-based button. A touch-based button closes upon receiving contact from a physical object, such as a finger or stylus, and does not require an amount of force to close. For example, a touch-based button may be displayed on a touchscreen computing device. Touch-based buttons may also be found in appliances and toys. A touch-based button may have a resistor or capacitive surface that detects a touch through a change to an electrical circuit of which the resistor or capacitors are a part.
[0027] The multifunction button 122 includes the ability to determine a duration for which the multifunction button 122 is held open or closed. For example, the multifunction button 122 may be able to determine that it was held in the closed position 0.5 seconds, then open for one second, and then closed for 0.4 seconds. The multifunction button 122 is able to trigger responses based on interactions meeting different criteria.
[0028] Aspects of the invention are not dependent on the particular component of a storage device 110 that responds to the button input. For example, a multifunction button 122 could provide an indication of its status to another component, such as the controller 118 . A program running on the controller 118 could respond to the status messages to initiate an associated control function in response to the interaction reflected by the status. In another aspect, the responses could be triggered by the multifunction button 122 .
[0029] The invention may be described in the general context of computer code or machine-useable instructions, including computer-executable instructions such as program components, being executed by a computer or other machine, such as a personal data assistant or other handheld device. Generally, program components, including routines, programs, objects, components, data structures, and the like, refer to code that performs particular tasks or implements particular abstract data types. Aspects of the invention may be practiced in a variety of system configurations, including handheld devices, consumer electronics, general-purpose computers, specialty computing devices, etc. Aspects of the invention may also be practiced in distributed computing environments where tasks are performed by remote-processing devices that are linked through a communications network.
[0030] Storage device 110 and computing device 130 typically include a variety of computer-readable media. Computer-readable media can be any available media that can be accessed by a computing device and includes both volatile and nonvolatile media, removable and non-removable media. By way of example, and not limitation, computer-readable media may comprise computer storage media and communication media. Computer storage media includes both volatile and nonvolatile, removable and non-removable media implemented in any method or technology for storage of information such as computer-readable instructions, data structures, program modules, or other data.
[0031] Computer storage media includes RAM, ROM, EEPROM, flash memory or other memory technology, CD-ROM, digital versatile disks (DVDs) or other optical disk storage, magnetic cassettes, magnetic tape, and magnetic disk storage or other magnetic storage devices. Computer storage media does not comprise a propagated data signal or other forms of communication media.
[0032] Communication media typically embodies computer-readable instructions, data structures, program modules, or other data in a modulated data signal such as a carrier wave or other transport mechanism and includes any information delivery media. The term “modulated data signal” means a signal that has one or more of its characteristics set or changed in such a manner as to encode information in the signal. By way of example, and not limitation, communication media includes wired media such as a wired network or direct-wired connection, and wireless media such as acoustic, RF, infrared, and other wireless media. Combinations of any of the above should also be included within the scope of computer-readable media.
[0033] Although the various blocks of FIG. 1 are shown with lines for the sake of clarity, in reality, delineating various components is not so clear, and metaphorically, the lines would more accurately be grey and fuzzy. For example, processors have memory. The inventors hereof recognize that such is the nature of the art and reiterate that the diagram of FIG. 1 is merely illustrative of an exemplary computing device that can be used in connection with one or more aspects of the invention. Distinction is not made between such categories as “workstation,” “server,” “laptop,” “handheld device,” etc., as all are contemplated within the scope of FIG. 1 and refer to “computer” or “computing device.”
[0034] FIG. 2 is a diagram of a storage device having a multifunction button that is tapped once to initiate a first function, in accordance with an aspect of the present invention. As mentioned, aspects of the present invention may be used to transfer files from storage devices that are intended to capture a child's voice, video, or other user input. In this case, the storage device is a heart-shaped toy 200 . The toy 200 includes a speaker 220 and a microphone 210 . The storage device also includes a multifunction button 230 that is being depressed by a finger 240 . The storage device 200 may be similar to the storage device 110 described previously with reference to FIG. 1 .
[0035] FIG. 2 includes a timeline 250 that illustrates actions that comprise a single tap and cause a function associated with a single tap to be performed. The timeline 250 runs from zero to ten seconds. At zero seconds, a button press 252 is detected. At 0.5 seconds, a button release 254 is detected. Thus, the duration of the button press is 0.5 seconds. In one aspect, a tap is defined as a button press lasting 0.75 seconds or less, for example, 0.5 seconds, 0.25 seconds, or less. In one aspect, a button press lasting greater than 0.75 seconds is defined as a button hold. In one aspect, an audible prompt is not provided in response to a button press defined as a tap. In one aspect, a single tap corresponds to an instruction to play a recorded audio or video file.
[0036] Turning now to FIG. 3 , a diagram of a storage device having a multifunction button that is tapped twice to initiate a second function is provided, in accordance with an aspect of the present invention. The storage device 200 depicted in FIG. 3 is the same as the storage device 200 depicted in FIG. 2 . The timeline 350 shows interactions that comprise a double tap. At zero seconds, a button press 352 is detected. At 0.4 seconds, a button release 354 is detected. Accordingly, the first button press is interpreted as a tap because it only lasted 0.4 seconds. A tap could be defined as two seconds or less, for example 1.5 seconds, one second, or 0.5 seconds. At 1.2 seconds, a second button press 360 is detected. At 1.8 seconds, a button release 362 is detected. Accordingly, the second button press is also interpreted as a tap because it lasted only 0.6 seconds.
[0037] The time elapsed between taps determines whether each tap is interpreted separately or as a combination. In this case, 0.8 seconds elapsed between the first tap concluding at 0.4 seconds and the second tap being initiated at 1.2 seconds. In one aspect, an elapsed time of one second or less between taps causes the task to be interpreted as a double tap. A double tap may be associated with a different functionality from a single tap. For example, a single tap may play a recording while a double tap causes a new recording to be created.
[0038] In addition to taps, pressing and holding the multifunction button for different durations of time may be associated with different functionalities. As the hold approaches a threshold, an audible cue may be played to let the user know what action will be taken if the user releases the button. For example, three different functions may be associated with a single button based on the length of time the button is held. In one aspect, common tasks are associated with shorter hold times. A three-function button could play a recording if pressed and held less than a first threshold, record when pressed and held longer than the first threshold, and lock or unlock an active recording when pressed and held longer than a second threshold. In one aspect, the short threshold is two seconds and the long threshold is ten seconds. FIGS. 4 and 5 illustrate different press and hold scenarios.
[0039] Turning now to FIG. 4 , a storage device having a multifunction button that is held down for a short threshold is provided, in accordance with an aspect of the present invention. The storage device 200 is the same as described previously. The timeline 450 runs from zero to ten seconds. At zero seconds, a button press 452 is detected. At 2.2 seconds, a button release 458 is detected. After two seconds, the short threshold 454 is reached. A short threshold of two seconds is provided as an example. Aspects of the invention are not limited to a two-second threshold. Upon reaching the short threshold, an audible announcement 456 is made by the storage device 200 notifying the user that a file transfer may be initiated by releasing the multifunction button 230 . Upon releasing the button beyond the short threshold, the file transfer is initiated. Had a user released the multifunction button 230 prior to reaching the short threshold 454 , then a function associated with a press and hold of less than the short threshold 454 could be initiated. In one aspect, pressing and releasing the multifunction button 230 before reaching the short threshold constitutes a single tap. In other words, the tap threshold may correspond to the short threshold 454 . In this arrangement, a press and hold of less than the short threshold is a tap.
[0040] Turning now to FIG. 5 , a long press and hold is illustrated, in accordance with an aspect of the present invention. Timeline 550 runs from zero seconds to eleven seconds. The long threshold 558 is set at ten seconds. At zero seconds, a button press 552 is detected. At 10.3 seconds, a button release 554 is detected. Upon the press and hold reaching the long threshold 558 , an audible announcement 556 is played by the storage device 200 . The audible announcement 556 indicates that releasing the button will cause a stored audio file to be locked. In one aspect, the long threshold is associated with changing the lock status of an active audio file. The active audio file may be the one most recently created or played. When only one audio file is stored, then the single audio file is the active audio file. Changing the lock status will cause a locked file to be unlocked and an unlocked file to be locked. A locked file may not be deleted or altered.
[0041] In one aspect, the multifunction button is associated with three or more different functions each associated with a unique interaction. For example, the multifunction button may be associated with four or more functions, five or more functions, or six or more functions. Exemplary functions include playing an audio file, pausing or stopping an audio file from playing, fast-forwarding an audio file, rewinding an audio file, deleting an audio file, selecting an audio file among several audio files, transferring an audio file, changing the lock status of an audio file, and recording a new audio file.
[0042] The functions and combination of functions may be context specific. For example, pausing or stopping an audio file from play may be available only when an audio file is playing. The same button interaction may produce a different result based on context. For example, a single tap may result in playing an audio file. When playing, a double tap may pause the audio file. When paused, another double tap may fast-forward the audio file. When paused, a triple tap may rewind the audio file. Thus, in one aspect, rewinding or fast-forwarding may only occur after an audio file is paused. When an audio file is not playing, a double tap may record a new audio file.
[0043] In one aspect, a multifunction button is the only control button provided on a storage device. As used herein, a control button causes different functions on the storage device to be performed. Turning the power on and off may not be considered as a function of the storage device. Even when only a single control button is provided, a second non-control button or switch may be used to turn the device power on and off.
[0044] In another aspect, a control function may be tied to a multifunction button interaction that comprises a single tap followed by a press and hold. The single tap may be identified by pressing the multifunction button for a duration that is less than a tap threshold, or less than a short hold threshold, for example, less than two seconds. The hold may be defined by pressing the multifunction button for greater than a threshold duration. In one aspect, the threshold duration is the tap threshold. The tap and the press and hold may need to be separated by less than a designated duration. For example, the press and hold action may need to occur with less than one second passing with the multifunction button in the open position from the tap.
[0045] As an example of the tap once and then press and hold interaction, a user may activate the function by pressing the multifunction button for two seconds or less, releasing the multifunction button for less than one second, and then pressing and holding the multifunction button for more than two seconds.
[0046] Turning now to FIG. 6 , a method 600 of providing multiple functions through a single button is shown, in accordance with an aspect of the present invention. The button may be described herein as a multifunction button. Method 600 may be performed by a computing device, such as storage device 200 described previously. The storage device may store audio and/or visual recordings. The audio and/or visual recordings may be captured by sensors, such as a camera or microphone, on the storage device. The storage device may have computer-executable instructions for performing method 600 when the computer-executable instructions are executed by a processor associated with the storage device.
[0047] At step 610 , a first interaction with a multifunction button is received. As mentioned, the multifunction button may be integrated with a computing device. The multifunction button may be a hard button that is depressed and released by a user's finger or some other object. The multifunction button may also be a touch-sensitive button, such as a button found on a touchscreen display or other touch-sensitive interface. A touch-sensitive button may not move when activated or deactivated. The first interaction may comprise activating the multifunction button by depressing the multifunction button or touching the multifunction button. The interaction may be a tap or a press and hold event.
[0048] At step 620 , in response to the first interaction, a first control function is initiated. The first control function may play an existing audio recording. An existing audio recording is a recording that is stored on the computing device.
[0049] At step 630 , a second interaction with a multifunction button is received. A significant period of time may have elapsed between the first interaction and the second interaction. For example, ten seconds, ten minutes, ten hours, or ten days may have elapsed between the first interaction and the second interaction. The second interaction with a multifunction button is different from the first interaction. For example, the first interaction may be a tap on the multifunction button and the second interaction may be a short hold. A tap and a short hold have been explained previously.
[0050] At step 640 , in response to the second interaction, a second control function is initiated at the computing device. A second control function is distinct from the first control function. For example, the first control function may play an existing recording while the second control function deletes the existing recording.
[0051] At step 650 , a third interaction with a multifunction button is received. The third interaction is distinct from the first interaction and the second interaction. The third interaction may be separated from the first and second interactions by a period of time, such as ten seconds, ten minutes, ten hours, etc. The third interaction is also distinct in character from the first and second interactions. For example, the first interaction may be a tap, the second interaction a short press and hold, and the third interaction a long press and hold of the multifunction button. As used herein, “press” and “press and hold” may be used interchangeably.
[0052] At step 660 , a third control function is initiated in response to the third interaction. Like the first and second control functions, the third control function is distinct from the others. For example, the third control function may cause an existing audio file to be transferred to a different device. The transfer could be initiated over a wireless coupling or a wired coupling, such as via a USB cable.
[0053] Turning now to FIG. 7 , a method 700 of controlling audio visual functions in a media storage device through a single multifunction button is described. The media storage device may be similar to storage device 200 described previously. The multifunction button may be a hard physical button that moves up and down in response to a user's finger or some other object. The multifunction button may also be a soft button, such as may be found on a touchscreen device.
[0054] At step 710 , an activation of a multifunction button is received at a first point in time. The activation corresponds to depression of the multifunction button. In this case, “depression” of the multifunction button can mean touching a soft multifunction button on a touchscreen or other touch-sensitive interface where the surface does not move noticeably in response to the touch.
[0055] At step 720 , a deactivation of the multifunction button is received at a second point in time. The activation and deactivation may be received through a signal generated by the multifunction button or some other intermediary component. The deactivation corresponds to a release of the multifunction button, which can be a physical release of a button or the removal of an object from a touch-sensitive button. Together, the activation and deactivation of the multifunction button form an interaction with the multifunction button.
[0056] At step 730 , a duration of time for the interaction is determined as a difference between the first point in time when the activation occurred and the second point in time when the deactivation occurred. For example, if the first point in time was 2.5 seconds prior to the second point in time, then the duration would be 2.5 seconds.
[0057] At step 740 , the interaction is classified as either a tap, a short press, or a long press based on the duration of time. Other classifications, such as a double tap, extra-long tap, or other classification, are possible. The interaction may be classified as a tap when the duration of time is between 0.1 seconds and a short threshold duration, such as two seconds. The interaction is classified as a short press when the duration falls between the short duration threshold and a long duration threshold. For example, the short duration threshold could be greater than two seconds. The interaction is classified as a long press when the duration exceeds a long duration threshold. In one aspect, the long duration threshold is greater than five seconds. When a long duration threshold is used with the multifunction button, the short duration classification occurs when the duration is greater than the short duration and less than the long duration threshold.
[0058] At step 740 , a control function that maps to either the tap, the short press, or the long press is activated depending on the classification that occurred at step 730 . A different control function is associated with each of the tap, the short press, and the long press.
[0059] In one aspect, at a third point in time between the first point in time and the second point in time, a determination is made that the multifunction button has been activated for a duration longer than the short duration threshold. This determination occurs when the button is still effectively pressed down and has not yet been released. Prior to the second point in time when the button is released, an audible instruction is output through a speaker in the storage device that identifies a control function associated with the short press. In other words, the audible instruction identifies what control function will be activated if the user deactivates the multifunction button at the point in time when the message is broadcast or potentially shortly thereafter. Similarly, an audible message could be generated upon determining that the press duration has crossed the end of the short duration threshold into the long press range to identify the control associated with the long press.
[0060] Aspects of the invention have been described to be illustrative rather than restrictive. It will be understood that certain features and subcombinations are of utility and may be employed without reference to other features and subcombinations. This is contemplated by and is within the scope of the claims.
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Aspects of the present invention enable a storage device (e.g., a recordable book, toy, computing device) to be controlled with a single control button that performs multiple functions. Different interactions with the button produce a different control input. In one aspect, the storage device is an audio recording device that can record, lock, unlock, transfer to a separate storage device, or play back one or more audio recordings. These five functions (i.e., recording, locking, unlocking, transferring, and playing back) are initiated or facilitated by depressing a single button located on the audio storage device for different lengths of time or in different patterns. Audio recordings may be played in response to user interactions with the button to help the user interact with the button properly and warn the user of action that is about to be taken.
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This application is a continuation of application Ser. No. 14/301,212 filed Jun. 10, 2014, entitled IMPACT MARKING GARMENT, which is a continuation of application Ser. No. 13/006,419 filed Jan. 13, 2011, now U.S. Pat. No. 8,769,713, issued Jul. 8, 2014, entitled IMPACT MARKING VEST, all of which are fully incorporated herein by reference.
FIELD OF INVENTION
This invention relates to an apparatus for indicating the point of impact of a projectile fired from a non-lethal firearm. In particular, this invention relates to an addition to a traditional ballistics vest that will aid in true impact and directional assessment allowing for improved instruction during simulated force-on-force ballistics training.
BACKGROUND OF THE INVENTION
Over the past decade, force-on-force (FOF), or reality based lethal force simulation training, has become established within the Law Enforcement and Military communities as an essential training method. Generally, FOF training involves role playing participants that are armed with non-lethal marking or replica type firearms that fire 6 mm or 8 mm plastic projectiles. During the course of training, participants' reactions and tactics are analyzed and reviewed in order to better train the participants to function in a heightened adrenaline state and survive a potentially lethal confrontation.
Typically FOF training simulations require equipment consisting of two basic types: firearms modified to fire paint filled marking cartridges; or, replicas shooting plastic spheres (BBs) commonly referred to as “Airsoft” guns.
BRIEF SUMMARY OF THE INVENTION
Several embodiments of the present invention answer the above and other needs by providing an Impact Marking Vest (IMV) system for use in indicating the position and angle of an impact on a ballistic vest.
In one embodiment, the invention may be characterized as an impact marking vest comprising: a backing layer comprising a flexible material for forming a three-dimensional (3D) target surface; a substrate layer bonded to the backing layer such that the substrate layer covers at least a portion of an exterior surface of the backing layer, wherein the substrate layer comprises a first color; a coating layer disposed on the substrate layer and covering substantially an entire exterior surface of the substrate layer, wherein the coating layer is a second color different from the first color of the substrate layer; and an attachment device connected to the backing layer and configured for attachment to a ballistic vest.
In another embodiment, the invention may be characterized as a method of forming a ballistic impact marking vest comprising the steps of: forming a backing layer comprising a flexible material into a three-dimensional (3D) target surface; bonding a substrate layer to the backing layer such that the substrate layer covers at least a portion of an exterior surface of the backing layer, wherein the substrate layer comprises a first color; disposing a coating layer on the substrate layer such that the coating layer substantially covers an exterior surface area of the substrate layer, wherein the coating layer is a second color, different from the first color of the substrate layer; and fixing an attachment device to the backing layer, wherein the attachment device is configured for attachment to a ballistic vest.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of an impact marking vest cooperated together with a ballistic vest according to one embodiment of the present invention;
FIG. 2 is a perspective view of the impact marking vest of FIG. 1 ;
FIG. 3 is a schematic view of a back panel used in forming the impact marking vest comprised of a backing layer, a substrate layer and a target surface formed from the substrate layer;
FIG. 4 depicts the back panel of FIG. 3 , together with the backing layer, the substrate layer, a target surface, an adhesive coating and a coating layer;
FIG. 5 depicts a schematic view of side panels used in forming the impact marking vest comprising a backing layer, a substrate layer and a target surface formed from the substrate layer;
FIG. 6 depicts a schematic view of the side panels of FIG. 5 , together with the backing layer, the substrate layer, the target surface formed from the substrate layer and a coating layer;
FIG. 7 depicts a two-dimensional schematic view of the complete panel used in forming the impact marking vest;
FIG. 8 depicts a cross-sectional view of the layers composing the impact marking vest, including the coating layer, substrate layer and backing layer; and
FIG. 9 depicts a coating layer patch comprising an adhesive patch coating and a coating patch layer.
DETAILED DESCRIPTION
The following description is not to be taken in a limiting sense, but is made merely for the purpose of describing the general principles of exemplary embodiments. The scope of the invention should be determined with reference to the claims.
Widely acknowledged drawbacks to marking cartridge systems include the high per-round unit cost of marking cartridge ammunition as well as the increased need for enhanced safety protocols. For example, modified firearms pose the risk that some participants may convert live firearms to function with marking cartridge ammunition, increasing the probability that live ammunition and fully functioning firearms will be introduced into the training environment. Although, the use of Airsoft guns and plastic BBs serves to mitigate the cost of simulation training, plastic BBs fail to provide the marking indications necessary for the verification of impact or impact angles on a role player.
Referring now to FIG. 1 , which depicts a ballistic vest 110 together with the impact marking vest (IMV) 120 comprising attachment device 130 , coating layer 140 and a target surface formed from a substrate layer 150 .
In one embodiment, the ballistic vest 110 is a protective vest system that may function as a ballistic vest, overlying the body of a user. In a preferred embodiment, the ballistic vest 110 is configured to overlay the upper body or torso region of a user and will contain holes for the user's arms, neck and torso. However, in alternative embodiments, the ballistic vest 110 may be shaped or configured to cover essentially any portion of a user's body. To facilitate cooperation with a user's body, the ballistic vest 110 may include one or more fastening devices. By way of example, the ballistic vest 110 may include fastening means such as, but not limited to: straps, elastic straps, fasteners, zippers, buttons, magnetic means, adhesive means or a hook and loop type fastening device, such as VELCRO or a functional equivalent, etc. The ballistic vest 110 may also be constructed of one or more layers; however, in preferred embodiments, the ballistic vest 110 will be comprised of a flexible and impact resistant material. By way of example, the ballistic vest 110 may be comprised of free-floating layers of plastic or Kevlar, nylon or cotton fabric.
In one preferred embodiment, the impact marking vest (IMV) 120 is mechanically cooperated with ballistic vest 110 via attachment device 130 such that the IMV 120 substantially covers the entire outside surface of the ballistic vest 110 . In this configuration, the torso of a user wearing the ballistic vest 110 together with the IMV 120 will be covered by the IMV 120 over substantially the same areas as if the ballistic vest 110 were to be worn alone. In one preferred embodiment, the attachment device 130 used to fasten the IMV 120 to the ballistic vest 110 comprises a hook and loop type fastening device, such as VELCRO or a functional equivalent. However, cooperation between the IMV 120 and ballistic vest 110 can be accomplished using virtually any suitable fastening means, including but not limited to: straps, elastic straps, fasteners, zippers, buttons, magnetic means, adhesive means or a hook and loop type fastening device, such as VELCRO or a functional equivalent, etc.
In an alternative embodiment, the IMV 120 may be mechanically cooperated with the ballistic vest 110 via a carrying device (not shown) such as a wire frame or a ballistic nylon holder. In this embodiment, the IMV 120 may cooperate with the carrying device such that at least a portion of the IMV 120 is exposed on the outer surface. Regardless of whether the IMV 120 is worn together with the ballistic vest 110 or worn alone, the outer surface of the IMV 120 effectively forms a three-dimensional (3D) target face.
In yet another embodiment, the IMV 120 may be worn without the use of the ballistic vest 110 altogether. For example, the IMV 120 may be worn alone or may be worn over the user's clothing. In some embodiments, the attachment device 130 may be configured to cooperate with, or adhere to an article of the user's clothing. In other embodiments, the attachment device 130 may be configured to cooperate with a portion of the user's body such that mechanical cooperation with clothing or the ballistic vest 110 is unnecessary for effective use of the IMV 120 .
As will be described in further detail below, the IMV 120 is comprised of a coating layer 140 disposed on top of an underlying substrate layer 150 such that a target design is formed by the regions of the substrate layer 150 not obscured by coating layer 140 (by exposed regions of the substrate layer 150 ). In one embodiment, the substrate layer 150 may be comprised of a paper or plastic material. In alternative embodiments the substrate layer may be comprised of a plastic film; however, the substrate layer may be comprised of essentially any material suitable for indicating a contrast between the substrate layer 150 and the coating layer 140 .
In some embodiments, the coating layer 140 may completely cover the substrate layer 150 such that the underlying substrate layer 150 is not immediately visible and no target pattern is discernable. Alternatively, the target design may be in or on the coating layer 140 , or in or on the substrate layer 150 (and either obscured by the coating layer 140 or aligned with regions of the substrate layer 150 not obscured by the coating layer 140 ). The target pattern may include a concentric circle pattern (i.e., a target design) or may indicate more highly valuable target locations, such as regions where a target may be more exposed, and not protected by his/her ballistic vest, such as at the armpits.
In operation, a user wearing the cooperated ballistic vest 110 and IMV 120 combination will be effectively covered by the IMV 120 outer surface. Accordingly, when used in conjunction with simulated training firearms, the coating layer 140 disposed on the outer surface of IMV 120 will flake away upon ballistic impact, exposing the underlying substrate layer 150 . In a preferred embodiment, the coating layer 140 will be of a dark color or pigment in order to contrast with a brightly colored substrate layer 150 such that the direction and point of impact on the IMV 120 will be easily ascertainable by an observer. In some embodiments, the coating layer 140 may be of a black, matte-black, matte-olive drab or earth tone color and substrate layer 150 may be a bright orange, yellow or green color. However, the coloration of coating layer 140 and substrate layer 150 may be of any combination that provides a visible contrast between the substrate layer 150 and coating layer 140 . Alternatively, this contrast may be invisible in the visible spectrum, but detectable in, e.g., the infrared spectrum, or under a source of irradiation selected to cause, e.g., fluorescence, e.g., of the exposed substrate layer 150 , and not of the coating layer 140 .
In a preferred embodiment, the IMV 120 will be used in conjunction with a non-lethal marking firearm or replica firearm (e.g., an “Airsoft” gun) that fires 6 mm or 8 mm plastic BBs. However, the IMV 120 may conceivably be used with any firearm/firearm replica or projectile suitable to cause the removal of the coating layer 140 on the outer surface of the IMV 120 .
Referring now to FIG. 2 , which depicts a more detailed perspective view of the IMV 120 comprising attachment device 130 , a coating layer 140 , a backing layer 210 and a target surface 220 formed from the substrate layer 150 .
In one preferred embodiment, the backing layer 210 is configured in a three-dimensional vest shape and forms the inner surface of IMV 120 . For example, the backing layer 210 may be comprised of thin-film high density foam for conforming to the curvature of a user's body. In alternative embodiments the backing layer may comprise substantially any suitably flexible and/or rigid material. However, in preferred embodiments, the backing layer 210 will be constructed of a semi-penetrable material that will facilitate the flaking away of the coating layer 140 , as will be further discussed below.
In operation, the substrate layer 150 is disposed on the backing layer 210 , using an adhesive coating (as will be described in further detail below), such that the substrate layer 150 covers either all or a portion of the outer surface of the backing layer 210 . The outer surface of the substrate layer 150 is then covered with the coating layer 140 such that a target surface 220 is defined by the visible (or, as noted above, otherwise distinguishable) portion of the substrate layer 150 that is revealed by the absence of the coating layer 140 . In alternative embodiments, the coating layer 140 may cover the entire outer surface of substrate layer 150 or may cover any fractional portion thereof to form substantially any desired pattern or design. The attachment device 130 is then fixed to the backing layer 210 and configured for attachment to a ballistic vest 110 such as that shown in FIG. 1 , above.
Referring now to FIG. 3 , which depicts a 2D schematic view of a back panel 310 of the IMV 120 together with the substrate layer 150 forming the target surface 220 . In one preferred embodiment, the substrate layer 150 is configured such that the resulting target surface 220 only covers a portion of the back panel 310 . However, in alternative embodiments, the substrate layer 150 may be sized such that the resulting target surface 220 covers substantially any desired portion of the surface area of back panel 310 .
Referring now to FIG. 4 , which depicts a 2D cut-away view of the back panel 310 of the IMV 120 . The back panel 310 comprising the backing layer 210 , the substrate layer 150 , the adhesive coating 410 and coating layer 140 . In a preferred embodiment the adhesive coating 410 is comprised of a pressure-sensitive adhesive. In some embodiments, the adhesive coating 410 is disposed on the surface of the substrate layer opposite the coating layer 140 such that the substrate layer 150 can be removably attached to the backing layer 210 . In an alternative embodiment, the adhesive coating 410 can be disposed on the outer surface of the backing layer 210 to achieve the similar purpose of removably attaching the substrate layer 150 .
In practice, the adhesive coating 410 enables the convenient replacement of portions of the substrate layer 150 attached to the backing layer 210 . This feature allows a user to readily change/replace the outer surface of the IMV 120 such that used or worn portions of the substrate layer 150 may be easily exchanged with the new substrate layer 150 portions containing the newer coating layer 140 .
Referring now to FIG. 5 , which depicts a schematic view of the side panels 510 together with a target surface 520 defined by the substrate layer 150 . The side panels 510 form the side and front segments of the IMV 120 .
In one preferred embodiment, when the IMV 120 is cooperated with the ballistic vest 110 the target surface 520 depicted in FIG. 5 will be configured to wrap around the user's torso covering the underarm and chest portions of the ballistic vest 110 . This particular positioning of target surface 520 may facilitate in instructing a FOF participant to avoid exposure of the underarm and chest regions when engaged in a real or simulated firefight. In alternative embodiments, the substrate layer 150 may be configured to create a target surface 520 in essentially any desired position or arrangement with respect to the outer surface of the IMV 120 .
Referring now to FIG. 6 , which depicts the side panels of FIG. 5 together with coating layer 140 , backing layer 210 and substrate layer 150 for forming target surface 520 . In a preferred embodiment, the coating layer 140 covers only a portion of the substrate layer 150 such that a strip of the underlying substrate layer 150 is revealed by the region wherein the coating layer 140 is absent. This revealed portion of the substrate layer 150 defines the border of the target surface 520 that can be visibly identified on the outer surface of IMV 120 . However, although the border of the target surface 520 may be visually identifiable, the majority of the target surface 520 remains obscured by the coating layer 140 . In alternative embodiments, the coating layer 140 may cover substantially the entire surface of the substrate layer 150 such that the underlying target surface 520 is wholly obscured.
In practice, the side panels 510 are configured to form the side portions of IMV 120 . In such a configuration, the target surface 520 will form a three-dimensional (3D) surface spanning a region from beneath the participant's arms to the center chest portion of the IMV 120 . In alternative embodiments, the target surface may be located on substantially any portion of the IMV 120 and may cover the entire outer surface area of the IMV 120 , or any portion thereof.
Referring now to FIG. 7 , which depicts a schematic (2D) view of a complete panel 710 comprising the backing layer 210 . In practice, the backing layer 210 of the complete panel 710 is molded into a three-dimensional vest shape for use in forming the IMV 120 , as described above with respect to FIGS. 1 and 2 . However, in alternative embodiments the backing layer 210 may be configured to form essentially any shape to produce a 2D or 3D target surface for use in registering an impact event.
Referring now to FIG. 8 , which depicts a cross-sectional view of the IMV 120 comprising the coating layer 140 , the substrate layer 150 , the adhesive coating 410 and the backing layer 210 . In one embodiment, the structure of the IMV 120 is formed by the bonded coating layer 140 , the substrate layer 150 and the backing layer 210 as shown in FIG. 8 . In one preferred embodiment, the adhesive coating 410 is permanently fixed to the backing layer 210 such that an adhesive surface is formed on the outer surface of the backing layer 210 . In this configuration, the substrate layer 150 can be removably bonded with the backing layer 210 via the adhesive surface of the adhesive coating 410 . In an alternative embodiment, the adhesive coating 410 can be permanently disposed on the underside of the substrate layer 150 , opposite the coating layer 140 .
In practice, the coating layer 140 is configured to flake away upon ballistic impact, exposing the underlying substrate layer 150 . In one preferred embodiment, the substrate layer 150 is composed of a bright color (e.g. a bright orange or yellow color) that can be easily contrasted with a darker color of the coating layer (e.g. a black, matte-black, matte-olive drab or earth tone color). However, the coating layer 140 and the substrate layer 150 may be comprised of virtually any materials that are distinguishable from one another (visibly or otherwise). With this contrasting color scheme, a user may visually identify a point or angle of ballistic impact by identifying the location on the IMV 120 surface where the coating layer 140 has flaked away to expose the underlying substrate layer 150 .
After a ballistic impact has been incurred by the IMV 120 , it may be desirable to renew the coating layer 140 on the outer surface of the IMV 120 . In a preferred embodiment, the new coating layer 140 may be added to the IMV 120 by simply replacing the underlying substrate layer 150 with a new substrate layer containing the new coating layer 140 . In one embodiment, the substrate layer 150 comprises the adhesive coating 410 disposed on the side opposite of the coating layer 140 . In this configuration, the substrate layer 150 may be removably attached to the backing layer 210 such that a user may peel away the used substrate layer 150 and the adhesive coating 410 for easy replacement.
Referring now to FIG. 9 , which depicts a cut-away view of a coating layer patch 910 comprising coating patch layer 930 and adhesive patch coating 920 . The coating patch layer 930 of the coating layer patch 910 is similar to the coating layer 140 discussed above with respect to the IMV 120 . The coating layer patch 910 comprises the coating patch layer 930 on one surface and an adhesive patch coating 920 on the opposite surface. In a preferred embodiment, the coating layer patch will be of a circular shape measuring approximately one-inch in diameter; however, in alternative embodiments the coating layer patch may be of substantially any shape or size.
In practice, the coating layer patch 910 may be used to touch-up the coating layer 140 of the IMV 120 . For example, the coating layer patch 910 may be used to cover portions of the coating layer 140 on the IMV 120 that have flaked away due to ballistic impact. As such, the coating layer patch 910 offers a quick and inexpensive way to repair the outer surface of the IMV 120 without the need for replacing the entire the substrate layer 150 .
While the above is a complete description of the preferred embodiment of the present invention, it is possible to use various alternatives, modifications and equivalents. Therefore, the scope of the present invention should be determined not with reference to the above description but should, instead be determined with reference to the appended claims, along with their full scope of equivalents. Any feature described herein, whether preferred or not, may be combined with any other feature described herein, whether preferred or not.
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A method and apparatus for use in facilitating force-on-force (FOF) training. Specifically, an impact marking vest (IMV) for use in registering a ballistic impact event upon a three-dimensional target surface.
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BACKGROUND OF THE INVENTION
[0001] The present invention relates generally to an apparatus for securing a small recreational vehicle to a bed of a towing vehicle. In particular, the invention relates to an apparatus for securing an all terrain vehicle (“ATV”) or other small recreational vehicle to a trailer or a bed of a pickup without the use of tie down straps or ropes.
FIELD OF THE INVENTION
[0002] ATVs and other small recreational vehicles oftentimes must be transported to sites where they are to be driven. To transport the ATV or other small vehicle, the vehicle is usually loaded onto a bed of a pickup truck or a flatbed of a trailer. Once the vehicle is loaded, the ATV is secured to the bed of the pickup or towing vehicle through the use of chains or ropes which are wrapped around various parts of the ATV, including the wheels, axles, and towing hitch. These chains and ropes or other tie down straps are hard to handle and time consuming to attach to the flatbed and the vehicle while at the same time they are often inadequate for securing the vehicles to the pickup trucks or trailers. Oftentimes there is a danger of these chains, ropes, and tie down straps of working their way loose, thereby creating the potential for damage to the towing vehicle, nearby traffic, or the small vehicle itself.
[0003] Different securing systems and anchoring assemblies have been devised to secure the ATVs or other small vehicles to a bed of a pickup or trailer that limit the use of chains, ropes, and tie down straps. Several systems or assemblies require the user to attach a mounting assembly to the flatbed itself of a pickup or a trailer. Such systems have at least two problems.
[0004] By attaching an assembly to the flatbed itself, valuable space, which can be used to haul other equipment or items besides the vehicle, is consumed, thereby limiting the opportunity to maximize the available storing capacity of the pickup truck or the trailer on which the vehicle is placed. A greater concern for the use of assemblies that are attached to the flatbed itself is that such assemblies can compromise the center of gravity for the towing vehicle. On single axle trailers and flatbeds of pickup trucks the optimum placement for the load is between the two supporting axles of the vehicles. For example, for a single axle trailer, the placement of the load will preferably be between the back axle of the transport vehicle to which the trailer is hitched and the axle of the trailer itself. For a pickup truck, it is preferable to place added weight between the front axle of the truck and the back axle. Preferably, the weight of a vehicle loaded on the flatbed of a trailer or a pickup truck will place most of its weight if not all of its weight between these two supporting axles.
[0005] By using assemblies that must be attached to the flatbed, the ability to place the small vehicle on the flatbed in a position that optimizes the center of gravity for the towing vehicle can be compromised. In order for the assemblies to be useful and not overly complicated to use, these assemblies must be attached to the front of the bed between the two supporting axles to allow for easier removal and loading of the vehicle on the flatbed. If the assembly was placed on the back of the bed, it would require the assembly to be unattached every time the vehicle is moved on or off of the bed. By placing the assembly at the front of the bed of the trailer or pickup truck, the bed is effectively shortened and by consequence, the vehicle is moved closer to the back supporting axle. If such a bed is not long enough, then part of the weight of the vehicle will actually be on the outside of the back supporting axle. Such a situation at best does not maximize the center of gravity of the loaded towing vehicle. At worse, it can disrupt the center of gravity of the towing vehicle, causing an unsafe condition for transporting the small vehicle at all but the slowest speeds. By not maximizing the center of gravity of the towing vehicles, these assemblies create opportunity for damage to the towing vehicles as well as unsafe conditions for transporting the small vehicle.
[0006] A need still exists for an apparatus for securing a small recreational vehicle to a bed of a towing vehicle that can be easily used to secure the small vehicle while at the same time optimize the towing space and the center of gravity of the towing vehicle.
SUMMARY OF THE INVENTION
[0007] Various features and advantages of the invention will be set forth in part in the following description, or may be obvious from the description, or may be learned through practice of the invention.
[0008] The present subject matter provides for an apparatus for securing a small recreational vehicle such as an ATV, snowmobile, lawnmower, etc. to a bed of a towing vehicle. The apparatus has a mounting shaft securably positionable proximal to a bed of a utility vehicle. A receiver is operably attached to the mounting shaft to receive a securing device, for example, a securing ring from a securing ring assembly, that has been attached to the small recreational vehicle. The securing ring securably engages the receiver when the small recreational vehicle is placed on the bed of the towing vehicle, thereby holding the small recreational vehicle on the bed of the towing vehicle. The receiver may be adjustable along the mounting shaft to allow alignment with the securing ring assembly that is attached to the small recreational vehicle.
[0009] In an exemplary embodiment, the receiver comprises a U-shaped bracket with parallel arms extending outward from the mounting shaft. The securing ring fits between the parallel arms of the U-shaped bracket to secure small recreational vehicle to the towing vehicle. In some embodiments, the parallel arms define apertures therein to which fastening device, such as a hitch pin, is positionable. In such embodiments, the securing ring is placed between the parallel arms so that an aperture formed in the securing ring aligns with the apertures formed in the parallel arms. The hitch pin may be placed through both the parallel arms and the securing ring to fasten the securing ring assembly and thereby the small recreational vehicle to the securing apparatus attached to the towing vehicle. The securing ring may then be locked to the receiver. Also a lock may be used instead of a hitch pin to be placed through the apertures of the parallel arms and the securing ring. Other devices may also be used instead of a hitch pin to fasten the securing ring to the receiver.
[0010] The securing ring assembly may be made up of a securing ring that is mounted to a ring plate. The ring plate may be mountable to different parts of the small recreational vehicle including a bush guard or other parts of the frame of the small recreational vehicle. The securing ring assembly may also include a holding plate which is attachable to the ring plate around a portion of the small recreational vehicle, thereby securing the securing ring assembly to the small recreational vehicle without altering the small recreational vehicle.
[0011] The towing vehicle may be a vehicle such as a truck that has a flatbed or a trailer, which could be attached to the back of an automobile. In such embodiments where the towing vehicle is a trailer, a mounting shaft can be attached to the tongue of the trailer, which is attachable to a trailer hitch on an automobile.
[0012] In embodiments where the towing vehicle is a truck, a receiver mounting plate having a unitary U-shaped receiver may be securably mounted to a side wall of the bed of the truck. As described above, a securing ring of a securing ring assembly attached to a small recreational vehicle may then engage a receiver to hold the small recreational vehicle in the bed of the truck. In these embodiments where the securing apparatus is comprised of a unitary U-shaped receiver which is mountable to a side wall of a bed of a towing vehicle, the receiver may be adjustable along a mounting plate to adjust for different placements of the securing ring assembly and for different sizes of the small recreational vehicles.
[0013] In some embodiments of the present subject matter, the mounting shaft used in the securing apparatus may be a U-shaped channel strut. The receiver may be placed in the channel to add lateral support to the receiver as well as to prevent easy detachment of the receiver from the mounting shaft when the securing ring assembly attached to the small recreational vehicle has engaged the receiver.
[0014] In further embodiments, the receiver may be integral to the mounting shaft. While in other embodiments, the receiver may be adjustable along the mounting shaft. By having the receiver adjustable along the mounting shaft, the mounting shaft may be made of a unitary structure, (meaning it is a single unit, not consisting of two separate pieces) while still allowing for proper alignment of the receiver with different positions of the securing ring on a small recreational vehicle or with the different sizes of small recreational vehicles. Further, by having the receiver adjustable along the mounting shaft instead of having the mounting shaft adjustable, the strength of the mounting shaft is not compromised.
[0015] In embodiments of the securing apparatus that use a unitary mounting shaft with a receiver attached thereto or in the embodiment, that employ a unitary U-shaped receiver mounted to a mounting plate, both the mounting shaft and the mounting plate may be affixed to a grounding member or a stable structure such as a wall, a driveway, a foundation, etc., to secure the small recreational vehicle from theft. These stationary positionings of the securing apparatuses allow all the user of the small recreational vehicle to lock up the vehicle when not in use, thereby deterring theft of such a vehicle.
[0016] In a further embodiment, the securing apparatus includes a mounting shaft which extends in a longitudinal length and has a first end and a second end at opposite ends of the longitudinal length of the mounting shaft. A mounting base is integral to the shaft at the first end. The mounting base can be attached to the tongue of the towing vehicle by having the mounting base interact with and engage a holding plate so that the second end of the shaft extends above the bed of the towing vehicle. A U-shaped receiver may then be operably attached to the shaft by securing bolts. The U-shaped receiver has parallel arms and extend outward from the shaft when the receiver is attached thereto. The parallel arms each define an aperture which are in parallel alignment with each other.
[0017] A securing ring that defines a ring aperture may then be attached to the small recreational vehicle. The securing ring fits between the extended arms of the U-shaped receiver when the small vehicle is placed on the bed of a towing vehicle so that the securing ring extends past the apertures defined in the parallel arms, thereby aligning the aperture formed by the securing ring with the apertures in the parallel arms.
[0018] A removable fastening device can then be positioned in the apertures in the parallel arms and through the ring aperture of the securing ring. This securing ring, which is attached to the small recreational vehicle, engages the receiver so that the small recreational vehicle is secured to the bed of the towing vehicle. To accommodate different sized small recreational vehicles or to accommodate different placements of a securing ring, the receiver may be adjustable along the mounting shaft.
[0019] Other features of the present invention will be described in greater detail below through the use of appended figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] FIG. 1 shows a perspective view of an embodiment of a securing apparatus for securing a small recreational vehicle to a bed of a towing vehicle according to the present subject matter;
[0021] FIG. 2 shows an exposed view of an embodiment of the securing apparatus according to the present subject matter;
[0022] FIG. 3 shows side views of two positions of the securing apparatus on a tongue of a towing vehicle according to the present subject mater;
[0023] FIG. 4 shows a perspective view of a further embodiment of the securing apparatus in operation on a towing vehicle to secure a small recreational vehicle to the towing vehicle in accordance with the present subject matter;
[0024] FIG. 5 shows a perspective view of a further embodiment of a securing apparatus according to the present subject matter.
[0025] FIG. 6 shows a perspective view of another embodiment of a securing apparatus attached to a side wall of a bed of a truck according to the present subject matter;
[0026] FIG. 7 shows an exploded perspective view of a further embodiment of a securing apparatus according to the present subject matter; and
[0027] FIGS. 8A and 8B show side views of small recreational vehicles secured to beds of towing vehicles using two embodiments of the securing apparatuses according to the present subject matter.
DETAILED DESCRIPTION
[0028] Reference will now made in detail to the presently preferred embodiments of the invention, one or more of examples of which are shown in the figures. Each example is provided to explain the invention, and not as limitations of the invention. In fact, features illustrated or described as part of one embodiment can be used with another embodiment to yield still a further embodiment. It is intended that the present invention cover such modifications and variations.
[0029] FIG. 1 shows an exemplary embodiment of a securing apparatus, generally 10 , used to secure a small recreational vehicle to a bed of a towing vehicle. In particular, in FIG. 1 , the securing apparatus 10 is secured to a tongue 22 of a towing vehicle, or trailer, generally 20 . The trailer 20 has a flatbed 24 on which a small recreational vehicle, or, in this case, an all terrain vehicle (“ATV”) generally 30 , is placed. The securing apparatus 10 has a mounting shaft 11 integral to a mounting base 18 . To attach the mounting shaft 11 to the tongue 22 , the mounting base 18 can be connected to a holding plate 16 by securing bolts 39 and securing nuts 38 . The mounting base 18 is placed on the bedside 23 of the tongue 22 while the holding plate is placed on the roadside 25 of the tongue 22 . Securing bolts 39 are then placed through apertures in the holding plate 16 and the mounting base 18 in a known manner. Securing nuts 38 are then screwed onto the securing bolts 9 to tighten and hold the mounting base 18 and the mounting shaft 11 in an erect position above the flatbed 24 of the trailer 20 . Other manners for securing the mounting shaft 11 to the trailer tongue 22 as are known in the art may be used. For example, the mounting shaft 11 may be welded onto the tongue 22 or may be removable attached in some other manner.
[0030] The securing apparatus 10 also includes a receiver 12 which can be mountably attached to the mounting shaft 11 . In the example shown in FIG. 1 , the receiver 12 is a U-shaped bracket which opens toward the bed 24 of the trailer 20 . When the small recreational vehicle 30 is driven, pushed or placed on the flatbed 24 of the trailer 20 , a securing device, or securing ring assembly, 13 engages the receiver 12 to allow the small recreational vehicle 30 to be locked onto the trailer. In an exemplary embodiment, a portion of the securing ring assembly enters the U-shaped receiver 12 , and a fastening device 14 , which has a hitch pin, is then placed through apertures 26 (see FIG. 2 ) formed in the arm of the U-shaped receiver. The fastening device 14 fastens the securing ring assembly 13 and thus by the small recreational vehicle 30 to the mounting shaft, thereby holding the small recreational vehicle 30 to the flatbed 24 of the trailer 20 . The securing ring assembly 13 can be attached to any portion of the small recreational vehicle 30 that will hold the small recreational vehicle 30 in place on the flatbed 24 . Preferably, the securing ring assembly 13 will attach to a portion of the frame of the small recreational vehicle 30 . In the embodiment shown, the securing ring assembly 13 is attached to a bush guard 32 of the ATV 30 .
[0031] FIG. 2 shows an exploded view of the securing apparatus 10 . As stated before, the mounting shaft 11 may be put in the proper position by placing the mounting base 18 integral to the mounting shaft 11 on the tongue of a trailer or other device and connecting a holding plate 16 opposite the mounting base 18 . For example, the mounting base 18 may be fastened to the holding plate 16 through the use of the securing bolts 39 and securing nuts 38 . By using the securing nuts 38 and securing bolts 39 , the mounting shaft may be securely fastened to a tongue of a trailer or some other device to allow the mounting shaft to be proximal to the flatbed on which a small recreational vehicle is to be placed. At the same time, the securing nuts 38 and the securing bolts 39 allow the securing apparatus 10 to be removal and/or adjustable.
[0032] The mounting shaft 11 shown in the embodiment of FIG. 2 is a four-walled shaft having mounting apertures 7 defined through the walls that run parallel to the flatbed of a vehicle when the shaft 11 is properly mounted. The receiver 12 can be mounted to the mounting shaft 11 . The U-shaped receiver has mounting apertures 27 which can be aligned with mounting apertures 7 of the mounting shaft 11 , thereby allowing securing bolts 9 to be inserted through both the mounting apertures 27 of the receiver 12 and the mounting apertures 7 of the mounting shaft 11 . Securing nuts 8 may then be screwed onto the securing bolts 9 to secure the receiver 12 to the mounting shaft 11 .
[0033] As can be seen in FIG. 3 , due to the multiple mounting apertures 7 within the mounting shaft 11 , the placement of the receiver 12 is adjustable in the vertical direction of the arrows V 2 . Further, as stated before, the mounting shaft 11 is also adjustable in a horizontal direction as shown by the arrows V 1 . These adjustable combinations of the mounting shaft and the U-shaped receiver allow for the adjustment of the securing device to adapt to different sized small recreational vehicles. For example, in FIG. 3 , the receiver 12 of the securing apparatus 10 shown in the solid lines is positioned for the right height of the securing ring 13 , which may be attached to a larger vehicle or attached where the placement of the securing ring assembly is at a higher position on the vehicle. The placement of the receiver 12 so that the securing bolts 9 may be properly placed through the appropriate mounting apertures 7 and then secured through the securing nuts 8 allow for the proper alignment of the receiver 12 to accept the securing ring assembly 13 , thereby allowing the hitch pin 14 to fasten the small recreational vehicle to the mounting shaft 11 .
[0034] This same mounting shaft can be adjusted to fit a different vehicle, for example, a snowmobile, which may extend further into the area of the tongue 22 , of a flatbed and may require the securing ring assembly to be attached at a lower position as depicted in FIG. 3 as securing apparatus 10 ′ (shown in a dotted outline in FIG. 3 ). Securing apparatus 10 ′ has been moved further back along the tongue 22 away from the flatbed by loosening the securing nut 38 ′ and the securing bolt 39 ′ to allow the securing apparatus 10 ′ to be shifted. When the securing apparatus 10 ′ is in its proper place, the securing bolts 39 ′ and the securing nuts 38 ′ may be tightened to secure the mounting plate 18 ′ and the holding plate 16 ′ to the tongue 22 , thereby fastening the securing apparatus 10 ′. To accommodate for the lower location of the securing ring 13 ′, the receiver 12 ′ may be removed from its other location and secured to a lower location by placing the securing bolts 9 ′ in the proper mounting aperture 7 ′ and then tightening the U-shaped receiver 12 ′ to the mounting shaft 11 ′ by tightening the securing nuts 8 ′ on the securing bolts 9 ′. In this manner, the receiver 12 ′ may be adjusted to receive the securing ring 13 ′ that is positioned in a different location on the same vehicle, or placed on a different vehicle.
[0035] Referring back to FIG. 2 , it can be seen that the securing ring assembly 13 may be composed of multiple parts. In the shown embodiment, the securing ring 13 has a ring 19 attached to a ring plate 17 . The ring plate 17 has mounting apertures 21 placed on either side of the securing ring 19 . The securing ring assembly 13 also includes a holding plate 15 that may be placed on the opposite side of the portion of the small recreational vehicle to which the securing ring assembly will be attached. As with the ring plate 17 , the holding plate 15 has mounting apertures 21 that will align with the mounting apertures 21 of the ring plate 17 . In some embodiments, it may be preferable to have multiple sets of mounting apertures in both the holding plate and the ring plate to allow the ring assembly 13 to be adaptable to different positions on a small recreational vehicle or be adaptable to different types of small recreational vehicles. Once the mounting apertures 21 of the holding plate 15 and the ring plate 17 are properly aligned, mounting bolts 29 may be inserted through the mounting apertures of the ring plate 17 and the holding plate 15 to secure the securing ring assembly 13 to the small recreational vehicle. Securing nuts 28 may then be screwed onto the securing bolts 29 to securely hold the securing ring assembly to the small recreational vehicle.
[0036] The securing ring 19 forms a ring aperture 37 which allows the securing ring assembly and thereby the small recreational vehicle to be securely attached to the mounting shaft 11 and thereby to the bed of the towing vehicle to which the mounting shaft 11 is attached. The ring 19 enters the receiver 12 so that the aperture 37 is aligned with the locking apertures 26 in the arms of the receiver 12 . At this point, a hitch pin 14 or other device which may be inserted through the locking apertures 26 as well as the ring aperture 37 to secure the ring assembly 13 to the mounting shaft 11 . In the embodiment shown in FIG. 2 , the hitch pin 14 has a locking passage 35 , which passes through an end portion of the hitch pin 14 . This locking passage 35 allows a lock or a cotter pin to be placed through the hitch pin 14 to lock the hitch pin 14 in place, thereby further securing the securing ring assembly 13 to the mounting shaft 11 . In this manner, the small recreational vehicle may be secured to a flatbed of the towing vehicle.
[0037] While not necessary, it is beneficial to place the securing ring assembly 13 on the front of a small recreational vehicle, like an ATV, for example. By placing the securing ring assembly 13 on the front portion of an ATV, the ATV can be driven onto the bed of a trailer, truck, or other towing vehicle and the securing ring 19 can be easily aligned with the receiver 12 . When the securing ring assembly is placed on the back of an ATV, the ATV, is most cases, has to be walked onto the bed. At the same time, maneuvering the ATV to align the securing ring 13 with the receiver 12 is also harder because steering of the ATV is done at the end of the ATV furthest away from the securing ring 19 , receiver 12 , and the point of attachment.
[0038] FIG. 4 illustrates a further embodiment of a securing device, generally 210 . As with previous embodiments, a mounting shaft 211 may be mounted proximal to a flatbed 24 of a towing vehicle, or in this case a trailer, generally 20 . The mounting shaft 211 has a U-shaped receiver 212 securely mounted thereto. To secure the small recreational vehicle 30 to the mounting shaft 211 , a securing ring assembly 213 is permanently attached to a portion of the small recreational vehicle 30 , in particularly, a bush guard 32 . Unlike the previously securing ring assemblies, the securing ring assembly 213 is permanently attached to the bush guard 32 . In this manner, it makes it harder for someone interested in improperly removing the vehicle from the bed of the towing vehicle from doing so by preventing such a person from detaching the securing ring assembly 213 from the small recreational vehicle 30 . In such an embodiment, the securing ring 213 is made up of a ring plate 217 and a securing ring 19 . The ring plate 217 in this example is welded to the bush guard 32 of the small recreational vehicle 30 .
[0039] Other shapes and designs of ring plate assemblies which may be permanently attached or which may be removably attached to small recreational vehicles can be used without departing from the scope of this invention. For example, a single ring may be screwably attached, welded, or clamped to the frame or some other securable place on a small recreational vehicle. The use of securing bolts and securing nuts are not required. Further, a securing ring attached to a ring plate may also be screwably attached to the small recreational vehicle without the benefit of a holding plate. Other examples of the securing ring assemblies are also known in the art and are covered by the scope of the present invention.
[0040] FIG. 5 shows a further embodiment of a securing apparatus 110 . In this embodiment, the securing apparatus 110 has a mounting shaft 111 which is a U-shaped channel strut that is attached to a mounting base 118 . In operation, a receiver 112 having parallel arms is placed in the channel of the mounting shaft 111 so that the arms of the receiver 112 extend outward. The receiver 112 may be attached at an appropriate height to align a receiver with a securing ring assembly 113 , which may be attached to a small recreational vehicle. To obtain the proper alignment, an aperture in the portion of receiver 112 running parallel to the shaft 111 is aligned with an appropriate mounting aperture 107 through which a securing bolt 109 is placed. A securing nut 108 is then tightened onto the security bolt 109 to securely attach the receiver 112 to the mounting shaft as can be seen in the cut a way view of the mounting shaft 111 . By having the receiver placed on the inside of the channel in shaft 111 , the receiver 112 is prevent from being twisted around the securing bolt 104 . Further, such placement of receiver 112 in the shaft 111 adds lateral support to the receiver 112 .
[0041] The bolt in this example is place inward through the appropriate mounting aperture 107 so that the threaded end extends through the channel of the mounting shaft 111 . The securing nut 108 is then tightened onto the bolt 109 . In this manner, when the securing ring assembly 113 is in an engaged position in the receiver 112 , the receiver 112 cannot be loosened from the mounting shaft 111 . Thereby, possible theft may be deterred.
[0042] A securing ring assembly 113 of the securing apparatus 110 also has a different configuration. The securing ring 119 is cut out of an L-shaped bracket. In this manner, the securing ring 119 serves as the ring as well as the ring plate. Such a securing ring 119 is easily manufactured out of an L-shaped material which can be stamped to form the ring aperture through which a hitch pin 114 may pass. The securing ring 119 may be attached through securing bolts and securing nuts to a holding plate 115 . As described above, mounting apertures 121 in both the securing ring 119 and the holding plate 115 may be aligned to allow insertion of a bolt or some other securing device. In some embodiments, multiple sets of mounting apertures 121 may be placed in the securing ring 119 and the holding plate 115 (only shown in the holding plate 15 in FIG. 5 ) to allow the securing ring assembly to be attached to different small recreational vehicles or to be attached to the same vehicle in different locations.
[0043] Once the securing ring 119 of the securing ring assembly 113 is placed between the arms of the receiver 112 , the hitch pin 114 may be placed through locking apertures in the arms of the receiver 112 and the ring aperture of securing ring 119 . A lock 140 may then be placed through a passage 135 in the hitch pin 114 to lock the securing ring to the mounting shaft. In this manner, the small recreational vehicle is also secured to the mounting shaft.
[0044] The embodiment shown in FIG. 5 may also be used to secure the small recreational vehicle in a stationary position. The mounting shaft 111 may be attached to a grounding member 145 such as a cement slab, paved driveway, or some other foundation. Also, the grounding member 145 may be a wall or some other stationary non-movable object. In cases where a wall is used, the mounting shaft may be constructed at a right angle so that the mounting shaft is actually one unitary piece to add strengthened stability to prevent bending or breaking of the mounting shaft. In this manner, the mounting shaft may be mounted to a side of the wall and still allow a small recreational vehicle to be positioned so that it may engage the receiver 112 .
[0045] The mounting shaft 11 , 111 , 211 of FIGS. 1 through 5 are constructed of a unitary piece of metal or other material which may withstand the forces place upon on it. By having mounting apertures 7 , 107 placed in at least one side of the mounting shaft to allow the receiver 12 , 112 , 212 to be adjustable up and down, a situation is avoided where the mounting shaft has to be in two pieces to allow it to be adjustable. By having the mounting shaft 11 , 111 , 211 as a unitary piece, the strength of the mounting shaft 11 , 111 , 211 is not compromised. If the mounting shaft itself had been made adjustable by being made in two pieces, then it is possible that you are creating weak points within the mounting shaft, thereby making it easier for the small recreational vehicle to be detached from the towing vehicle or a non-movable object depending on the use of securing apparatus 10 , 110 , 210 . Therefore, the unitary mounting shaft is beneficial for use in a securing apparatus 10 , 110 , 210 .
[0046] FIG. 6 shows a further embodiment of the present subject matter. A securing apparatus 50 is attached to a front sidewall 42 of a towing vehicle 40 , in this example, a truck. The securing apparatus comprises a mounting plate 52 which can be secured to the front side wall 42 by securing bolts 59 in a known manner. The mounting plate may have a receiver 51 which possesses parallel arms 54 that create a receptacle for a securing ring assembly or a securing ring which may be attached to a small recreational vehicle that is to be loaded onto a bed 44 of the towing vehicle 40 . As shown in this embodiment, the receiver 51 and its parallel arms 54 may be permanently attached to the mounting plate 52 . In such an arrangement, multiple holes may be drilled into the front side wall 42 to allow the mounting plate 52 and receiver 51 to be adjusted to the right height to accommodate securing rings positioned at different heights. As discussed above, parallel arms 54 define locking apertures 55 , which allow a lock or a hitch pin or some other device to be inserted through the apertures to secure the small recreational vehicle to the bed of the truck 40 .
[0047] It should be understood by those skilled in the art that other types and designs of receivers may be used in combination with the mounting shaft and the securing ring assembly to form a securing apparatus. These receivers may be self-locking, which, once engaged by a securing ring, automatically hold the ring and do not permit the ring to become loose until such time that a release mechanism is activated. It should be understood that the present subject matter includes such receivers as well as other receivers which are known in the art.
[0048] In such embodiments as shown in FIG. 6 , it is beneficial to have the securing apparatus 50 centered on the front side wall 42 between the two parallel side walls 46 of the towing vehicle 40 when the securing ring assembly is attached to a center position on the small recreational vehicle. In this manner, the weight of the small recreational vehicle is distributed evenly on the flat bed 40 in a known manner. At such point in time that the vehicle is properly placed on the flatbed 44 of the towing vehicle 40 the tailgate 48 may then be closed.
[0049] In FIGS. 1 through 4 , with the mounting shafts 11 , 211 secured to the tongue 22 of a trailer 20 , the mounting shafts 11 , 211 and the receivers 12 , 212 attached to the mounting shaft 11 , 211 are centered relative to the flatbed 24 of the trailer 20 . Thereby, if the securing ring assembly 13 , 213 is centered on the small recreational vehicle, then the weight of the small recreational vehicle 30 should be evenly distributed across the length of the flatbed 24 . Such a design helps to stabilize the trailer 20 during travel.
[0050] FIG. 7 shows a similar embodiment to the securing apparatus 50 shown in FIG. 6 . A securing apparatus 150 has a mounting plate 152 having parallel locking walls 156 integral thereto. The parallel locking walls 156 have mounting apertures 157 which are properly aligned to receive and secure a receiver 151 . The receiver 151 has parallel arms 154 which define apertures 155 therethrough to receive a hitch pin, or other fastening device, 124 . Further, the receiver 151 also defines securing apertures 153 that may be aligned with the appropriate mounting apertures 157 to allow a securing bolt 159 to engage both the mounting apertures 157 and the securing apertures 153 to hold the receiver 151 in a proper position to receive a securing ring assembly. To secure the receiver 151 to the locking wall 156 , a securing nut 158 is then tightened onto the end of the securing bolt 159 to lock the receiver 151 in place.
[0051] Other types of mechanisms that allow the receiver 151 to be adjustable may be used. For example, pins, springs, spring pins, etc. can be employed. Any such mechanisms that allow the receiver to be adjustable along a locking wall that is known in the art can be used and is considered within the scope of the present subject matter.
[0052] The mounting plate 152 may be attached to a side wall, preferably, a front side wall, of a towing vehicle in several different manners including permanently attaching the mounting plate 152 to the side wall through welding or some other known manner of attachment. In the embodiment shown in FIG. 7 , a holding plate may be placed on the opposite of the side wall and securing bolts 9 may engage both the mounting plate 152 and the holding plate 149 by passing through the side wall of the towing vehicle. Securing nuts 8 may then be tightened onto the securing bolts 9 to secure the mounting plate 152 to the side wall of the towing vehicle. In such an embodiment, the securing apparatus 150 may be permanently attached to the vehicle while still allowing the receiver 151 to be adjustable in-height to accommodate different positions of the securing ring assembly on a small vehicle or to accommodate different sizes of small recreational vehicles.
[0053] By placing the securing apparatuses on towing vehicles as shown in FIGS. 1, 3 and 6 and not to the bed of the towing vehicle, several benefits can be realized. For example, as shown in FIG. 8A , the small recreational vehicle 70 is attached to a front wall 68 of a towing vehicle, in particular, a truck 60 . By having the small recreational vehicle 70 attached to a securing apparatus 80 on the front wall 68 of the flatbed 66 of the vehicle 60 then the placement of the small recreational vehicle 70 is optimized. First, the weight G 1 of the small recreational vehicle 70 is placed between the two load bearing points L 1 and L 2 of the axles 62 and 64 of the vehicle 60 . This placement helps to stabilize the towing vehicle 60 during travel, especially when such vehicles are running at higher rates of speed. Even in such situations where the small recreational vehicle may not fall within these two load bearing points L 1 , L 2 , the position of the small recreational vehicle is still optimized due to the fact that as much of the weight G 1 of the small recreational vehicle 70 as possible is placed between these two load bearing points L 1 , L 2 .
[0054] In a similar manner, a securing apparatus 180 shown in FIG. 8B optimizes the placement of the weight of G 2 of a small recreational vehicle 170 between the two load bearing points L 3 and L 4 of the towing vehicle configuration shown. An automobile 161 may tow a trailer 160 , which has a flatbed 166 and a tongue 165 . By placing the securing apparatus 180 on the tongue 165 of the trailer 160 , the small recreational vehicle 170 can be placed at the very front of the trailer bed 166 to insure that the placement of the weight G 2 of the recreational vehicle 170 is optimized between the back axle 162 of the automobile and the axle 164 of the trailer. Again, this placement helps to stabilize the trailer 160 as it is being pulled by the automobile 161 , especially at higher rates of speeds. As stated with the truck shown in FIG. 8A , even if all the weight G 2 of the small recreational vehicle 170 does not fall between the load bearing points L 3 and L 4 , at least the most optimal amount of such weight will reside between the load bearing points L 3 and L 4 due to the placement of the small recreational vehicle 170 at the front of the flatbed 166 . In this manner the small recreational vehicle can be more safely transported to the areas where it will be used.
[0055] As illustrated in FIGS. 8A and 8B , a further benefit is the storage area still available after placement of the small recreational vehicles 70 , 170 on the flatbed 66 , 166 . The extra space allows other equipment and devices or goods to be placed on the bed 66 , 166 behind the small recreational vehicles. Thereby, the space available on the flatbed 66 , 166 can be optimized.
[0056] It would be appreciated by those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope of the invention. It is intended that the present invention includes such modifications and variations as come within the scope of the appended claims and their equivalents.
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An apparatus for securing a small recreational vehicle to a bed of a towing vehicle or to a grounding member is provided. The apparatus includes a mounting shaft that is securably positionable proximal to the bed of the towing vehicle or mountable on a grounding member. A receiver is operably attachable to the mounting shaft. A securing device, for example, securing ring, that is attachable to the small vehicle securably engages the receiver to hold the small recreational vehicle on the bed of the towing vehicle or to fasten the small recreational vehicle to the grounding member. In a further embodiment, the apparatus includes a receiver mounting plate that is securably mountable to a sidewall of a bed of a towing vehicle or to a grounding member. A receiver is disposed on the receiver mounting plate, and a securing ring is attachable to said small recreational vehicle. The securing ring securably engages the receiver to hold the small recreational vehicle on the bed of the towing vehicle or to fasten the small recreational vehicle to the grounding member.
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BACKGROUND OF THE INVENTION
This invention pertains to medical grade film and a method of sterilizing medical grade film and, more particularly, to medical grade film and a method of sterilizing the same wherein the film can be gamma or electron beam sterilized without any color change, and the sterilized medical grade film produced thereby.
Medical grade film, e.g., film meeting the requirements of Class VI plastics as set forth in the U.S. Pharmacopeia, Volume XX, is useful for manufacturing products which can be used for medical treatments and for manufacturing containers for products such as pharmaceuticals, cosmetics and foods. Suitable applications for such films are enteric feeding bags, kidney dialysis bags, barium enema bags, colostomy bags, bloodwashing bags, blood storage bags, urinary drainage bags, incontinent products, inflatable splints, hospital I.D. bracelets, traction devices, burn mattresses, comfort cushions and waterproof hospital sheeting.
Currently, the medical industry utilizes a medical grade film containing polyvinyl chloride (PVC) resin. The industry sterilizes this medical grade film using ethylene oxide. However, this is a cumbersome, time-consuming and expensive method of sterilization. The industry prefers using the gamma-radiation sterilization method since it is more effective biologically, less expensive and less time-consuming. However, irradiation levels of 1 to 5 megarads used in this sterilization method cause the polyvinyl film to yellow. While this yellowing does not render the film nonfunctional, it is considered undesirable aesthetically.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide a medical grade film which may be gamma or electron beam sterilized without any color change.
It is a further object of the present invention to provide a method of sterilizing a medical grade film with gamma or electron beam radiation without any color change in the film.
It is an additional object of the present invention to provide a sterilized medical grade film.
These objects are accomplished by providing a halogen containing resin film including barium sulfate. The halogen containing resin is preferably a vinyl chloride resin such as PVC. In addition to polyvinyl chloride and varium sulfate, the film can also contain a plasticizer such as di-2-ethylhexyl adipate, epoxidized soybean oil, a stabilizer such as an organo zinc soap blend or an organotin salt, and a lubricant such as stearic acid.
The medical grade film of the present invention can be successfully gamma or electron beam sterilized without any color change. For example, gamma radiation doses can range from 1 to 5 megarads.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
A medical grade film of the present invention includes a halogen containing resin and, more particularly, a vinyl chloride resin. The vinyl chloride resin may be a homopolymer of vinyl chloride or a mixed polymer, such as copolymers or graft polymers of vinyl chloride which have been prepared by known continuous or batch polymerization processes. Suitable monomers for copolymerization with vinyl chloride are olefins, vinyl esters of carboxylic acids, acrylonitrile, styrene and cyclohexylmaleimide. Polymers useful for graft polymerization with vinyl chloride include elastomeric polymers of butadiene, ethylene, propylene, styrene and/or acrylonitrile.
The medical grade film of the present invention may contain any of a number of known stabilizers. Suitable stabilizers include organo zinc soap blends and metallic soaps of calcium and zinc. A preferable stabilizer is Mark QTS (an organo zinc soap blend manufactured by Argus Chemical Division of Witco Chemical Corp.).
The medical grade film of the present invention may contain any of a number of known lubricants. Such lubricants include calcium stearate, hydrogenated tallow and fatty acids (food grade). Preferably lubricants include stearic acid and calcium stearate.
Known plasticizers may also be included in the medical grade film of the present invention. Examples of such plasticizers are phthalate plasticizers such as dioctyl phthalate (D.O.P.). However, the preferred plasticizer is di-2-ethylhexyl adipate.
The medical grade film may contain other additives such as epoxidized soybean oil and FDA approved pigments.
The advantageous effects of the present invention are obtained by including barium sulfate in the medical grade film.
The foregoing raw materials are preferably included in the medical grade film of the present invention in the following proportions by weight percent: the amount of PVC resin preferably contained in the composition is 60 to 69%; the amount of plasticizer is preferably 19 to 25%; the amount of stabilizer is preferably 0.5 to 1.3%; the amount of lubricant is preferably 0.15 to 0.2%; the amount of epoxidized soybean oil is preferably 9.5 to 10.5%; and the amount of barium sulfate is preferably 0.5 to 5%, most preferably 2.9%.
The raw materials can be mixed by blending then Banburying. The composition obtained thereby can then be calendered to form films having a thickness in the range of 2 to 30 mils, preferably 6 to 18 mils.
The films can be shaped by known techniques such as electronic heat sealing to form useful articles.
Sterilization is preferably accomplished by exposing the films or shaped articles to gamma radiation. Gamma radiation sources are known in the art, e.g., a cobalt 60 source may be used. Typical irradiation levels are in the range of 1 to 5 megarads. Electron beam radiation may also be employed.
EXAMPLE 1
A film was prepared by blending the following raw materials followed by Banburying and calendering:
PVC resin--100 parts by weight,
Di-2-ethylhexyl adipate (DOA plasticizer)--33 parts by weight,
Mark QTS (manufactured by Argus Chemical Division of Witco Chemical Corp.)--0.75 parts by weight,
Drapex 6.8 (epoxidized soybean oil manufactured by Argus Chemical Division of Witco Chemical Corp.)--15 parts by weight,
Barium sulfate--4.47 parts by weight, and
Industrene 7018 FG (Food Grade 70% stearic acid manufactured by Humko Chemical Division of Witco Chemical Corp.)--0.25 parts by weight.
The film was successfully sterilized using 1 to 5 megarads of gamma radiation without any color change.
Large scale processing of the film can be accomplished in the following manner. The PVC resin can be stored in resin silos. Bulk plasticizer such as D.O.P. and epoxidized soybean oil can be stored in separate plasticizer tanks. Bulk PVC resin, D.O.P. and epoxidized soybean oil can be pumped and weighed into blenders. The other ingredients, such as lubricants and barium sulfate, can be kept in drums and/or bags and can be weighted into the blender. The total weight of the raw materials in the blender can be approximately 4,000 lbs. These materials are then blended for 25 minutes at approximately 200° F.
Two-hundred-fifty pounds of the blended raw materials are then transferred into the Banbury where the materials are mixed for 31/2 minutes, reaching a temperature of 340° F., until the formulation is fused. The plastic formulation is then transferred to a two-roll mill which is at a temperature of 320° F. This mill performs the function of mixing and storage.
The material is then transferred to an extruder-strainer which is at a temperature of 325° F. The material is strained and extruded into a continuous web approximately 3 inches in diameter which is fed to a calender. A calender, such as a four-roll inverted-L calender, can be used. The calender rolls are heated, top to bottom, from 350° F. to 310° F. The calender forms the (webbed) material into a sheet of various widths and thickness. The calender sheet is then cooled by cooling drums and a beta gauge measures the thickness of the sheet. A winder rolls the sheet into a roll which is then slit into smaller rolls on a slitter. The rolls can then be packaged into, e.g., a polyethylene bag which is wrapped with Kraft paper. The thus-formed medical grade film can be used to fabricate desired products by conventional electronic heat sealing equipment. The film or products can be sterilized using gamma or electron beam radiation.
While the invention has been described and illustrated by the example included herein, it is not intended that the invention be strictly limited thereto, and other variations and modifications may be employed within the scope of the following claims.
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A medical grade film, a method of sterilizing a medical grade film and the sterilized medical grade film produced thereby, wherein the film contains a vinyl chloride resin, such as PVC, and barium sulfate. The film can be sterilized by exposure to gamma radiation of one to five megarads without any color change. Electron beam radiation may also be employed.
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This application is a continuation of application Ser. No. 08/100,880, filed Aug. 2, 1993 now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a seesaw switch performing the switching operation by tilting an operating lever around a supporting shaft in both directions with respect to the supporting shaft, and more specifically to a seesaw switch with double action capable of performing double switching operations along with click feelings by tilting an operating lever in one direction.
2. Description of the Related Art
FIG. 6 is a sectional view showing a prior art seesaw switch with double action of this type, which has been disclosed in Unexamined Japanese Utility Model Publication No. SHO 60-35442. In this figure, reference numeral 1 indicates an operating lever, which is supported so as to be rockable in both the directions of the arrows A and B around a supporting shaft 2. Four pressing portions 1a, 1b, 1c and 1d are hangingly provided on the back surface of the operating lever 1, wherein the two pressing portions 1a and 1b are provided on the right side of the supporting shaft 2 and the two pressing portions 1c and 1d are provided on the left side. Reference numeral 3 indicates a click rubber composed of a silicon rubber or the like, which is mounted on a printed circuit board 4. The click rubber 3 is provided with four projecting portions 5, 6, 7 and 8 corresponding to the pressing portions 1a to 1d, respectively. Movable contact points 5a, 6a, 7a and 8a are provided on the lower surfaces of the projecting portions 5, 6, 7 and 8, respectively. On the vertexes of the two projecting portions 5 and 7 located on the inner side, cylindrical portions 5b and 7b are respectively formed in such a manner as to be respectively elastically contacted with the lower surfaces of the pressing portions 1a and 1c. On the contrary, the two projecting portions 6 and 8 located on the outer side are respectively opposed to the lower surfaces of the pressing portions 1b and 1d with specified intervals. Further, fixed contact points 1a, 1b, 1c and 1d are provided on the surface of the printed circuit board 4 so as to correspond to the movable contacts 5a, 6a, 7a and 8a, respectively. The movable contact point 5a and the fixed contact point 4a form a first switch S 1 ; the movable contact point 6a and the fixed contact point 4b form a second switch S 2 ; the movable contact point 7a and the fixed contact point 4c form a third switch S 3 ; and the movable contact point 8a and the fixed contact point 4d form a fourth switch S 4 .
In the seesaw switch thus constructed, the operating lever 1 is usually applied with an elastic force from both the cylindrical portions 5b and 7b of the click rubber 3 to be held at the neutral position shown in FIG. 6. In this case, the first to fourth switches S 1 , S 2 , S 3 and S 4 are all in the off-state. When the operating lever 1 is tilted in the direction of the arrow A from the neutral position shown in FIG. 6, first, the pressing portion 1a near the supporting shaft 1 presses the cylindrical portion 5b of the projecting portion 1a.
Consequently, the projecting portion 5 is buckled, to generate a first click feeling (stepping feeling), and also the movable contact point 5a is contacted with the fixed contact point 4a to make only the first switch S 1 in the on-state. When the operating lever 1 is further tilted in the direction of the arrow A, the pressing portion 1b apart from the supporting shaft 1 presses the projecting portion 6, while the pressing portion 1a crushes the cylindrical portion 5b of the pressing portion 5.
Consequently, the projecting portion 6 is buckled, to generate a second click feeling, and also the movable contact point 6a is contacted with the fixed contact point 4b to make the second switch S 2 in the on-state, that is, to make both the first switch S 1 and the second switch S 2 in the on-state.
On the contrary, when the operating lever 1 is tilted in the direction of the arrow B from the neutral state shown in FIG. 6, first, the pressing portion 1c near the supporting shaft 2 presses the cylindrical portion 7b of the projecting portion 7, to generate a first click feeling, and also the movable contact point 7a is contacted with the fixed contact point 4c to make only the third switch S 3 in the on-state. When the operating lever 1 is further tilted in the direction of the arrow B, the pressing portion 1d apart from the supporting shaft 2 presses the projecting portion 8, to generate a second click feeling, and also the movable contact point 8a is contacted with the fixed contact point 4d, to make both the switch S 4 and the third switch S 3 in the on-state.
In the prior art seesaw switch described above, by tilting the operating lever 1 in one direction, the two switches are made in the on-state with the click feelings in an interlocking manner. Accordingly, in the case of using such a seesaw switch as an input switch of a power window device mounted on a vehicle, a manual action and an automatic action can be performed by the first and second switchings, respectively. For example, assuming that the direction of the arrow A is taken as an UP side and the direction of the arrow B is taken as a DOWN side, by tilting the operating lever 1 in the direction of the arrow A, it is possible to perform a manual UP during the first switch S 1 is in the on-state, and to perform an automatic UP when the second switch S 2 following on the switch S 1 is turned on. On the contrary, by tilting the operating lever 1 in the direction of the arrow B, it is possible to perform a manual DOWN during the third switch S 3 is in the on-state, and to perform an Automatic DOWN when the fourth switch S 4 following on the third switch S 3 is turned on.
However, for realizing such a double action, the two switches for one side, that is, the four switches S 1 to S 4 in total, which are operated by the tilting of the operating lever 1, are required. This brings about such disadvantages that the seesaw switch is enlarged in size, and the circuit additionally formed on each of the switches S 1 to S 4 is complicated, resulting in the increased cost.
SUMMARY OF THE INVENTION
In view of the above situation, the present invention has been made, and an object of the present invention is to provide a seesaw switch with double action suitable for miniaturization with a low cost.
To achieve the above object, according to the present invention, there is provided a seesaw switch comprising: an operating lever rockably supported around a supporting shaft; and a first and second click projecting portions provided at opposed positions with respect to the supporting shaft, which are buckled by tilting of the operating lever; whereby the on-off operation of the first and second switches are performed by the buckling of the first and second click projecting portions. In the above seesaw switch, an action bar bridging the first and second click projecting portions is interposed between the operating lever and the first and second click projecting portions.
The function of the present invention will be described below.
When the operating lever is tilted in one direction, the action bar is rotated around the second click projecting portion side in the same direction as in the operating lever. Consequently, the first click projecting portion is pressed on the action bar, so that the first switch is turned on along with a first click feeling. When the operating lever is further tilted in the same direction, the action bar cannot press the first click pressing portion beyond that; accordingly, the action bar is rotated around the first click projecting portion in the direction reversed to that of the operating lever. Accordingly, the second click projecting portion is pressed by the action bar, so that the second switch is turned on along with a second click feeling.
When the operating lever is tilted in other direction, the operation quite reversed to the above is performed: namely, first, the second switch is turned on along with a first click feeling, and further, the first switch is turned on along with a second click feeling by further tilting the operating lever.
Accordingly, for example, only the first and second switches can realize four kinds of processings: a manual UP taken as the case that only the first switch is turned; a manual DOWN taken as the case that only the second switch is turned on; an automatic UP taken as the case that the second switch is turned on after the first switch is turned on; and an automatic DOWN taken as the case that the first switch is turned on after the second switch is turned on.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional view showing a neutral state of a seesaw switch according to an embodiment of the present invention;
FIGS. 2(a) and 2(b) are section side views for explaining the action of the seesaw switch in FIG. 1 on one directional side;
FIGS. 3(a) and 3(b) are section side views for explaining the action of the seesaw switch in FIG. 1 on the other directional side;
FIG. 4 is a circuit block diagram of a power window device mounted on a vehicle to which the seesaw switch in FIG. 1 is applied;
FIG. 5 is a flow chart showing an operational procedure of FIG. 4; and
FIG. 6 is a sectional view of a seesaw switch with double action according to a prior art.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Hereinafter, embodiments of the present invention will be described with reference to the accompanying drawings.
FIG. 1 is a sectional view of a seesaw switch according to one embodiment of the present invention; FIG. 2 is a view for explaining the action of the seesaw switch of FIG. 1 which is tilted in one direction; FIG. 3 is a view for explaining the action of the seesaw switch of FIG. 1 which is tilted in the other direction; FIG. 4 is a circuit block diagram of a power window device; and FIG. 5 is a flow chart showing the action procedure of a CPU of FIG. 4.
In FIGS. 1 to 3, reference numeral 10 indicates an operating lever, which is supported in such a manner as to be rockable around a supporting shaft 11 in the directions of the arrows A and B. A first pressing projection 12 and a second pressing projection 13 are hangingly provided on the back surface of the operating lever 10. These pressing projections 12 and 13 are symmetric with respect to the supporting shaft 11. Reference numeral 14 indicates a click rubber, which is mounted on a printed circuit board 15. A first projecting portion 16 and a second projecting portion 17 are provided on the click rubber 14. Movable contact points 18a and 18b are respectively formed on the lower surfaces of the projecting portions 16 and 17. On the other hand, a pair of fixed contact points 19a and 19b are formed on the surface of the printed circuit board 15. The movable contact point 18a and the fixed contact point 19a form a first switch S 1 , and the movable contact point 18b and the fixed contact point 19b form a second switch S 2 . Reference numeral 20 indicates an action bar, which is formed of a high rigidity material such as synthetic resin or metal. The action bar 20 is mounted to be bridged across the projecting portions 16 and 17. The pressing projections 12 and 13 are abutted on the upper surface of the action bar 20.
In the seesaw switch thus constructed, the operating lever 10 is usually applied with an elastic force from both the projecting portions 16 and 17 of the click rubber 14 to be held in such a neutral position as shown in FIG. 1. In this case, both the first switch S 1 and second switch S 2 are in the off-state.
When the operating lever 10 is tilted in the direction of the arrow A from the neutral state shown in FIG. 1, the rotational force is transmitted from the first pressing projection 12 to the action bar 20. As a result, as shown in FIG. 2(a), the action bar 20 is rotated around the second projecting portion 17 in the direction of the arrow C, to press the first projecting portion 16. Thus, the first projecting portion 16 is buckled to generate a first click feeling, and also the movable contact point 18a is contacted with the fixed contact point 19a to make the first switch S 1 in the on-state. When the operating lever 10 is further tilted in the direction of the arrow A, the action bar 20 cannot press the first pressing portion 16 beyond that: accordingly, as shown in FIG. 2(b), the action bar 20 is rotated around the first projecting portion 16 in the direction of the arrow D, to press the second projecting portion 17. Thus, the second projecting portion 17 is buckled to generate a second click feeling, and also the movable contact point 18b is contacted with the fixed contact point 19b to also make the second switch S 2 in the on-state. Namely, when the operating lever 10 is tilted in the direction of the arrow A, the first switch S 1 is made in the on-state along with the first click feeling, after which the second switch S 2 is made in the on-state along with the second feeling.
On the contrary, when the operating lever 10 is tilted in the direction of the arrow B from the neutral state shown in FIG. 1, first, as shown in FIG. 3(a), the action bar 20 is rotated around the first projecting portion 16 in the direction of the arrow D, to press the second projecting portion 17 Thus, the second projecting portion 17 is buckled to generate a first click feeling, and also the movable contact point 18b is contacted with the fixed contact point 19b to make the second switch S 2 in the on-state. When the operating lever 10 is further tilted in the direction of the arrow B, the action bar 20 cannot press the second projecting portion 17 beyond that; accordingly, as shown in FIG. 3(b), the action bar 20 is rotated around the projecting portion 17 in the direction of the arrow C, to press the first projecting portion 16. Thus, the first projecting portion 16 is buckled to generate a second click feeling, and also the movable contact point 18a is contacted with the fixed contact point 19a to also make the first switch S 1 in the on-state. Namely, when the operating lever 10 is tilted in the direction of the arrow B, the second switch S 2 is made in the on-state along with the first click feeling, after which the first switch S 1 is made in the on-state along with the second click feeling.
The action of the seesaw switch according to the above embodiment which is applied to an input switch of a power window mounted on a vehicle will be described below. In this case, as shown in FIG. 4, signals outputted from the first and second switches S 1 and S 2 are read by a CPU 21. On the basis of the signals, the CPU 21 performs the following operations, to transmit four kinds of control signals to a motor 22. The motor 22 rotates in either normal or reverse direction on the basis of the control signals. For example, in the case of the normal rotation, there are performed a manual UP action by which a window is ascended during the switch is in the on-state, and an automatic UP action by which the window is automatically ascended when the switch is once turned on. On the other hand, in the case of the reverse rotation, there are performed a manual DOWN action by which the window is descended during the switch is in the on-state, and an automatic DOWN action by which the window is automatically descended when the switch is once turned on.
Namely, as shown in FIG. 5, the above CPU 21 performs the first reading of switch in a step S-1, to determine the on-off state of the first and second switches. Here, if the first switch S 1 is in the on-state and the second switch S 2 is in the off-state, that is, in such a state as shown in FIG. 2(a), the process goes on from a step S-2 to a step S-3, wherein the above manual UP processing is performed. Subsequently, the second reading of switch is performed in a step S-4. Thus, if the switch S 1 is in the on-state and the second switch S 2 is in the off-state as before in a step S-5, the process is returned to the step S-3, wherein the manual UP processing is performed again. If NO in the step S-5, the process goes on to a step S-6. Thus, if both the first and second switches S 1 and S 2 are in the on-state in the step S-6, that is, in such a state as shown in FIG. 2(b), the process goes on to a step S-7, wherein the above automatic UP processing is performed. In addition, if the first and second switches S 1 and S 2 are in the off-state, that is, in the case that both the switches S 1 and S 2 are returned from the state of FIG. 2(a) to the neutral position of FIG. 1, the process is returned to the step S-1.
On the other hand, if the first switch S 1 is not in the on-state in the step S-2, the process goes on to a step S-8, wherein it is determined whether or not the first switch S 1 is in the on-state and the second switch S 2 is in the on-state. If NO in the step 8, that is, in the case that both the switches S 1 and S 2 are in the off-state and is thus in the state of FIG. 1, the process is returned to the step S-1. If YES in the step S-8, that is, in the state of FIG. 3(a), the process goes on to a step S-9, wherein the above manual DOWN processing is performed. Subsequently, the second reading of switch is performed in a step S-10. Thus, if the first switch S 1 is in the off-state and the second switch S 2 is in the on-state as before in a step S-11, the process is returned to the step S-9, wherein the manual DOWN processing is performed again. If NO in the step S-11, the process goes on to a step S-12. Thus, if both the first and second switches S 1 and S 2 are in the on-state in the step 12, that is, in the state of FIG. 3(b), the above automatic DOWN processing is performed. In addition, if both the first and second switches S 1 and S 2 are in the off-state in the step S-12, that is, in the case that both the switches S 1 and S 2 are returned from the state of FIG. 3(a) to the neutral position of FIG. 1, the process is returned to the step S-1.
Thus, in the above embodiment, by tilting the operating lever 10 in one direction, it is possible to operate both the first and second switches S 1 and S 2 along with the click feelings. Further, since the order of turning on the first and second switches S 1 and S 2 is changed depending on the tilting direction of the operating lever 10, it is possible to output four kinds of signals by the combination of one operating lever 10 and two switches S 1 and S 2 . Accordingly, as compared with the prior art using four switches according to four kinds of signals, it is possible to reduce the number of the switches in half. As a result, it is possible to reduce the whole size of the seesaw switch, and to simplify the circuit additionally provided on each switch resulting in the lowered cost.
In addition, in the above embodiment, the movable contact points 18a, 18b and the fixed contact points 19a, 19b forming the first and second switches S 1 and S 2 are provided on the click rubber 14 and the printed circuit board 15, respectively.
However, in place of each contact, there may be used a switch called as a membrane switch provided on a film, which is so constructed as to be pressed and driven by the projecting portions 16 and 17.
Further, in the above embodiment, the click rubber 14 composed of a rubber material is used as a click member. However, there may be used a click member composed of an elastic metal plate formed in a circular arm shape.
As described above, according to the present invention, by tilting the operating lever in one direction, the first and second switches are turned on along with the click feeling. Further, the order of turning on both the switches is changed depending on the tilting direction of the operating lever. Therefore, it is possible to provide a seesaw switch with double action suitable for miniaturization with a low cost.
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A seesaw switch including a rigid member bridging first and second elastic click members, each elastic click member carrying a moveable contact positioned over a fixed contact. A lever is pivotably positioned over the rigid member and includes a first projection contacting the rigid member near the first elastic click member, and a second projection contacting the rigid member near the second elastic click member. When the lever is pivoted a first angular amount in a clockwise direction, the first projection presses against the rigid member, causing the rigid member to rotate with respect to the second elastic member to buckle the first elastic click member. Further pivoting of the lever in the clockwise direction causes the rigid member to rotate with respect to the buckled first elastic click member, thereby buckling the second elastic click member. Similarly, when the lever is pivoted a first amount in the counterclockwise direction, the second elastic click member is buckled, and further pivoting of the lever subsequently causes the first elastic click member to buckle.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Application No. 61/445,679 filed 23 Feb. 2011, the entire contents and substance of which are hereby incorporated by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to the field of conductive polymers.
2. Description of Related Art
Printed electro-active composites are emerging as a useful class of materials to fabricate ultra-low cost disposable consumer electronic devices. The tunable properties and processability of electro-active composite materials make them suitable for use in photovoltaics, transistors, displays, batteries, radio frequency devices, and sensors. Furthermore, the ability of electro-active composite materials to be printed and processed at low temperatures enables printing of components directly on unmodified paper or textiles with minimal impact on function or form factor. Using these printable materials, functional electronic components, including thermochromic displays, cellulose based batteries, antennas and disposable radio frequency identification (RFID) tags have been produced on low cost textiles and paper.
All electronic devices require electrodes to provide power, signal and ground to active and passive components. Printed conductive materials are fundamental to the development of printed electronic devices. Current materials for printed conductors can be stratified into two categories: low temperature sinterable nano-inks and epoxy-based electrically conductive composites (ECC). However, both of these methods to print conductors have their limitations. Sinterable nano-inks have low resistivity (˜2×10 −6 to ˜5×10 −5 Ωcm), but have insufficient abrasion resistance, adhesion and are typically too expensive for low cost applications. On the other hand, ECCs are relatively lower in cost and have excellent adhesion and abrasion resistance, but have relatively high resistivity (10 −4 -10 −3 Ωcm) at filler loading of 80 wt %. The relatively high resistivity of ECC results from minimal contacts between conductive fillers. This high resistivity of conventional epoxy-based composites makes them inefficient for uses in conventional low powered, high performance or high frequency devices.
Furthermore, the preparation of flexible highly conductive interconnect materials at low temperatures (preferably 150° C. or below) is important for the future of low-cost flexible electronics. The popularity of flexible circuits and building electronic devices on flexible substrates requires the interconnect materials to be mechanically compliant and highly conductive. Low processing temperatures of the interconnect materials are also required to enable the wide use of low cost, flexible substrates such as paper and polyethylene terephthalate (PET). Flexible conductive polydimethylsiloxane (PDMS) composites have been developed for various microelectronic applications, owing to the unique physical and chemical properties of PDMS. These properties include relatively superior elasticity and flexibility, optical transparency, biocompatibility and stable physical and chemical properties over a wide range of temperatures from −50° C. to +200° C.
The resistivity of PDMS filled with 80 wt % bimodal distribution of micron-sized silver flakes is about 7×10 −4 Ωcm. A lower point of resistivity of 2×10 −4 Ωcm for PDMS filled can be realized with 80 wt % silver particles, but the resistivity levels off even after increased filler loading. This high resistivity of PDMS-based conductive composites translates into large losses and low efficiency, especially at high frequency. Another limitation of flexible conductive PDMS composites lies in the poor adhesion on metal surfaces due to the low surface energy of PDMS. This further limits their wide application as a flexible interconnect material.
The resistivity of a conductive polymer composite is determined by the composite composition (such as filler loading), the surface properties of conductive fillers (such as the presence of a thin layer of lubricant or oxide film on the surface of silver flakes), physiochemical properties of polymer matrix (such as cure shrinkage and the interaction between the polymer matrix and conductive fillers), interlayer thickness, temperature, processing conditions of conductive polymer composites, etc. The resistance of conductive polymer composites is the sum of filler resistances (R f ) and inter-particle contact resistances (R c ). The contact resistance is composed of constriction resistance and tunneling resistance. Constriction resistance occurs because the current must squeeze through the small area of contact. Tunnel resistance is due to an intermediate layer between conductive fillers.
In conductive polymer composites, conductive fillers can be separated by a thin layer of polymer, oxide or lubricant for most commercial silver flakes which have been extensively used for the preparation of highly conductive polymer composites. The thickness of the interface can vary from 10 to 100 Å, depending on the physiochemical properties of the polymer matrix, filler, filler concentration, and the conditions of composite preparation. Relatively low conductivity of conductive polymer composites such as conductive PDMS composites results from physical contact, instead of metallurgical joints, between conductive fillers.
Reducing or even eliminating the contact resistance between conductive fillers is an important aspect for the preparation of highly conductive polymer composites. Therefore, new interconnect materials with low electrical resistivity, good adhesion, flexibility and low processing temperatures are desired for electronic applications.
BRIEF SUMMARY OF THE INVENTION
Briefly described, in exemplary form, the present invention comprises a method for improving the electrical conductivity of polymer composites. The polymer composites typically comprise of a thermoset polymer (such as an epoxy resin), curing agent (such as anhydride), catalyst, commercially available micro-sized silver flakes and other additives. A thin layer of lubricant, i.e. silver salt of fatty acid or silver carboxylate, is typically present on the surface of commercial silver flakes. The lubricant prevents the aggregation of silver flakes during production and improves the dispersion of silver flakes in an epoxy resin. However, the presence of this thin layer of lubricants prevents the metal-metal contact among silver flakes, decreasing the electrical conductivity.
An exemplary method of the present invention comprises in situ reduction of the lubricant (silver carboxylate) on the surface of silver flakes by adding a reducing agent. The reducing agent can be an additive or a flexible epoxy with reduction capability. The reducing agent helps to cause surface reactive nano/submicron-sized particles to form during the curing phase of an epoxy. At room temperature, the mixing of the reducing agent with silver flakes in the formulation does not reduce the silver carboxylate. Thus, the silver flakes in the epoxy resin can be dispersed as intended and desired at room temperature. As the temperature increases during curing, silver carboxylate present on the silver flakes are reduced to form silver nano/submicron-sized particles.
The reduction of the silver salts of fatty acids causes the simultaneous debonding of the surfactant and growth of colloidal silver nanoparticles. The nanoparticles formed on the surface of the silver flakes can be uniformly dispersed and surfactant free. The nanoparticles are surfactant free with a higher surface energy than pre-fabricated nanoparticles, which are stabilized by surfactants. The high surface energy of these in-situ formed particles makes them thermodynamically unstable. As a result, the nanoparticles spontaneously sinter with neighboring silver flakes. The sintering leads to the formation of metallurgical joints, which reduces, or even eliminates, the contact resistance. The method can further involve the removal of the silver flake surface lubricant and reduction of silver oxide, which enables direct metal-metal contacts between the silver flakes, decreasing the contact resistance further. The reduction in contact resistance translates to a significant increase in electrical conductivity of polymer composites such as ECC.
Various embodiments of the present invention can achieve sintering of conductive fillers without the incorporation of pre-fabricated nanoparticles to achieve relatively high conductivity, facile processing, and large throughput. Various embodiments of the present invention disclose a simple, cost-effective and highly processable approach to create highly conductive sintered ECC without the inclusion of pre-fabricated nanoparticles by sintering micron-sized Ag flakes at low temperatures (150° C. or below).
One embodiment of the present invention is a method for in situ preparation of a conductive adhesive comprising an epoxy resin, curing agent, catalyst (typically 1 wt %), 80 wt % silver flakes and a few percentage of ethylene glycol (EG). Without EG, the electrical resistivity of the composite was 1.3(±0.5)×10 −3 Ωcm. As the weight percentage of EG increases, the resistivity decreases. The ECC with 5 wt % EG has a resistivity of 5.3(±1.9)×10 −5 Ωcm, 3.86% of the resistivity of ECC without EG. The measured resistivity is about one order of magnitude lower than commercial conductive polymer composites filled with similar filler loadings of 80 wt % Ag flakes. In some further embodiments, the reducing agent is selected from the group consisting of glycerol and polyethylene glycol with different molecular weights (Mw=400-1000).
Another embodiment of the present invention is a method for in situ preparation flexible conductive adhesive having a plurality of silver flakes and surface reactive silver nano/submicron-sized particles on at least a portion of a surface and/or an edge of a least a portion of the plurality of silver flakes, wherein at least a portion of the surface reactive silver nano/submicron-sized particles are sintered with a portion of the silver flakes to form metallurgical joints between at least a portion of the silver flakes. In some embodiments, a portion of surface lubricant is removed from at least a portion of the surface of the plurality of silver flakes. In the embodiment, a flexible epoxy with reduction capability is selected from the group consisting of diglycidyl ether of polypropylene glycol and diglycidyl ether of polyethylene glycol.
A still further embodiment of the present invention comprises a method making a conductive adhesive comprising a polymer matrix and a plurality of silver flakes. The method comprises adding a reducing agent to grow surface reactive silver nano/submicron-sized particles on at least a portion of a surface of and/or an edge of a least a portion of the plurality of silver flakes to facilitate in-situ sintering between a portion of the plurality of silver flakes, and forming metallurgical joints between at least a portion of the silver flakes. The method can further comprise removing at least a portion of surface lubricant from at least a portion of the surface of the plurality of silver flakes.
In some embodiments, the reducing agent is an additive or flexible epoxy with reduction capability. The additive can be selected from the group consisting of ethylene glycol, glycerol and polyethylene glycol. In some embodiments, the weight % of the additive is in the range of 0.5-10 wt %.
In some embodiments, the flexible epoxy is selected from the group consisting of diglycidyl ether of polypropylene glycol and diglycidyl ether of polyethylene glycol. In some embodiments, the weight % of the flexible epoxy is in the range of 5-20 wt %.
In still further embodiments, the method further comprises curing the polymer matrix at a temperature range of approximately 150° C. to approximately 200° C. The curing time can be from approximately 30 minutes to approximately 1 hour.
In some embodiments, the weight % of the plurality of silver flakes in the polymer composite is in the range of 60-90 weight %, more preferable in the range of 70-85 wt % and most preferably at 80 wt %.
An additional embodiment of the present invention is a conductive adhesive polymer composite. The conductive adhesive polymer composite comprises a plurality of silver flakes, surface reactive silver nano/submicron-sized particles created by the addition of a reducing agent, wherein the surface reactive silver nano/submicron-sized particles are on at least a portion of a surface and/or an edge of a least a portion of the plurality of silver flakes, and wherein at least a portion of the surface reactive silver nano/submicron-sized particles are sintered with a portion of the silver flakes to form metallurgical joints between at least a portion of the silver flakes.
In some embodiments, a portion of surface lubricant is removed from at least a portion of the surface of the plurality of silver flakes.
In further embodiments, the reducing agent is an additive or flexible epoxy. The additive can be is selected from the group consisting of ethylene glycol, glycerol and polyethylene glycol.
In some embodiments, the weight % of the additive is in the range of 0.5-10 wt %. In further embodiments, the flexible epoxy is selected from the group consisting of diglycidyl ether of polypropylene glycol, and diglycidyl ether of polyethylene glycol. In some embodiments, the weight % of the flexible epoxy is in the range of 5-20 wt %.
In still further embodiments, the conductive adhesive polymer composite can comprise a plurality of silver flakes, wherein the weight % of the plurality of silver flakes in the conductive adhesive polymer composite is in the range of 60-90 weight %, more preferable in the range of 70-85 wt % and most preferably at 80 wt %.
In some further embodiments, the conductive adhesive is stencil printable or the conductive adhesive is a flexible composite.
These and other objects, features and advantages of the present invention will become more apparent upon reading the following specification in conjunction with the accompanying drawing figures.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate multiple embodiments of the presently disclosed subject matter and, together with the description, serve to explain the principles of the presently disclosed subject matter; and furthermore, are not intended in any manner to limit the scope of the presently disclosed subject matter.
FIG. 1 illustrates the molecular structures of diglycidyl ether of polypropylene glycol (DGEBF) and diglycidyl ether of bisphenol F (DGEBF).
FIG. 2 is a mass spectrum of DGEPG analyzed by fast atom-bombardment-mass spectrometry using thioglycerol as a matrix.
FIG. 3 are Raman spectra of the lubricant on the surface of (a) Ag-FA and (b) Ag-FB. Inset is the spectra in the range of 2800-3200 cm −1 .
FIG. 4 thermogravimetric analyzer graph of (a) Ag-FA and (b) Ag-FB. The inset is the first derivative of curve a and b in the temperature range of 100-300° C.
FIG. 5 is a differential scanning calorimetry graph of (a) Ag-FA and (b) Ag-FB.
FIG. 6 are scanning electron microscope images of Ag-FA treated with DGEBF for (a) 10 min, (b) 30 min and with DGEPG for (c) 10 min, (d) 30 min at 150° C.
FIG. 7 are scanning electron microscope images of Ag-FB treated with DGEBF for (a) 10 min, (b) 30 min and with DGEPG for (c) 10 min, (d) 30 min at 150° C.
FIG. 8 is a differential scanning calorimetry graph of Ag-FB treated with DGEBF (a) 10 min, (b) 30 min and with DGEPG (c) 10 min, (d) 30 min at 150° C.
FIG. 9 is a Raman spectra of (a) the lubricant on the surface of Ag flakes (Ag-FB), (b) DGEBF, Ag flakes treated with (c) DGEBF and (d) DGEPG at 150° C.
FIG. 10 illustrates the electrical resistivity of polymer composites filled with 80 wt % silver flakes by using different polymer matrices including DGEBF (100%), a 50:50 mixture of DGEBF and DGEPG, a 30:70 mixture of DGEBF and DGEPG, and DGEPG (100%).
FIG. 11 are scanning electron microscope images of cross-sections of polymer composites filled with 80 wt % Ag flakes by using different polymer matrices (a) DGEBF (100%); (b) 50:50 mixture of DGEBF and DGEPG, (c) 30:70 mixture of DGEBF and DGEPG, (d) DGEPG (100%).
FIG. 12 illustrates the effect of ethylene glycol on the electrical resistivity of conductive polymer composites filled with 80 wt % silver flakes.
FIG. 13 are differential scanning calorimetry curves of (a) silver flakes and (b) silver flakes with ethylene glycol.
FIG. 13 a is a mass spectrum of the supernatant from the reaction mixture of EG and silver flakes.
FIG. 14 are scanning electron microscope images of silver flakes (A) untreated, (B) treated with EG at 150′C for 10 min, and (C) treated with EG at 150′C for 30 min.
FIG. 15 are scanning electron microscope images of the cross-sections of the ECC with EG (A) 0 wt %, (B) 0.5 wt %, (C) 2 wt %, and (D) 5 wt %.
FIG. 16 illustrates the S-parameters of 50Ω Cu line and ECC microstrip lines. Inset shows the signal and ground planes of the microstrip lines used for high frequency measurements.
FIG. 17 are antenna measurements showing (A) picture of the fabricated antenna in the chamber setup (B) measured efficiency (C) measured vs. simulated 2D radiation pattern (D) measured 3D radiation pattern.
FIG. 18A is a picture of an array of stencil-printed antenna.
FIG. 18B illustrates an S11 measurement result showing the effect of placing the band-aid antenna on the human body.
DETAILED DESCRIPTION OF THE INVENTION
To facilitate an understanding of the principles and features of the various embodiments of the invention, various illustrative embodiments are explained below. Although exemplary embodiments of the invention are explained in detail, it is to be understood that other embodiments are contemplated. Accordingly, it is not intended that the invention is limited in its scope to the details of construction and arrangement of components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced or carried out in various ways. Also, in describing the exemplary embodiments, specific terminology will be resorted to for the sake of clarity.
It must also be noted that, as used in the specification and the appended claims, the singular forms “a,” “an” and “the” include plural references unless the context clearly dictates otherwise. For example, reference to a component is intended also to include composition of a plurality of components. References to a composition containing “a” constituent is intended to include other constituents in addition to the one named.
Also, in describing the exemplary embodiments, terminology will be resorted to for the sake of clarity. It is intended that each term contemplates its broadest meaning as understood by those skilled in the art and includes all technical equivalents which operate in a similar manner to accomplish a similar purpose.
Ranges may be expressed herein as from “about” or “approximately” one particular value and/or to “about” or “approximately” another particular value. When such a range is expressed, other exemplary embodiments include from the one particular value and/or to the other particular value.
By “comprising” or “containing” or “including” is meant that at least the named compound, element, particle, or method step is present in the composition or article or method, but does not exclude the presence of other compounds, materials, particles, method steps, even if the other such compounds, material, particles, method steps have the same function as what is named.
It is also to be understood that the mention of one or more method steps does not preclude the presence of additional method steps or intervening method steps between those steps expressly identified. Similarly, it is also to be understood that the mention of one or more components in a composition does not preclude the presence of additional components than those expressly identified.
The materials described as making up the various elements of the invention are intended to be illustrative and not restrictive. Many suitable materials that would perform the same or a similar function as the materials described herein are intended to be embraced within the scope of the invention. Such other materials not described herein can include, but are not limited to, for example, materials that are developed after the time of the development of the invention.
Disclosed are methods that enable the formation of metallurgical joints between silver flakes within a polymer matrix by incorporating a reducing agent as an additive or a flexible epoxy with reduction capability that leads to relatively flexible, relatively highly conductive polymer composites. In some embodiments, the present invention involves in situ reduction of silver carboxylate present on the surface of silver flakes by a reducing agent such as diglycidyl ether of polypropylene glycol (DGEPG) to form nano/submicron-sized silver particles, preferably both on the surface of and at the edge of silver flakes. The present invention is not limited to DGEPG, as other suitable reducing agents can be used, including, but not limited to, ethylene glycol, glycerol, polyethylene glycol with M w =400-1000, and diglycidyl ether of polyethylene glycol.
The in situ formed nano/submicron-sized silver particles, due to high surface area-to-volume ratios and lack of strong capping agents, are highly surface reactive. This results in low temperature sintering between silver flakes during curing. Sintering enables the formation of metallurgical joints and reduces or even eliminates the contact resistance among the conductive fillers, increasing the conductivity of the conductive polymer composites. In some embodiments, the reducing agent added also removes lubricant and silver oxide present on the surface of the silver flakes, reducing the resistivity even further.
Laboratory Experiments and Results (I)
Epoxy resins that can be used include, but are not limited to, diglycidyl ether of polypropylene glycol (DGEPG, D.E.R. 732, Dow Chemical) or diglycidyl ether of bisphenol F (DGEBF, EPON 862, Shell Chemical Co.), illustrated in FIG. 1 . DGEPG has a much lower viscosity (60-70 mPas) than DGEBF (2500-4500 mPas). Molecular structures of the epoxy resins were verified by Mass Spectrometry, as shown in FIG. 2 . The mass spectrum of DGEBF was analyzed by fast atom bombardment-mass spectrometry (FAB-MS) using thioglycerol as a matrix. The mass spectrum of DGEPG was collected with the Voyager 4700 MALDI-TOF-TOF system (ABI) operated in reflector mode. Alpha-Cyano-4-hydroxycinnamic acid (CHCA) was used as a matrix for MALDI. The curing agent was hexahydro-4-methylphthalic anhydride (HMPA) or 1-cyanoethyl-2-ethyl-4-methylimidazole (2E4MZ-CN, Shikoku Chemicals Corp.) Two silver flakes with different sizes and surface lubricants (Ag-FA and Ag-FB, Ferro Corp.) were used to improve the packing density and adjust the viscosity of the formulated paste.
An epoxy resin (DGEBF or DGEPG) was mixed with silver flakes and then heated at 150° C. for 10 or 30 min. The silver flakes appeared to have lost their luster and the surface appeared dull after being treated with DGEPG, while no significant change of surface appearance was observed for silver flakes treated with DGEBF. Acetone was added to the mixture and the resulting mixture was centrifuged. After removal of the supernatant, the silver flakes were re-dispersed in acetone. Five cycles of dispersing and centrifugation were used in an effort to remove the residual epoxy resin. The lubricant on the surface of silver flakes was hardly washed off by acetone during the process. Finally, the silver flakes were dried in vacuum before the characterization.
Different ratios of DGEBF and DGEPG were mixed with 80 wt % silver flakes (Ag-FA and Ag-FB with a mass ratio of 1:1), HMPA and the catalyst. Two strips of a Kapton tape (Dupont) were applied onto a pre-cleaned glass slide. The formulated pastes were printed on the glass slide. Then, the pastes were thermally cured at 150° C. in air for 1 hour. To show flexibility of conductive polymer composites, the formulated pastes were printed on the surface of polyethylene terephthalate. After curing, the samples were bended conformally to the surface of cylinders with different radii to measure the resistivity change under bending condition.
After curing, bulk resistances (R) of polymer composite strips were measured by a Keithley 2000 multimeter. The widths and lengths of the specimens were measured by digital caliber (VWR). The thickness of the specimen was measured by Heidenhain (thickness measuring equipment, ND 281B, Germany). Bulk resistivity, ρ, was calculated using ρ=Rtw/l, where l, w, t are the length, width and thickness of the sample, respectively.
Weight loss of silver flakes during heating in air was studied using thermogravimetric analyzer (TGA, TA Instruments, model 2050). The heating rate was 20° C./min. Morphologies of the treated silver flakes and the polymer composites were studied by field emission scanning electron microscopy (SEM, LEO 1530). Decomposition of the lubricants on the surface of silver flakes was studied by differential scanning calorimetry (DSC, TA Instruments, Q100). The heating rate was 10° C./min. Raman spectra were obtained by using a LabRAM ARAMIS Raman confocal microscope (HORIBA Jobin Yvon) equipped with a 532 nm diode pumped solid state (DPSS) laser. Si wafer was used as a substrate for Raman measurements.
As previously mentioned, a thin layer of lubricant is typically present on the surface of commercial silver flakes to prevent the aggregation of silver flakes during production. This layer of lubricant affects the interaction of silver flakes with other silver flakes and with the polymer system, and thus, affects the dispersion of silver flakes, the rheology of formulated pastes, and the electrical conductivity of the resulting polymer composites. FIG. 3 shows Raman spectra of the lubricant on the surface of silver flakes. The presence of carboxylate groups on the surface of silver flakes was verified by the symmetric (ν s (COO − )) stretching at 1432 cm −1 (or 1438 cm −1 ) and asymmetric (ν as (COO − )) stretching at 1591 cm −1 (or 1587 cm −1 ). This result is consistent with previous studies that the lubricant layer is indeed silver carboxylate. The distinct differences between the two spectra were i) the intensity of the peaks at 930 and 664 cm −1 in FIG. 3 , data set (a), assigned to the C—COO − stretching and the deformation of —COO − , was much stronger than that of the corresponding peaks in FIG. 3 , data set (b).
The SERS peaks of C—H stretching of the lubricant on Ag-FA were well resolved, compared with those of the lubricant on Ag-FB, as shown in FIG. 3 , inset. Methylene twisting, wagging and scissor appeared at 1297, 1362 and 1474 cm −1 , respectively in FIG. 3 , data set (b). The intensity of these peaks was much stronger than that of the corresponding peaks in FIG. 3 , data set (a). These distinct differences are related to the chain length of lubricants and their surface orientation and conformation.
FIG. 4 shows TGA results of the silver flakes. Ag-FA and Ag-FB showed significant weight losses at 188° C. and 218° C., respectively, as shown in FIG. 4 , inset. This indicates the presence of lubricants on the surface of silver flakes. Weight losses of Ag-FA and Ag-FB at 450° C. were 0.09% and 0.23%, respectively. Both Ag-FA and Ag-FB showed endothermic peaks at 232 and 247° C., respectively, as shown in FIG. 5 . It is understood that silver flakes lubricated with fatty acids of a longer chain show exothermic DSC peaks at higher temperatures. These exothermic DSC peaks in air of lubricated silver flakes are due to the oxidation of the lubricant layer. These results indicated that the lubricant on the surface of Ag-FB can have a longer chain than that on Ag-FA.
To investigate the reduction of silver carboxylate and the formation of silver particles on the surface of silver flakes, Ag-FA and Ag-FB were treated with DGEBF and DGEPG at the curing temperature (150° C.). FIGS. 6 and 7 show the surface morphology changes of silver flakes after isothermal treatment. When treated with DGEBF at 150° C. for 10 min, the surface of silver flakes remained relatively smooth, as shown in FIGS. 6 a and 7 a . Compared with silver flakes treated with DGEBF, silver flakes treated with DGEPG showed growth of silver nano/submicron-sized particles on their surfaces and at their edges, as shown in FIGS. 6 c and 7 c . As the time for treatment increased, silver flakes treated with DGEBF became rough, as shown in FIGS. 6 b and 7 b.
The relatively rough surface is the result of the reduction of silver carboxylate and the formation of highly surface reactive silver nano/submicron-sized particles. These particles then sintered with the silver flakes. The growth of silver nano/submicron-sized particles was more prominent when silver flakes were treated with DGEPG for 30 min, as shown in FIGS. 6 d and 7 d . Moreover, neckings between silver flakes were observed. The neckings between silver flakes are indicative of effective sintering between silver flakes. This can result from the relatively stronger reduction capability of the primary —OH group in DGEPG than secondary —OH group in DGEBF at 150° C.
FIG. 8 shows DSC of silver flakes (Ag-FB) treated with DGEBF or DGEPG. Ag-FB shows an exothermic peak and a mild broad peak at 276° C. after isothermal treatment with DGEBF for 10 and 30 min, respectively. The shift of the exothermic peak from 247° C., as shown in FIG. 5 , to 276° C. can result from the physical absorption of DGEBF onto the surface of silver flakes that delays the oxidation of the lubricant. The physical absorption was verified by the peak at 915 cm −1 , shown in FIG. 9 , data set (c), the characteristic vibration of epoxy rings, in the Raman spectrum of silver flakes treated with DGEBF.
After treatment with DGEPG, the exothermic DSC peak disappeared, shown in FIG. 8 . Raman peaks of the lubricant on the surface of silver flakes almost disappeared, shown in FIG. 9 , data sets (a) and (d). Both DSC and Raman results indicated that silver carboxylate on the surface of silver flakes was reduced and at least partially, if not fully, removed. This was consistent with the lack of luster on the surface of DGEPG treated silver flakes. It is known that organic molecules on the surface of silver particles play an important role in the sintering onsets, the extent of densification and final grain sizes. These organic molecules provide an energy barrier to sintering. The particles sinter if the thermal energy is sufficient to overcome the activation energy provided by the organic molecules. The nearly complete removal of the lubricant from the surface of silver flakes facilitated the sintering between silver flakes for DGEPG treated silver flakes and thus the electron transport.
Electrical conduction of a metal-filled epoxy-based polymer composite can be established through the cure shrinkage of the polymer matrix, which brings metal fillers into intimate contacts and forms 3-D conductive networks within the polymer matrix. FIG. 10 shows bulk resistivity of composites filled with 80 wt % silver flakes using different ratios of DGEBF and DGEPG as polymer matrices. DGEBF filled with 80 wt % silver flakes shows an averaged resistivity of 2.3×10 −4 Ωcm, which is comparable to that of commercially available electrically conductive adhesives. The averaged resistivity decreased to 1.4×10 −4 Ωcm and the lowest resistivity was 6.5×10 −5 Ωcm for the composites with equal amounts of DGEBF and DGEPG.
The polymer composites showed a lower electrical resistivity (3.5×10 −5 Ωcm) with an increased DGEPG content (70 wt % of the mixture of DGEBF and DGEPG). This could be due to the enhanced reduction of silver carboxylate and increased necking area between silver flakes. The resistivity of the DGEPG filled with 80 wt % silver flakes is 2.5×10 −5 Ωcm, about one order of magnitude lower than that of the composites composed of DGEBF and 80 wt % silver flakes. FIG. 11 shows the cross-sections of the conductive polymer composites. Without DGEPG, the surface of silver flakes within the polymer matrix was relatively smooth, shown in FIG. 11 a . There are lubricants (or possibly oxide) at the interface between silver flakes. The presence of the lubricants increases the tunneling resistance between silver flakes.
With the incorporation of DGEPG, silver nano/submicron-sized particles formed both on the surface and at the edges of the silver flakes, shown in FIG. 11 b . As the content of DGEPG increased, larger particles and neckings between silver flakes formed, FIGS. 11 c and 11 d . Therefore, two factors contribute to the significantly improved electrical conductivity of the polymer composites with the incorporation of DGEPG. First, the growth of highly surface reactive silver nano/submicron-sized particles facilitates the sintering between silver flakes. The sintering leads to the formation of metallurgical joints and reduces or even eliminates the contact resistance effectively. Second, the removal of surface lubricant, as verified from FIG. 9 , enables direct metal-metal contacts between silver flakes, decreasing the contact resistance.
Various embodiments of the present invention provide for highly conductive polymer composites that have been prepared by low temperature sintering (<200° C.) of silver flakes. Flexible, highly conductive polymer composites with electrical resistivity as low as 2.5×10 −5 Ωcm were prepared at 150° C. by incorporating flexible epoxy (DGEPG) into the composite formulation. DGEPG functioned as a mild reducing agent for the in situ reduction of silver carboxylate on the surface of silver flakes. The reduction of silver flakes by DGEPG removed the surface lubricant and allowed the metallurgical joints and direct metal-metal contacts between the conductive fillers. This reduced or even eliminated the contact resistance effectively, enabling the preparation of flexible highly conductive polymer composites at a low temperature.
The approach developed offers many significant advantages such as i) reduced materials cost, as in some examples, there is no need to incorporate pre-fabricated nanoparticles to improve electrical conductivity; ii) low processing temperature compatible with low cost, flexible substrates such as paper and PET; iii) simple processing; and iv) low viscosity of the formulated pastes with DGEPG, allowing them to be used for low cost jet-dispensing technologies; v) tunable mechanical properties; and vi) flexibility and high electrical conductivity. Future printed electronics require the epoxy-based polymer composites to be mechanically compliant to fit the non-planar forms, to have a high conductivity, to have strong adhesion on many substrates and to have low processing temperatures to be compatible with low cost, flexible substrates. The multi-functional polymer composites developed in this study are attractive for current and emerging applications in flexible electronics such as, for example, printed electro-active composites.
Laboratory Experiments and Results (II)
A reducing agent is used as an additive to enhance the conductivity of the ECC. The electrical resistivity of ECC prepared with EG concentrations in the polymer matrix up to 5 wt % is shown in FIG. 12 . The ECC with 5 wt % EG has a resistivity of 5.3(±1.9)×10 −5 Ωcm, 3.86% of the resistivity of ECC without EG. The measured resistivity is about one order of magnitude lower than commercial conductive polymer composites filled with similar filler loadings of 80 wt % Ag flakes. The reaction between silver salts of fatty acids and EG was verified by DSC, as shown in FIG. 13 . Without EG, the decomposition of silver salts of fatty acids occurs at 207.1° C., indicated by the exothermic peak in FIG. 13 . With EG, the exothermic peak downshifts to 137.8° C., indicating that EG facilitates the reduction of silver salts of fatty acids. It is well known that silver (silver flakes in this case) can catalyze EG oxidation to glycolaldehyde and glyoxal. FIG. 13 a is a mass spectrum of the supernatant collected from the reaction mixture of EG with silver flakes at 150° C. The mass spectrum shows the presence of acetaldehyde, diacetyl, glycolaldehyde, glyoxal, glycolic acid, glyoxilic acid and oxalic acid, providing evidence that EG reduces the silver salts of fatty acids on the surface of the silver flakes at 150° C. Table 1 below further explains the mass spectrum of FIG. 13 a .
TABLE 1
Assignment of m/z in the mass spectrum of the supernatant from the reaction
mixture of EG and silver flakes.
m/z
Formula
Chemical Name
90
HOOC—COOH
Oxalic acid
87
CH 3 CO—COCH 3
Diacetyl
77
HOOC—CH 2 OH
Glycolic acid
75
HOOC—CHO
Glyoxylic acid
60
OHC—CH2OH
Glycoaldehyde
58
OHC—CHO
Glyoxal
45
OHC—CH 3
Acetaldehyde
To observe the sintering process, low-temperature sintering of silver flakes using EG was achieved at 150° C. FIG. 14 shows the SEM images of untreated silver flakes and silver flakes treated with EG for 10 min and 30 min at 150° C. Compared to the untreated silver flakes, silver flakes treated with EG for 10 min show metallurgical bridges between silver flakes. These metallurgical bridges develop as colloidal silver formed during the reduction reaction sinters with adjacent Ag flakes. Increasing the flake treatment time to 30 min causes edge-by-edge sintering between silver flakes.
To demonstrate that sintering of silver flakes is achievable while within an epoxy matrix, SEM of cured ECC with EG concentrations of 0, 0.5, 2 and 5 wt % is shown in FIG. 15 . With addition of 0.5 wt % EG, no significant morphological change was observed compared to the ECC without EG. However, the morphology of the composite changes significantly when increasing the concentration of EG to 2 wt %. As seen in the SEM images of the ECC with 2 and 5 wt % EG in FIGS. 15C and 15D , it appears that the epoxy resin has adsorbed on the surface of the silver flakes. This change in morphology of the composite is observed because during curing, EG removes the surfactant from the surface of the silver flakes, leaving the silver flake surface bare. The bare silver flake surface has a very high surface energy, thus the epoxy resin in the composite readily adsorbs on the silver surface.
This edge-by-edge sintering results in much wider metallurgical bridges, dramatically reducing contact resistance. The reduction in contact resistance translates to significant increase in electrical conductivity of the ECC. In addition, EG can also reduce silver oxide, which can be present on the surface of silver flakes. The reduction of silver oxide possibly present on the surface of silver flakes to metallic silver can also contribute to the enhanced electrical conductivity of ECC prepared with EG.
Exemplary Uses
Increasing the conductivity of ECC can significantly reduce resistive losses, enabling the fabrication of low-cost, simple and efficient RF devices. Increasing the conductivity of ECC would enable the fabrication of low-cost RF devices, which could be used in a wide variety of sensory and communication applications.
To show the effect of the EG on the RF performance of ECC, microstrip transmission lines were fabricated and tested as described in the experimental methods. Transmission lines were fabricated on TMM10 high frequency ceramic polymer composite substrate (Rogers Corp.), with a relative dielectric constant of 9.2 and loss tangent of 0.0022 at 10 GHz. The microstrip lines were designed using a transmission line calculator to have a characteristic impedance of 50Ω, with both the signal and the ground plane made of the same material, as shown in FIG. 16 . For comparison, an identical reference Cu line was fabricated. The S-parameters of the microstrip lines from 100 MHz to 6 GHz were measured with an E8364B PNA Network Analyzer using a SOLT calibration.
The S-parameters of the microstrip lines are shown in FIG. 16 . ECC microstrip lines show good performance compared to Cu at up to 6 GHz. The ECC without EG has an insertion loss of 0.16 dB/cm more than the line without EG at 6 GHz.
To demonstrate the practicality of composites according to various embodiment of the present invention in wireless communications, a half wavelength dipole antenna was fabricated. Half wavelength dipole antennas are simple radiators consisting of two collinear conductors each measuring a quarter of the operating wavelength, with a small gap between them. The dipole antennas are fed in the center by applying radio frequency voltage between the two conductors. Dipoles are omnidirectional antennas, with maximum gain in the plane perpendicular to the antenna and zero gain in the direction of the wires. The main challenges in designing dipole antennas in the ISM frequency band (902 to 928 MHZ) for consumer applications like RFID tags and wireless sensor networks are miniaturization and large bandwidth.
To achieve miniaturization and large bandwidth, a folded bow-tie meander line dipole antenna was designed using the full wave HFSS simulator. The meander line enables the miniaturization of the antenna structure, while the bow tie shape at the end of the lines improves the antenna bandwidth. Antennas were designed and fabricated on Rogers TMM-3 substrate, with a dielectric constant of 3.27 and loss tangent of 0.002. These antennas were fabricated by stencil printing ECC onto the TMM-3 substrate using a using a flat plate stencil 200 μm thick (Mini Micro Stencil Inc.) and then cured at 150° C. for 60 minutes.
The fabricated antenna is shown in FIG. 17 . The 3D radiation pattern of the fabricated antenna was tested using a Stargate 64 antenna chamber. It was found that the antenna fabricated had a maximum gain of 1.81 dB with an efficiency of 74.63% at a frequency 930 MHz. Comparison of the measured radiation pattern showed excellent agreement to the simulation as shown in FIG. 17 . Moreover, the measured 3D radiation pattern of the antenna fabricated showed a standard donut shaped radiation pattern expected for dipole antennas.
Printable low-cost composite materials which can be processed at low-temperature enable a new way to integrate wireless communication systems on pre-existing products with minimal impact on the form factor or function. The composite material developed is low cost, simple to process, mechanically robust, flexible and easy to print via stencil, screen or roll-to-roll processes. Furthermore, the composite developed has adhesive properties enabling it to be used to directly connect to sensory devices or other integrated circuits. The simple fabrication, excellent mechanical properties and RF-performance is unmatched by any current materials or processes.
To the materials and processes of the present invention, a large quantity of antennas was fabricated. An array of antennas printed is shown in FIG. 18 a . The fabrication process is highly scalable, enabling it to be used in a plethora of low cost consumer devices. As an example, a similar but smaller antenna designed to resonate at 1.8 GHz on band-aids purchased from a local store was fabricated. After printing and curing the composite 150° C. for 1 hour, the band-aids were undamaged and the adhesive backing was still intact.
Antennas were successfully printed on a wide variety of band-aids including: plastic, sheer, fabric, etc. The antenna printed on the band-aid from 1 GHz to 2.5 GHz with an E8364B PNA Network Analyzer using a SOLT calibration was tested. The antenna showed a resonance at 1.9 GHz, close to the designed resonance frequency of 1.8 GHz. Because the conductive composite is flexible, the band-aid antenna was attached to the curvilinear surface of the human body. An antenna attached to a person's wrist was tested. Due to the higher dielectric constant of the human body compared to air, the resonance frequency of the antenna shifted significantly to 1.58 GHz, shown in FIG. 18 b . This shift in resonance frequency due to the higher dielectric constant of the human body compared to air can be simulated and accounted for when designing antennas.
Various embodiments of the present invention enable antennas to be fabricated on pre-existing products with minimal additional processing steps. Typically an antenna could be printed onto a textile or fabric surface in a three step process: 1. ECC preparation; 2. printing of antenna; 3. curing. The integration of small sensory devices and power generation/harvesting systems would enable the mass production of low-cost minimally invasive sensors capable of communicating with wireless body area networks.
In summary, various embodiments of the present invention provide for a relatively simple method to significantly decrease the electrical resistivity of ECC by in-situ nanoparticle formation and sintering using EG. Microstrip transmission lines were fabricated to test the RF performance of the ECC. Due to the lower resistivity, the lines built with ECC with EG have a much lower insertion loss than the lines built with ECC without EG. Using ECC of the present invention, it is possible to rapidly fabricate highly efficient dipole antennas on a wide variety of substrates including commercially available band-aids. This approach offers significant advantages such as reduced materials cost, simple processing and low processing temperature compatible with low cost polymer substrates such as paper and fabric. The developed highly conductive ECC is attractive for use in emerging printed electronics and low cost radio frequency devices.
While the invention has been disclosed in its exemplary forms, it will be apparent to those skilled in the art that many modifications, additions, and deletions can be made therein without departing from the spirit and scope of the invention and its equivalents, as set forth in the following claims.
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The present invention provides for a relatively simple method to decrease the electrical resistivity of conductive adhesives by in-situ nanoparticle formation and sintering using a reducing agent. The reducing agent was found to cause sintering within the conductive adhesive by facilitating the reduction of the silver salts of fatty acids on the surface of silver flakes, leading to the formation of nano-/submicron-silver necks. These silver necks bridge neighboring silver flakes, decreasing the contact resistance between flakes within the conductive adhesives. The reducing agent also removes at least a portion of the lubricant commonly found on silver flakes used in conductive adhesives, thus reducing the tunneling resistance between the silver flakes.
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This application claims the benefit of application 60/570,151, filed May 12, 2004.
FIELD OF THE INVENTION
This invention provides a method for removing certain sulfur-containing groups from polymers, especially those made via RAFT polymerization processes.
BACKGROUND
There is increasing interest in developing polymerization processes that can be predictably controlled to produce polymers having specifically desired structures. One of the means for achieving such results is through a process of living polymerization. Such a process provides a higher degree of control during the synthesis of polymers having predictably well-defined structures and properties as compared to polymers made by conventional polymerization processes.
Controlled radical polymerization processes such as RAFT (reversible addition fragmentation chain transfer) provide useful embodiments of living polymerization processes. RAFT processes using xanthate or dithiocarbamate chain transfer RAFT agents are disclosed in WO 99/31144. RAFT processes using dithioester or trithiocarbonate chain transfer agents are disclosed in WO 98/01478, WO 200500319, WO 2005000924 and WO 2005000923.
The polymers produced by RAFT processes have end groups derived from the chain transfer agents used in these processes. For RAFT-derived polymers using xanthate, dithiocarbamate, dithioester or trithiocarbonate chain transfer agents, each polymer chain will contain at least one end group comprising a xanthate, dithiocarbamate, dithioester or trithiocarbonate functional group. In some end-use applications of the RAFT-derived polymers, it may be desirable to remove these functional groups and replace them with hydrogen.
WO 02/090397 discloses a process for substituting a dithiocarbonylated or dithiophosphorylated function on the chain end of a living organic polymer with a hydrogen atom by contacting the polymer with a source of free radicals and an organic compound bearing a labile hydrogen atom.
WO2005000923, WO2005003192, U.S. patent application Ser. No. 10/407,405, now U.S. Pat. No. 7,012,119 and U.S. patent application Ser. No. 10/609,225 now U.S. Pat. No. 6,988,439 disclose several methods for removing the sulfur-containing portion of a RAFT chain transfer agent from the polymer terminal end.
There remains a need for a RAFT end-group removal process that can be carried out on the RAFT polymer without first changing solvents or isolating the polymer product. There is also a need for a RAFT end-group removal process that allows for easy isolation of the end-group free polymer.
SUMMARY OF THE INVENTION
This invention provides a process for replacing a functional group, —SC(S)X, with —H, comprising contacting a polymer containing a functional group, —SC(S)X with a salt of hypophosphorous acid and a radical initiator, wherein
X is R, OR 1 , N(R 2 ) 2 , SR 3 , or P(O)(OR 4 ) 2 ; R is substituted or unsubstituted C 1 -C 25 alkyl; substituted or unsubstituted C 2 -C 25 alkenyl; substituted or unsubstituted C 2 -C 25 alkynyl; substituted or unsubstituted phenyl; substituted or unsubstituted naphthyl; and substituted or unsubstituted benzyl; and R 1 , R 2 , R 3 , and R 4 are substituted or unsubstituted C 1 -C 25 alkyl; substituted or unsubstituted C 6 -C 10 aryl; a 3- to 8-membered carbocyclic or heterocyclic ring, or N(R 2 ) 2 is a 3- to 8-membered heterocyclic ring.
DETAILED DESCRIPTION
Definition of Terms
By “radical initiator” is meant a substance that can produce radical species under mild conditions and promote radical reactions. Typical examples include peroxides, azo compounds and halogens.
By “nitrogen base” is meant a basic compound that contains nitrogen.
As used herein, the terms “comprises,” “comprising,” “includes,” “including,” “has,” “having” or any other variation thereof, are intended to cover a non-exclusive inclusion. For example, a process, method, article, or apparatus that comprises a list of elements is not necessarily limited to only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. Further, unless expressly stated to the contrary, “or” refers to an inclusive or and not to an exclusive or. For example, a condition A or B is satisfied by any one of the following: A is true (or present) and B is false (or not present), A is false (or not present) and B is true (or present), and both A and B are true (or present).
Also, use of the “a” or “an” are employed to describe elements and components of the invention. This is done merely for convenience and to give a general sense of the invention. This description should be read to include one or at least one and the singular also includes the plural unless it is obvious that it is meant otherwise.
Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. Although methods and materials similar or equivalent to those described herein can be used in the practice or testing of the present invention, suitable methods and materials are described below. All publications, patent applications, patents, and other references mentioned herein are incorporated by reference in their entirety. In case of conflict, the present specification, including definitions, will control. In addition, the materials, methods, and examples are illustrative only and not intended to be limiting.
Many of the chain transfer agents used in RAFT polymerization processes leave at least one sulfur-containing end-group on the RAFT-derived polymer. Typically, the sulfur-containing end-group has the structure —SC(S)X, where X is an alkyl, aryl, alkoxy, amine or alkylthio group. In some end-use applications of the RAFT polymer, the sulfur-containing end-group can be left in place. In other end-use applications, it is desirable to remove the sulfur-derived end-group and replace it with a hydrogen atom. Similarly, it may be desirable to remove sulfur-containing groups that are in the polymer backbone, as might be produced from a RAFT process using a symmetrical trithiocarbonate.
This invention provides a simple process for replacing a functional group, —SC(S)X, with —H, comprising contacting a polymer containing a functional group, —SC(S)X, with a salt of hypophosphorous acid and a radical initiator,
wherein
X is R, OR 1 , N(R 2 ) 2 , SR 3 , or P(O)(OR 4 ) 2 ;
R is substituted or unsubstituted C 1 -C 25 alkyl; substituted or unsubstituted C 2 -C 25 alkenyl; substituted or unsubstituted C 2 -C 25 alkynyl; substituted or unsubstituted phenyl; substituted or unsubstituted naphthyl; and substituted or unsubstituted benzyl; and
R 1 , R 2 , R 3 , and R 4 are substituted or unsubstituted C 1 -C 25 alkyl; substituted or unsubstituted C 6 -C 10 aryl; a 3- to 8-membered carbocyclic or heterocyclic ring, or
N(R 2 ) 2 is a 3- to 8-membered heterocyclic ring.
Suitable substituents include alkyl, aryl, ether, Cl, Br, F and silyl substitutents.
Suitable salts of hypophosphorous acid include salts in which the cation is a protonated nitrogen base or tetra-alkyl ammonium.
The process of this invention cleanly removes the sulfur-containing group, and can be carried out without first isolating the RAFT polymer. In many instances, it can be carried out in the same solvent in which the RAFT polymerization process was conducted. The use of a nitrogen-base salt of hypophosphorous acid can also simplify the purification of the end group-free polymer since, in many cases, the polymer will be less soluble than the salt in polar solvents.
In the process of this invention, the polymer containing a functional group, —SC(S)X, can be the product of a RAFT polymerization process, as described, for example, in WO 98/01478, WO99/31144, WO01/77198, WO 200500319, WO 2005000924 or WO 2005000923.
The functional group, —SC(S)X, can also originate as a functional group on one or more of the (co)monomers used to prepare the polymer.
In one embodiment of this invention the salt of hypophosphorous acid is formed by reaction of hypophosphorous acid, H 3 PO 2 , with a nitrogen base. The nitrogen base is selected from the group of primary, secondary, or tertiary nitrogen bases, and ammonium salts. Suitable tertiary nitrogen bases include, but are not limited to, trialkylamines, Dabco (1,4-diazabicyclo[2.2.2]octane), DBU (1,8-diazabicyclo[5.4.0]undec-7-ene), N-alkylpiperidines, morpholine and its derivatives, and tertiary amines substituted with aromatic groups. The alkyl and aromatic groups can be substituted with heteroatoms such as oxygen. It is important that primary and secondary amines are fully quaternized since excess reagent may give by-products.
In another embodiment of this invention the salt of hypophosphorous acid is a tetraalkylammonium salt. Suitable ammonium salts include tetra-alkylammonium, R′ 4 N + , and alkyl-substituted guanidinium hypophosphite salts, where R′ is C 1 -C 18 alkyl. Examples of R′ 4 N + H 2 PO 2 − are disclosed by J. Cabral, et al., J. Am. Chem. Soc. 1986, 108, 4672.
Hypophosphorous acid, which is usually provided as a 50% aqueous solution, can be mixed with the nitrogen base in an organic solvent (e.g., toluene), and the water removed under reduced pressure to form a salt. The salts can then be used in an aqueous or a non-aqueous process for removing the —SC(S)X functional group(s) from the polymer. Alternatively, hypophosphorous acid and the nitrogen base can be added to the reaction mixture separately to form the salt in situ. Non-aqueous systems may be preferred if the reagents are only sparingly soluble in water. A general procedure for preparing salts of hypophosphorous acid and a tertiary nitrogen base is disclosed by D. H. R. Barton, et al., Tetrahedron Letters 1992, 33, 5709.
The process is not limited by pressure constraints and can be carried out at, below, and above atmospheric pressure. There is no particular advantage in operating pressure vessels except to contain low-boiling or supercritical media. The reacting components (substrate, hypophosphite salt and radical source) must exhibit at least partial solubility during the reaction stage. Dissolution kinetics must be consonant with the lifetime of the radical generator at the temperature employed. Thus, the reaction medium can be an organic liquid, water, or a supercritical fluid such as CO 2 . Product isolation and purification methods are determined by the requirements of product use. For some applications, it is preferable that end-group and reagent residues and co-products be nearly completely removed. Preferred hypophosphite salts of this invention allow for practical purification using conventional, two-phase partitioning techniques, including adsorption, e.g., on an ion-exchange column. Useful reaction temperatures are governed by radical initiator and carbon-sulfur bond cleavage kinetics: suitable temperatures are from about 25° C. to about 150° C., with a preferred range of 50-120° C.
EXAMPLES
The following examples illustrate certain features and advantages of the present invention. They are intended to be illustrative of the invention, but not limiting. All percentages are by weight, unless otherwise indicated.
Definition of Chemicals and Monomers used (Commercial Source)
PGMEA=propylene glycol methyl ether acetate (Sigma-Aldrich Chemical Co., Milwaukee, Wis.) MAMA=methyl adamantyl methacrylate (Idemitsu Japan, Tokyo, Japan)
α-GBLMA=alpha-methacryloxy-gamma-butyrolactone (ENF Chemical, Seoul, South Korea)
β-GBLMA=beta-methacryloxy-gamma-butyrolactone (ENF Chemical, Seoul, South Korea)
PinMAc=2-methyl-2-propenoic acid, 2-hydroxy-1,1,2-trimethylpropyl ester [CAS Reg number 97325-36-5]
HAdMA=3-hydroxy-1-adamantyl methacrylate (Idemitsu Japan, Tokyo, Japan)
NBLMA=(JSR Corporation, Tokyo, Japan)
2,3-NBFOHMAc=3-(2,2-bis(trifluoromethyl)-2-hydroxyethyl)-endo-2-(2-methylpropenoyl)-bicyclo[2.2.1]-heptane
THF=Tetrahydrofuran (Sigma-Aldrich Chemical Co., Milwaukee, Wis.)
Vazo®67=2,2′-azobis(2-methylbutanenitrile) (E. I. du Pont de Nemours and Company, Wilmington, Del.)
Vazo®88=1,1′-Azobis(cyclohexanecarbonitrile) [CAS Registry number 2094-98-6] (E. I. du Pont de Nemours and Company, Wilmington, Del.)
1-Ethylpiperidine hypophosphite ([CAS registry no. 145060-63-5], Sigma-Aldrich Chemical Co., Milwaukee, Wis.
PBA=polybutylacrylate
PMMA=polymethylmethacrylate
PS=polystyrene
Characterization Methods
Size exclusion chromatography with the triple detection method was carried out using an SEC system Model Alliance 2690™ from Waters Corporation (Milford, Mass.), with a Waters 410™ refractive index detector (DRI) and Viscotek Corporation (Houston, Tex.) Model T-60A™ dual detector module incorporating static right angle light scattering and differential capillary viscometer detectors. Data reduction, incorporating data from all three detectors (refractometer, viscometer and light scattering photometer (right angle)), was performed with Trisec® GPC version 3.0 by Viscotek. The Flory-Fox equation was used for angular asymmetry light scattering correction. All chromatographic columns were obtained from Polymer Laboratories (Church Stretton, UK): two PL Gel Mixed C linear columns and one PL Gel 500A column to improve resolution at low molecular weight region of a polymer distribution. The mobile phase was THF, stabilized with 0.05% BHT from J. T Baker, Phillipsburg, N.J.
Preparation of Triethylamine Hypophosphite
A mixture of hypophosphorous acid (6.6 g of a 50% aqueous solution) and toluene (30 mL) was cooled in ice and treated dropwise with triethylamine (5.0 g). Water was removed by azeotropic distillation under vacuum, and then residual toluene was evaporated to provide a nearly colorless, viscous oil, 7.85 g (ca. 95%).
1 H NMR (CDCl 3 ): 7.15 (d, a=12.2), 4.4 (bd, a=6.2), 3.00 (q, a=31.1), 1.25 (t, a=49.9). 31 P NMR ( 1 H decoupled): 4.18 (s). 1 H NMR (CD 3 CN): 7.62 (s, a=4.91), 6.63 (s, a=4.90), 3.04 (q, a=26.4), 2.78 (bd s, exchangeable H+H 2 O), 1.29 (t, a=39.6). 31 P NMR ( 1 H decoupled): 3.0 (s). These spectra are in accord with the desired substance.
Preparation of PinMAc
A 3-neck round bottom flask fitted with thermowell, stir-bar and reflux condenser was charged with PPN chloride (bis(triphenylphosphine)-iminium chloride, 6.0 g, 10.5 mmol), methacrylic acid (104 g, 1.19 mol) and tetramethyloxirane (250 g, 2.5 mol). The resulting solution was heated at 90° C. for 24 hr. GC analysis showed the ratio of epoxide to 1/1-adduct was 0.37 and the ratio of 1/1 adduct to 2/1 adduct was 67/1. NMR showed essentially complete conversion of methacrylic acid. Excess epoxide was removed under vacuum, and the product was isolated by distillation using a small short-path still head. There was obtained a center fraction (200.1 g) with b.p. 42-47° C./0.05 mm. Total product yield was estimated as 204 g (92.3%). 1 H NMR (C 6 D 6 ): 5.96 (m, 1H), 5.13 (m, 1H), 3.00 (bd s, 1H), 1.73 (dd, J=ca. 1.2 Hz, 3H), 1.445 (s, 6H), 1.10 (s, 6H) was consistent with the desired methacrylic ester. (PinMAc)
Preparation of exo-2-(2,2-bis(trifluoromethyl)-2-hydroxyethyl)-endo-3-hydroxy-bicyclo[2.2.1]heptane and exo-2-(2,2-bis(trifluoromethyl)-2-hydroxyethyl)-exo-3-hydroxy-bicyclo[2.2.1]heptane. Sequential Addition Method, Giving Diastereomeric Mixture of Diols
A 3-neck flask, fitted with a thermowell, overhead stirrer, septum and N 2 inlet, was charged with norcamphor (22.0 g, 200 mmol) and t-butyl methyl ether (50 mL). The solution was cooled to −15° C., treated with hexafluorobutene epoxide (41 g, 228 mmol) by canula, and then a solution of lithium bis(trimethylsilyl)amide (36.8 g, 220 mmol) in 2/1 t-butyl methyl ether/heptane was added dropwise at a rate sufficient to maintain the temperature at −15° C. The mixture was stirred at −15° C. for 15 min, then allowed to warm to 0° C. and stirred for 40 min. The mixture was further warmed to room temperature, then to 28.5° C. as an exotherm took place. The mixture was stirred for an additional 1.75 hr after the reaction returned to room temperature. The lithium salt of the resulting hemiketal was reduced directly by treatment with lithium borohydride as follows.
The above reaction mixture was cooled to ca. 0° C. and treated dropwise with a solution of lithium borohydride (1.45 g, 66.7 mmol) in THF (10 mL). The mixture was stirred for 30 hr at 0° C. and was then allowed to warm slowly to room temperature and was then stirred at ambient temperature for 16 hr. The mixture was cooled to 0° C., treated drop-wise with water (5 mL) and then drop-wise with 100 mL of 2N HCl. The mixture was warmed to room temperature, and the pH was adjusted to ca. 5 by addition of more HCl. The organic layer was separated, dried (using Na 2 SO 4 and MgSO 4 ), and stripped to give 69 g of crude oil.
Kugelrohr distillation gave 49.1 g of product collected between 80° C. and 105° C. (0.05 mm). 19 F NMR analysis showed an isomeric mixture of diols (isomer ratio=75/25) and ca. 95% purity; 1 H NMR analysis featured signals at 3.8 (m, a=0.7), 3.28 to 3.2 (m, a=5.3). Distilled material was crystallized from hot hexane (ca. 75 mL) using progressive cooling to −10° C. with occasional agitation to give a first crop, 41.5 g. 19 F NMR (C 6 D 6 ): two sets of quartets, −74.83 and −79.10 (J=9.8; a=32.3), and −76.79 and −78.73 (J=9.8; a=100).
1 H NMR: 7.02 (s, a=0.24), 5.35 (s, a=0.76), 3.22 (m) and 3.17 (d, J=6.6 Hz, combined a=1.00; ratio of these two signals is 75/25), 2.1 to 0.52 (series of m's, combined a=12.6); signals at 3.22 and 3.17 are assigned to C H OH; down-field singlets are assigned to the fluoroalcohol OH groups.
Preparation of exo-3-(2,2-bis(trifluoromethyl)-2-hydroxyethyl)-endo-2-(2-methylpropenoyl)-bicyclo[2.2.1]heptane and exo-3-(2,2-bis(trifluoromethyl)-2-hydroxyethyl)-exo-2-(2-methylpropenoyl)-bicyclo[2.2.1]heptane
A solution of exo-2-(2,2-bis(trifluoromethyl)-2-hydroxyethyl)-3-hydroxy-bicyclo[2.2.1]heptane (a mixture of isomers, 11.68 g, 40.0 mmol) prepared as described above, in t-butyl methyl ether (40 mL) was cooled to −15° C. and treated drop-wise with a solution of potassium t-butoxide (9.42 g, 80 mmol) in tetrahydrofuran (50 mL) while maintaining the temperature below −10° C. The mixture was stirred for 10 min at −15° C. and then treated dropwise with methacrylic anhydride (6.78 g, 44 mmol) by syringe. The mixture was stirred for 1 hr at −15° C., then warmed to 0° C. for 3 hr. The reaction was quenched by dropwise addition of 20 mL 2 N HCl. The mixture formed two layers, and the pH of the bottom layer was adjusted to ca. 6-7, and the layers were separated. The top (organic) layer was diluted with t-butyl methyl ether, washed twice with sodium bicarbonate to remove methacrylic acid, then with distilled water. The organic layer was dried and methoxyphenol (30 mg) and phenothiazine (50 mg) were added. Solvent was stripped to give 15 g of crude product which was passed through a column of neutral alumina (4″×¾″) using 80/20 hexane/t-butyl methyl ether. Evaporation of the first 250 mL eluent provided 11.1 g of colorless liquid. Phenothiazine (50 mg) was added as stabilizer. Kugelrohr distillation provided 9.54 g, bp 73°-78° C./0.03 mm. GC showed two components, 8.18 and 8.26 min, area ratio=30/70, in good agreement with 19 F NMR analysis (C 6 D 6 ): 2 isomers, major with equal intensity quartets at −75.26 and −78.80 (70%), minor with quartets at −76.86 and −78.66 (30%). Purity>98%.
1 H NMR (C 6 D 6 ) showed a spectrum consistent with 2 isomers (30/70), with minor vinyl signals at 5.98 and 5.15 (m), major vinyl signals at 5.93 and 5.08 (m), major OH at 5.25, minor OH at 4.80, minor C H O at 4.45 (d of unresolved m's, J=7.3), major CHO at 3.85 (pseudo-triplet), other multiplets ca. 2.25 to 0.70.
Example 1
a. Preparation of Copolymer of 2,3-NBFOHMAc/PinMAc
A 3-neck flask fitted with reflux condenser and nitrogen gas inlet with adaptor to vacuum for de-gassing the reaction mixture before initiation, thermowell, and stir-bar was charged with a branched trithiocarbonate RAFT agent, C 12 H 25 SC(S)SC(CH 3 )(CN)CH 2 CH 2 CO 2 H (FW=403.66; 464 mg,=1.15 mmol), propylene glycol methyl ether acetate (20 mL), 2,3-NBFOHMAc (9.54 g, 26.5 mmol, prepared as described above), PinMAc (1.64 g, 8.82 mmol, prepared as described above) and Vazo®88 (38 mg, 0.15 mmol). The reaction mixture was cooled in ice and several vacuum/nitrogen fill cycles were applied to the system. The temperature was increased to 90° C. over a 0.5 hr time interval. The temperature was maintained at 90° C. for 23 hr.
The reaction solution was cooled to room temperature and added to hexane (350 mL) drop-wise with rapid stirring. The precipitated polymer was filtered and then dried in the vacuum oven (60° C., N 2 purge, 18 hr) to provide 9.91 g (89%) of polymer.
1 H NMR (THF-d8): 6.9 to 6.1 (bd singlets, with maxima at 6.7 and 6.4; combined a=1.00; ca. 30/70 ratio), 4.7 to 4.15 (bd m, a=1.02), 2.7 to 0.85 (bd m's, integral obscured by solvent peaks; geminal CH 3 group signals at 1.55 and 1.25. 19 F NMR (THF-d8): equal intensity bd singlets at −78.40 and −80.21.
Size exclusion chromatography (THF, RI detector, polystyrene standards) showed: Mw=7,690; Mn=6,520; Mw/Mn=1.18.
b. Removal of Trithiocarbonate End-Group from Methacrylate Copolymer
A sample of 2,3-NBFOHMAc/PinMAc copolymer (75/25, 4.00 g, Mn=6,520, 0.61 mmol) prepared in Ex. 1a was charged to a 3 neck flask and dissolved in 2-butanone (20 mL). Triethylamine hypophosphite (0.31 g, 1.83 mmol) and Vazo®67 (46 mg, 0.24 mmol) were added. The reaction mixture was heated to reflux for 2.5 hr. The nearly colorless solution was cooled and the product copolymer was precipitated by addition to heptane (200 mL). The product was filtered, washed with heptane, and dried to provide 4.02 g of polymer.
UV (THF, 1.052 g/liter; 1.0 cm) showed: A 305 =0.027, consistent with essentially complete removal of the trithiocarbonate end groups. SEC (THF; PMMA): Mw=7,990; Mn=6,750; Mw/Mn=1.18. 1 H NMR (THF-d8) showed some residual triethylamine hypophosphite contaminant. The product was dissolved in ethyl acetate, washed with dilute hydrochloric acid containing additional sodium chloride, followed by dilute sodium bicarbonate containing added sodium chloride. Ethyl acetate was removed under vacuum and the product was dissolved in methanol and precipitated in water to give copolymer free of reagent and RAFT-derived contaminants.
Example 2
a. Preparation of Tetrabutylammonium Hypophosphite
A mixture of 50% aqueous hypophosphorous acid (6.6 g, 50 mmol) and toluene (30 mL) was cooled in ice and treated with tetrabutyl-ammonium hydroxide solution (32.4 g of 40% solution in water). The pH was adjusted to 7.00 by the addition of sodium bicarbonate. Toluene and the remaining water were removed under reduced pressure. The residue was dissolved in methyl ethyl ketone, filtered, and evaporated. The residue was triturated with diethyl ether and dried to afford a hygroscopic crystalline solid, 15.5 g.
1 H NMR (CD 3 CN): 7.15 (d, a=4.79), 3.13 (m, a=18.6), 1.63 (m, a=19.0), 1.38 (m, a=19.0), 1.00 (t, a=28.9).
31 P NMR, 1 H decoupled (CD 3 CN): 4.0 (s)
b. Synthesis of Tetrapolymer of MAMA/β-GBLMA/HAdMA/NBFOHMAc
A 3-neck flask fitted with addition funnel and nitrogen gas inlet, thermowell, and stir-bar was charged with RAFT agent C 12 H 25 SC(S)SC(CH 3 )(CN)CH 2 CH 2 CO 2 CH 3 (2.34 g, 5.60 mmol), methyl ethyl ketone (80 mL), and monomer pre-charge, consisting of MAMA=39.44 g, β-GBLMA=3.12 g, HAdMA=2.89 g, NBFOHMAc=2.87 g, and Vazo® 88 (414 mg, 1.70 mmol). A solution of monomers, consisting of β-GBLMA=12.50 g, HAdMA=11.58 g, and NBFOHMAc=11.50 g in MEK (120 mL) was charged to the addition funnel. The reactor was filled with nitrogen, and two evacuation/fill cycles were performed. The temperature was increased to 84° C. over a 1.0 hr time interval. The monomer feed was continued over a 5 hr time period. The reaction gradually decreased from 84° C. to 81° C. over 20.5 hr.
The solution was cooled and added to methanol (2400 mL) dropwise with rapid stirring. The supernatant was decanted and the remaining polymer was treated with methanol and stirred to suspend finer particles. After settling, the supernatant was again decanted. This purification process was repeated, except the product was collected by filtration and dried to give 61.5 g of polymer.
SEC (THF, RI detector, PMMA standards) showed: Mw=11,000; Mn=9,370; Mw/Mn=1.17.
13 C NMR and 1 H NMR were consistent with polymer composition MAMA/β-GBLMA/HAdMA/NBFOHMAc as 44.9/25.4/16.9/12.8.
c. Reduction of Trithiocarbonate End Group from Methacrylate Copolymer using Tetrabutylammonium Hypophosphite
A sample of MAMA/β-GBLMA/HAdMA/NBFOHMAc (44.9/25.4/16.9/12.8; 6.00 g, 0.64 mmol) copolymer was charged to a 3 neck flask, dissolved in 2-butanone (30 mL), and combined with tetrabutylammonium hypophosphite (0.61 g, 2.0 mmol) and Vazo® 67 (48 mg, 0.25 mmol). The reaction mixture was heated to reflux for 5 hr and then cooled. The cooled solution was added to heptane (200 mL) to precipitate polymer. A solid was obtained (6.27 g) that was substantially reduced in color compared to the starting material. The UV spectrum (THF, 0.995 g/liter; 1.0 cm) showed: A 311 =0.04. For comparison, UV spectrum (THF; 0.997 g/liter; 1.0 cm) of starting copolymer exhibited: A 311.5 =0.867. This indicates that the trithiocarbonate group was essentially completely removed (>95% removal). 1 H and 13 C NMR showed that a fraction of β-GBLMA monomer units had been cleaved to methacrylic acid units in the polymer.
Example 3
Removal of Trithiocarbonate End-Group from Poly(acetoxystyrene) Homopolymer
A sample of poly(acetoxystyrene) (Mw=19,000; Mn=18,500; 4.00 g, 0.22 mmol), prepared with RAFT agent=C 12 H 25 SC(S)SCH 2 CN, was charged to a 3 neck flask and dissolved in methyl ethyl ketone (15 mL). Triethylamine hypophosphite (0.20 g, 1.2 mmol) and Vazo®67 (30 mg, 0.1 mmol) were added, and the reaction mixture was heated to 80° C. for 3 hr.
The reaction mixture was cooled, and then volatiles were removed under vacuum to provide a solid that was washed consecutively with hexane and methanol. Drying under vacuum provided 3.65 g of solid.
UV (THF) showed that the trithiocarbonate functional group was essentially completely removed.
SEC (THF; triple detection method, same as used for starting material): Mw=19,100; Mn=18,100; Mw/Mn=1.06.
Example 4
a. Preparation of NCCH 2 —PBA-SC(═S)SC 12 H 25
A solution containing n-butyl acrylate (6.0 mL), the RAFT agent C 12 H 25 SC(S)SCH 2 CN (400 mg), VAZO®64 (2.2 mg) and benzene (4.0 mL) was degassed and heated at 60° C. for 5 hr. Removal of the volatiles under reduced pressure provided a yellow polymer (3.4 g, 63% conversion) of Mn=3080 and Mw/Mn=1.09. The proton NMR of the polymer showed the presence of protons on carbon next to sulphur at 4.8 ppm [—CH(COOBu)SC(S)S—] and 3.3 ppm [—SC(S)SCH 2 C 11 H 23 ].
b. Removal of End-Group from NCCH 2 —PBA-SC(═S)SC 12 H 25
A mixture of NCCH 2 —PBA-SC(═S)SC 12 H 25 (154 mg, prepared in Ex. 4a), N-ethylpiperidine hypophosphite (45 mg, Sigma-Aldrich Co., Milwaukee, Wis.) and Vazo®88 (4 mg) in toluene (1 mL) was degassed and heated at 100° C. for 2 hrs. The solution was extracted with water and the toluene removed to give a colorless polymer. GPC analysis showed the polymer to have Mn=2850 and Mw/Mn=1.09.
The proton NMR of the product demonstrated the absence of the signals for protons on carbon next to sulphur, which were present in the starting material at 4.8 ppm and 3.3 ppm.
Example 5
a. Preparation of CH 3 ) 2 C(CN)—PMMA-SC(═S)SC 12 H 25
A solution of the RAFT agent C 12 H 25 SC(S)SC(CN)(CH 3 ) 2 (685 mg) and VAZO®88 (10.5 mg) in methyl methacrylate (7.0 mL) and benzene (3.0 mL) was degassed and then heated at 90° C. for 6 hr. Removal of the volatiles under reduced pressure afforded a yellow polymer (5.3 g, 81% conversion) of Mn=3400 and Mw/Mn=1.18. The end-group protons on carbon next to sulphur [—SC(S)SCH 2 C 11 H 23 ] appeared at 3.2 ppm in the proton NMR.
b. Removal of the End-Group from (CH 3 ) 2 C(CN)—PMMA-SC(═S)SC 12 H 25
A mixture of (CH 3 ) 2 C(CN)—PMMA-SC(═S)SC 12 H 25 (170 mg, prepared in Ex. 5a), N-ethylpiperidine hypophosphite (45 mg) and Vazo®88 (4 mg) in toluene (1 mL) was degassed and then heated at 100° C. for 2 hrs. The solution was extracted with water and the toluene removed to give a colorless polymer of Mn=3380 and Mw/Mn=1.16 by GPC analysis.
The NMR of the product showed that the dodecyl end group was no longer present.
Example 6
a. Preparation of (CH 3 ) 2 C(Ph)-PS—SC(═S)Ph
A solution of RAFT agent (CH 3 ) 2 C(Ph)SC(S)Ph (995 mg), VAZO®88 (16 mg) in styrene (16.0 mL) and benzene (4.0 mL) was degassed and then heated at 90° C. for 16 hr.
Removal of the volatiles under reduced pressure afforded a red polymer (2.2 g, 15% conversion) of Mn=333 and Mw/Mn=1.14. The end-group protons on carbon next to sulphur [—CH(Ph)SC(S)Ph] appeared in the proton NMR as a complex signal between 4.5 and 5.0 ppm. The aromatic protons ortho to the C═S group produced a signal at 7.9 ppm.
b. Removal of the End-Group from (CH 3 ) 2 C(Ph)-PS—SC(═S)Ph
A mixture of (CH 3 ) 2 C(Ph)-PS—SC(═S)Ph (170 mg, prepared as in Ex. 6a), N-ethylpiperidine hypophosphite (450 mg) and Vazo®88 (10 mg) in toluene (2 mL) was degassed and then heated at 110° C. for 4 hrs. The solution was diluted with ethyl acetate (5 mL), extracted with water and then the organic phase evaporated to give a near-colorless polymer of Mn=310 and Mw/Mn=1.19 by GPC analysis. The NMR of the product revealed the absence of the end-group proton on carbon next to sulphur, which in the starting material appeared as a complex signal between 4.5 and 5.0 ppm. Also absent were the end-group aromatic protons ortho to the C═S group which produced a signal in the starting material at 7.9 ppm, indicating that the end-group has been substantially removed (>95%).
Example 7
a. Preparation of Polystyrene of Mn=4475
A solution of RAFT agent C 12 H 25 SC(S)SCH 2 CN (584 mg), VAZO®88 (16 mg) in styrene (16.0 mL) and benzene (4.0 mL) was degassed and then heated at 90° C. for 16 hr. Removal of the volatiles under reduced pressure afforded a yellow polymer (8.4 g, 58% conversion) of Mn=4475 and Mw/Mn=1.06. The proton NMR showed the end-group proton [—CH(Ph)SC(S)S—] as a broad signal between 4.6 and 5.1 ppm and the methylene of the dodecyl group [—SC(S)SCH 2 C 11 H 23 ] at 3.25 ppm.
b. Removal of End-Group from Polystyrene of Mn=4475
A solution of NCCH 2 —PS—SC(S)SC 12 H 25 of Mn=4475 and Mw/Mn=1.06 (224 mg, prepared in Ex. 7a), N-ethylpiperidine hypophosphite (90 mg), VAZO®88 (5 mg) in toluene (1 mL) was degassed and then heated at 110° C. for 4 hr. The mixture was diluted with ethyl acetate (10 mL), extracted with water and then the organic phase evaporated. This produced a colorless polymer of Mn=3970 and Mw/Mn=1.10 by GPC analysis. The proton NMR revealed the absence of both of the end-group protons that appear in the starting material at 4.6-5.1 and 3.25 ppm.
Example 8
Preparation of 2,3-NBFOHMAc/MGM/HAdMA Copolymer
A 3-neck flask fitted with a thermocouple, reflux condenser, stir-bar, and nitrogen gas inlet with adapter to vacuum for de-gassing the reaction was charged with the trithiocarbonate RAFT agent, C 12 H 25 SC(S)SC(CH 3 )(CN)CH 2 CH 2 CO 2 CH 3 (1.472 g, 3.52 mmol), a monomer charge consisting of 2,3-NBFOHMAc (10.80 g, 30 mmol), 2-methyl-2-adamantyl glycolylmethacrylate (MGM) (12.28 g, 42.0 mmol), and 3-hydroxy-1-adamantylmethacrylate (HAdMA) (7.09 g, 30 mmol), methyl ethyl ketone (32 mL), sodium bicarbonate powder (0.170 g), and V601 initiator (230 mg, 1.0 mmol). The reactor was filled with nitrogen, and two more evacuation/fill cycles were performed. The temperature was increased to 67° C. over 0.5 h. The reaction was maintained at 67° C. for 20 h. 1 H NMR of an aliquot showed that total residual monomer content was very low, ca. 0.6 mol %.
The cooled mixture was diluted with methyl ethyl ketone, filtered, and added slowly to heptane (1000 mL) to provide a uniform solid that was filtered and air-dried. There was obtained 30.3 g of solid. 1 H NMR (THF-d8) showed no detectable monomers, and no carboxylic acid formation.
TGA showed onset of significant weight loss at ca. 175° C. MDSC exhibited Tg of 147° C. SEC analyses showed Mw=8340; Mn=7010; PD=1.19. UV (THF; 1.000 g/liter) showed A 310 =1.155. 13 C NMR analysis showed: 2,3-NBFOHMAc=27.9%; MGM=41.2%; HAdMA=30.9%.
Example 9
Reduction of Trithiocarbonate End Group from Methacrylate copolymer with Et 3 NH H 2 PO 2
A sample of 2,3-NBFOHMAc/MGM/HAdMA copolymer (20.0 g, 2.85 mmol), prepared as in Example 8, was charged to a 3-neck flask and dissolved in 2-butanone (70 mL). Triethylammonium hypophosphite (3.0 g, 18 mmol) and Vazo® 67 (288 mg, 1.5 mmol) were added, and the reaction mixture was heated to 68° C.-70° C. The yellow color intensity decreased substantially during the reaction period. Another charge of Vazo® 67 (90 mg) was added after 3 h, and heating was then continued for 1.5 h.
The cooled polymer solution was diluted with 10 mL MEK, filtered, then added slowly dropwise to a cold solution of 70/30 water/methanol (700 mL; −5° C., electronic grade). The mixture was filtered, and the solid was washed with additional water/methanol (4×100 mL) to provide white solid after air-drying. The polymer sample was re-precipitated twice using MEK and 70/30 water/methanol as above to completely remove NMR-detectable triethylammonium hypophosphite salt. There was obtained 19.0 g of polymer.
UV (THF; 1.000 g/liter; 1.0 cm) showed A 310 <0.01, showing high conversion of the trithiocarbonate functionality. SEC showed Mw=8100; Mn=6800; PD=1.19. Composition by 13 C NMR: 2,3-NBFOHMAc=28.8%; MGM=40.5%; HAdMA=30.7%. MDSC showed Tg at 140.7° C. TGA showed onset of thermal weight loss at 150° C.
Example 10
Preparation of Diazabicyclo[2.2.2]Octane Hypophosphite
A solution of 50% aqueous hypophosphorous acid (46.2 g, 0.35 mol) at 0°-7° C. was treated slowly with a solution of 1,4-diazabicyclo[2.2.2]octane (39.3 g, 0.35 mol) in water (80 mL). The pH of the resulting solution was estimated as 7.0. Water was removed under reduced pressure to give a solid residue that was triturated with methyl ethyl ketone to afford 57.9 g of white crystalline solid.
1 H NMR (CD 3 OD): 7.2 (d, a=2.0), 3.25 (s, a=12.0); 31 P 3.2 (t, J PH =507 Hz).
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This invention provides a method for removing certain sulfur-containing groups from polymers, especially those made via RAFT polymerization processes.
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FIELD OF THE INVENTION
The present invention relates to a switching power supply for controlling the amount of power supplied to a load from an alternating current (AC) power source and more specifically to a switching power supply for reducing disturbance to the AC power distribution system.
BACKGROUND OF THE INVENTION
Recently, more stringent standards have been proposed which seek to limit the level at which power-consuming devices are permitted to introduce noise, power frequency harmonics, or other disturbance onto the AC power line as a result of their operation. The IEC555-2 and IEC555-3 standards were initiated by the IEC, amended, approved, renumbered as EN60555-2 and EN60555-3, and implemented by CENELEC for use by members of the European Union. The EN60555-2 and EN60555-3 standards have more recently been updated and renumbered as EN61000-3-2 and EN61000-3-3. All of these standards will be collectively called the “IEC555 Standard”. The IEC555 Standard regulates the effects of the power draw of the load upon the current and voltage characteristics of the AC power line. Herein, the term disturbance is used to refer to any of the above-identified effects, as well as one or more of the following: increased average or root mean squared (rms) line current, reduced power factor, and distortions of the AC line voltage, including flattening of the peak voltage levels and/or periodic changes that would cause a visual flicker of the lighting. These specific types of disturbance to the AC power line voltage and current are known to be present when existing electrical equipment such as computers, audio-visual reproduction and recording equipment, lamp dimmers, motor drives, electronic ballast lights, and photocopying equipment, among others, are powered from an AC power line source.
Prior to the invention disclosed herein, no system known to the inventors was capable of supplying variable power from an AC power line source to a resistive AC load that could also meet the requirements of the IEC555 Standard for minimizing disturbance to the AC power line voltage and current. A system in use prior to the proposal of the IEC555 Standard is known as thyristor AC phase control. An example of such system is described in U.S. Pat. No. 5,373,224 to Rabier (“the Rabier Patent”). A further example is shown in FIG. 6A of an extended range full wave phase control circuit. In these types of systems, which may commonly be used in photocopiers, lamp dimmers, heater controls and cooking appliances, a triac placed between the AC power line and the load is “fired”, i.e. switched on, at some delay relative to the start of each half cycle of the AC power line voltage, such that power is supplied to the load during only a predetermined portion of each half cycle of the AC line voltage. In that way, the triac controls delivery of power to the load in accordance with the relative proportion of each AC power cycle in which the triac is switched on.
However, while prior triac-controlled switching power supplies are capable of meeting the voltage fluctuating requirements of the IEC555-3 (now EN61000-3-3) standard, they are incapable of meeting the harmonic requirements of IEC555-2 (now EN61000-3-2) standard because the voltage and current waveforms supplied to the load are not sinusoidal at substantially a single frequency.
An alternate method of controlling the triac-controlled power supply is to switch it on for several cycles and then off for several cycles, resulting in a very slow modulation frequency. An example of such a system is shown in FIG. 6B employing a solid state relay with zero crossing turn on. The circuit of FIG. 6B is similar to that of FIG. 6A, however, it can be controlled by a computer. Accordingly, the triac can be on for extended periods of time and is slowly modulated on and off to control the average power. Although this method, which is currently in use for many heater type applications in the electronics industry such as photocopiers meets the harmonic distortion requirements, it does not meet the fluctuating voltage restrictions and causes visual flicker to the lighting. Accordingly, it fails the standard IEC555-3 (now EN6100-3-3).
FIG. 1 contains a set of waveforms plotted versus time for 1) the voltage Vs and current Is on an AC power line with minimal disturbance present; 2) the voltage VL and current IL as supplied to a load through a prior triac-controlled supply; and 3) an example of the AC power line voltage Vs 1 and current Is 1 under disturbed conditions, i.e. as voltage and current being supplied to the load by the triac-controlled power supply. As shown in FIG. 1, irregular, non-sinusoidal voltage and current are supplied to the load as waveforms VL and IL The irregular current draw, in turn, disturbs the AC power line characteristics, resulting in the disturbed voltage and current waveforms Vs 1 and Is 1 .
Like the prior thyristor AC phase control system, the present invention is designed to supply power to AC loads used in photocopiers, lamp dimmers, heater controls, cooking appliances, and many other types of equipment which draw sinusoidal AC power. The present invention operates to minimize the level of disturbance to the AC power line while providing variable AC power to a load and meeting the requirements of the IEC555 standard.
Accordingly, it is an object of the present invention to provide a switching power supply which delivers a controlled amount of power to an AC load from an AC power line while minimizing disturbance to the voltage and current which are carried by the AC power line.
A further object of the invention is to provide a switching power supply which draws power at timed cycle intervals from a source while delivering a continuous sinusoidal voltage and current to the load.
Another object of the invention is to provide a switching power supply which draws power at timed cycle intervals from a source while maintaining substantially sinusoidal voltage and current waveforms at the source.
Another object of the invention is to provide a switching power supply which provides power to an AC load at a modulation frequency substantially higher than the AC source frequency so that there will be no fluctuating distortion on the source that would create a visible flicker.
Still another object of the invention is to provide a more reliable switching power supply which contains few components.
A still further object of the invention is to provide a low-cost switching power supply for use with a full spectrum of consumer and business equipment.
SUMMARY OF THE INVENTION
These and other objects are provided by the switching power supply of the present invention. In a first preferred embodiment of the present invention, the switching power supply includes an AC switch which responds to a control input to permit current to flow bi-directionally between the power source and the load for a duration proportional to the power level needed. The switching frequency is several orders of magnitude higher than that of the AC line so as not to produce unwanted line distortion and to allow a sinusoidal voltage and current to be realized. The switching power supply further includes an energy storage element which stores energy during the period that the AC switch is closed and releases the stored energy to supply current bi-directionally to the load during the period that the AC switch is off and the load is blocked. The energy storage element preferably includes an inductor, but may include a capacitor instead of or in addition to the inductor. The storage element additionally provides filtering of the high switching frequency to reduce the switching frequency ripple and noise content at the load. The switching power supply further includes an electromagnetic interference (EMI) reducing filter as an input filter to prevent current flow between the source and the load from introducing noise frequencies and harmonics of the fundamental AC power line frequency onto the voltage and current waveforms of the AC power line.
Preferably, the switching power supply includes a second AC switch coupled to the energy storage element which is operated at alternate intervals with respect to the first AC switch. The first switch is turned on while the second switch is turned off to permit bi-directional current flow between the source and the load. The second switch is turned on when the first switch is turned off to permit bi-directional current to flow between the energy storage element and the load.
Preferably, the switching power supply includes modulation control circuits which could be implemented by, but not limited to, pulse width modulation (PWM), frequency modulation (FM), phase modulation (PM), or any suitable energy modulation technique. These control circuits will generate periodic pulse trains to control the operation of the first and second AC switches. In a preferred embodiment, a first train of pulses is generated to control the operation of the first AC switch and a second train of pulses is generated to control the operation of the second AC switch. The first and second pulse trains are preferably opposite in phase with respect to each other to activate each AC switch at alternate intervals. Preferably, the control circuits are controlled automatically in accordance with the power requirements of the load, e.g. via feedback control signals delivered from load system circuitry.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows an example of voltage and current waveforms at the input and output of a prior art switching power supply.
FIG. 2 shows a block and schematic diagram of the switching power supply of the present invention.
FIG. 3 shows an example of drive pulse trains used to operate the switching power supply shown in FIG. 2 .
FIG. 4 shows an example of voltage and current waveforms supplied to a load from the output of the switching power supply shown in FIG. 2 .
FIG. 5 shows an example of voltage and current waveforms of the AC power line source at the input of the switching power supply shown in FIG. 2 while power is being supplied to a load.
FIG. 6A shows a prior circuit having thyristor AC phase control.
FIG. 6B shows a prior circuit having a slowly modulated triac control.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a set of waveforms plotted versus time for the following: 1) the voltage Vs and current Is on an AC power line source with minimal disturbance present; 2) the voltage VL and current IL as supplied to a load through a prior art triac controlled switching power supply; and 3) an example of the voltage Vs 1 and current Is 1 on an AC power line under disturbed conditions, e.g. when power is supplied to a load by the prior art triac controlled switching power supply having voltage and current characteristics as shown by the VL and IL waveforms.
As shown in FIG. 1, the voltage Vs and current Is on the AC power line with no disturbance present appear as sine curves having a single fundamental frequency at the power line frequency, e.g. a fixed frequency at 50 Hz, 60 Hz, or 400 Hz, etc. Ideally, the AC power line voltage Vs and current Is have no energy in frequencies other than the single fundamental frequency, such that there will be no energy in higher harmonics of the fundamental frequency, and no energy in other frequencies due to various sources of noise. If an AC power line is coupled to a load through a power modulation circuit that has the voltage VL and current IL characteristic shown in FIG. 1, disturbance is introduced onto the AC power line such that the voltage and current which remain on the AC power line more closely resemble the disturbed waveforms shown as Vs 1 and Is 1 in FIG. 1 .
FIG. 2 is a block and schematic diagram showing the switching power supply of the present invention. As shown in FIG. 2, the switching power supply includes a first AC switch consisting of Q 1 , D 1 , D 2 , D 3 , & D 4 . This switch is used to conduct power from a first (variable potential) AC input line 12 to a first AC output line 14 through an output filter 16 during either a positive or negative portion of the half cycle of the AC power line voltage. A second AC switch which consists of Q 2 , D 5 , D 6 , D 7 , & DS is used to permit the flow of current to be continuous between an energy storage element such as inductor L 1 in output filter 16 and the load through output line 14 when switch element Q 1 is turned off. First and second AC switch elements Q 1 and Q 2 can be of any one of many types of relatively fast switching voltage controlled or current controlled switches, such as bipolar junction transistors and field effect transistors, IGBTs, vacuum tubes, relays, etc., so long as their switching frequencies are at least one and preferably several orders of magnitude higher than the fundamental AC power line frequency. The first and second AC switches are coupled to the input lines of the source, i.e. a first (variable potential) AC input line 12 and a second (variable potential or common) AC input line 18 , via an input filter 17 for reducing electromagnetic interference (EMI).
Output filter 16 serves to continue the flow of current between the source and the load during portions of the positive and negative half cycles of the AC power line voltage when switch element Q 1 is turned off. For that purpose, output filter 16 includes an energy storage element shown representatively as inductor L 1 , and may also include a capacitor C 1 which also serves as an energy storage element and/or for the purpose of eliminating rapid fluctuations in the voltage or current flow between the load and the energy storage element or the source. Capacitor C 1 may also be used to correct for a phase lag between the voltage and the current supplied to the load.
Diodes D 1 -D 8 permit current to flow only in a single direction in switch elements Q 1 and Q 2 . Diodes D 1 and D 4 serve to permit the flow of current from AC input line 12 through connection point A to connection point B when switch element Q 1 is turned on during a positive half cycle of the AC voltage, and diodes D 2 and D 3 serve to permit the flow of current from connection point B through connection point A to AC input line 12 when switch element Q 1 is turned on during a negative half cycle of the AC voltage. When switch element Q 1 is turned off and switch element Q 2 is turned on during a positive half cycle of the AC voltage, diodes D 6 and D 7 permit the flow of current between inductor L 1 of output filter 16 to the AC output line 14 to the load to the AC (common) input line 18 through connection points C to B. Likewise diodes D 5 and D 8 permit the flow of current between inductor L 1 of output filter 16 through connection points B to C to the AC (common) input line 18 to the load to the AC output line 14 during a negative half cycle.
Pulse width modulation (PWM) circuits 20 and 22 generate controlled duration pulses, which in turn, control the duration and timing at which first and second source switch elements Q 1 and Q 2 are activated to permit current to flow between the source and the load. PWM control circuits 20 and 22 are controlled by an external control signal 24 which may be, for example, a reference voltage output of a potentiometer or a feedback control signal generated by load system circuitry to automatically control the amount of power delivered to the load. The external control signal 24 operates a control interface 26 to supply the signals required to operate PWM control circuits 20 and 22 . An optical isolator 28 may also be used, as appropriate, to galvanically isolate the control signal 24 from the AC lines 12 and 18 .
The construction of the switching power supply of the present invention having been described, attention will now be turned to its operation. FIG. 3 shows a pair of waveforms Q 1 D and Q 2 D which are output from PWM control circuits 20 and 22 , respectively, and which are used to control the operation of first and second AC switch elements Q 1 and Q 2 , respectively. The Q 1 D and Q 2 D waveforms are trains of pulses which vary between a first state L below the threshold for engaging switch elements Q 1 and Q 2 and a second state H at which switch elements Q 1 and Q 2 are engaged. The Q 1 D and Q 2 D waveforms are timed such that the Q 1 D waveform has the state H when the Q 2 D waveform has the state L and vice versa. Accordingly, the first and second AC switch elements Q 1 and Q 2 are operated such that whenever switch element Q 1 is turned on, switch element Q 2 is turned off, and whenever switch element Q 2 is turned on, switch element Q 1 is turned off.
Preferably, switch element Q 1 is turned on by waveform Q 1 D multiple times during every AC voltage cycle, and switch element Q 2 is turned on multiple times during the alternate portions of every AC voltage cycle. Hence, the preferred embodiment of the invention operates as follows for each cycle of the AC power line voltage. During a portion of the positive AC half cycle, switch element Q 1 is turned on multiple times by an ‘H’ pulse of waveform Q 1 D to permit current to flow from the source to the load through AC input line 12 and AC output line 14 through diodes Dl, D 4 and switch element Q 1 . During the alternate portions of the same AC half cycle, switch element Q 1 is turned off and switch element Q 2 is turned on to permit current to flow from an energy storage element such as inductor L 1 or capacitor C 1 in output filter 16 to the load through output line 14 to the AC common 18 and back through diodes D 6 , D 7 and switch element Q 2 to the energy storage element. Next during a portion of the negative AC half cycle, switch element Q 1 is again turned on multiple times by an ‘H’ pulse of waveform Q 1 D to permit current to flow from the load to the source through output filter 16 , connection point B, diodes D 2 and D 3 and switch element Q 1 , connection point A and to AC input line 12 through input filter 17 . During the alternate portions of the negative AC half cycle in which switch element Q 1 is turned off and switch element Q 2 is turned on, current is permitted to flow from a storage element such as inductor L 1 or capacitor C 1 in output filter 16 to connection point B, diodes D 5 and D 8 and switch element Q 2 to connection point C to the load and back to connection point 14 .
The voltage and current which appear at AC output line 14 and which are applied to the load by operation of the switching power supply of FIG. 2 have waveforms as shown in FIG. 4 . As will be understood from an examination of FIG. 4, the voltage and current waveforms applied to the load by the switching power supply are sinusoidal at the fundamental AC power line frequency and have minimal energy in harmonic frequencies of the fundamental frequency, and minimal noise energy.
During operation of the switching power supply shown in FIG. 2 the voltage and current waveforms which appear on the AC input line 12 have waveforms as shown in FIG. 5 . As will be understood from an examination of FIG. 5, the waveforms for the voltage and current of the AC power line source during operation of the switching power supply of FIG. 2 remain sinusoidal at the fundamental AC power line frequency and have minimal energy in harmonic frequencies of the fundamental frequency, and minimal noise energy. Accordingly, an examination of FIG. 5 shows that the switching power supply of the present invention meets its stated objective of controlling the power to an AC load while minimizing disturbances which could be coupled onto the AC power line source.
While the invention has been described in detail herein in accordance with certain preferred embodiments thereof, many modifications and changes therein may be effected by those skilled in the art. Accordingly, it is intended by the appended claims to cover all such modifications and changes as fall within the true spirit and scope of the present invention.
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A switching power supply system is disclosed for powering electrical equipment while minimizing disturbance to an AC power line source. The system includes first and second AC switches which are operated at alternate intervals with respect to each other to permit current to flow between the AC power line source and the load over intervals of the AC voltage cycle. An energy storage element is included in an output filter and stores energy during intervals of the AC voltage cycle and releases the stored energy during the alternate intervals of the AC voltage cycle. By the disclosed switching power supply, the voltage applied to the load and the current flow between the source and the load are sinusoidal, have minimal energy in frequencies other than the fundamental AC power line frequency, have minimal harmonic distortion, result in a power factor close to unity, and are steady and non fluctuating.
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BACKGROUND OF THE INVENTION
The present invention relates to integrated circuits, and more specifically to a current-controlled oscillator which utilizes a voltage independent multi-layered capacitor to reduce jitter in its output frequency and achieve highly symmetrical duty cycles in its output waveform.
In the operation of an oscillator, it is generally desirable that the frequency (f) of the oscillator vary only with input current, as this will ensure good frequency control. Since current (i) approximately equals capacitance (C) multiplied by voltage across the capacitor (V) multiplied by f, if C and V remain substantially constant, f will vary substantially linearly with respect to i.
Existing current-controlled oscillators generally utilize gate-oxide capacitance (C ox ) of MOSFET transistors as capacitors, as C ox capacitors occupy a relatively small area on a circuit layout. However, as shown in FIG. 1, the capacitance of a C ox capacitor with respect to applied voltage is non-linear, and it is voltage dependent. Since its capacitance is not constant, an oscillator utilizing a C ox capacitor will experience jitter in its output frequency.
Furthermore, an oscillator utilizing a C ox capacitor will have asymmetrical duty cycles in its output waveform. FIG. 2 shows the output waveform of an oscillator utilizing a C ox capacitor. Calculation of the duty cycle of the output waveform yields a value of 48.4 percent. Since the duty cycle is determined by dividing the high time of the output waveform by its period (which is the sum of the high time and the low time), this shows that the output waveform is not symmetrical.
SUMMARY OF THE INVENTION
The present invention solves the problem of the prior art by providing a method for reducing jitter due to varying frequency in the output frequency of an oscillator. The invention also provides an apparatus with highly symmetrical duty cycles in its output waveform, and reduced jitter in its output frequency.
In one aspect of the invention, a multi-layered voltage independent capacitor is utilized by a current-controlled oscillator fabricated on an integrated circuit substrate. The capacitor has a first metal layer, a second metal layer, and a polysilicon layer, and can be formed on top of a p-type or n-type substrate. The capacitance of the multi-layered capacitor is constant regardless of the voltage applied at the capacitor terminals. Hence, the output frequency of the oscillator varies only with input current, thereby reducing jitter in the output frequency of the oscillator.
In another aspect of the invention, the current-controlled oscillator has first and second differential comparators serving as inputs, first and second voltage independent multi-layered integrated capacitors corresponding to the first and second comparators, and a RS latch for switching operation between the two comparators thereby achieving oscillation. The voltage independent capacitors may be used in any CMOS fabrication process with multiple metalization layers. Although the voltage independent capacitors occupy a larger area on a circuit layout, additional metalization layers may be used to realize voltage independent capacitors with a smaller layout area. The capacitance of the voltage independent capacitors may also be increased or decreased as necessary.
Other features and advantages of the present invention will become apparent upon a perusal of the remaining portions of the specification and drawings. In the drawings, like reference numerals indicate identical or functionally similar elements.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows the nonlinear capacitance behavior of a prior art gate capacitance of a MOSFET transistor with respect to gate voltage;
FIG. 2 shows asymmetrical duty cycles of the output waveform of a prior art oscillator utilizing a gate capacitance of a MOSFET transistor as capacitor;
FIG. 3 shows the substantially linear capacitance behavior of a voltage independent multi-layered capacitor according to the present invention;
FIG. 4 shows symmetrical duty cycles of the output waveform of an oscillator utilizing a multi-layered voltage independent capacitor according to the present invention;
FIG. 5 shows a preferred construction of a multi-layered voltage independent capacitor according to the present invention;
FIG. 6 shows a preferred schematic connection of the voltage independent multi-layered capacitor according to the present invention;
FIG. 7 shows a preferred layout of the voltage independent multi-layered capacitor according to the present invention;
FIG. 8 shows a preferred layout of a differential voltage-controlled oscillator which utilizes the current-controlled oscillator according to the present invention;
FIG. 9 shows the schematic circuit diagram corresponding to the layout of FIG. 8; and
FIG. 10 shows the simplified schematic block diagram corresponding to the schematic circuit diagram of FIG. 9.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 3 shows the substantially linear capacitance behavior of a voltage independent multi-layered capacitor according to the present invention. As shown, the capacitance of the multi-layered capacitor is substantially constant regardless of the voltage applied across the capacitor. As previously discussed, an oscillator with a substantially constant capacitance has an output frequency which varies substantially linearly with respect to input current. Hence, a current-controlled oscillator utilizing a voltage independent capacitor substantially reduces jitters in its output frequency.
Furthermore, such a current-controlled oscillator has highly symmetrical duty cycles in its output waveform. FIG. 4 shows the output waveform of an oscillator using a multi-layered voltage independent capacitor according to the present invention. As indicated, the duty cycle of the output waveform is 50 percent. As previously discussed, the duty cycle of an output waveform is determined by dividing the high time of the output waveform by its period (which is the sum of the high time and the low time). A close examination of the prior art waveform shown in FIG. 2 shows that the high time 2 has a smaller value than the low time 4, hence, the duty cycle of the waveform is at 48.4 percent. On the other hand, a close examination of the FIG. 4 waveform shows that high time 6 and low time 8 are substantially equal, hence the duty cycle of the waveform is substantially symmetrical.
FIG. 5 shows a preferred construction of voltage independent multi-layered capacitor 500 according to the present invention. As can be seen, capacitor 500 is formed on top of a p-type substrate 10 by first forming a polysilicon layer 12 on top of substrate 10. A first metal layer 14 is then formed on polysilicon layer 12, and a second metal layer 16 is formed on first metal layer 14. Silicon oxide dielectric layers 11, 13, and 15 are inter-layered between the polysilicon and metal layers, and the substrate, to separate the layers from each other and from the substrate. As previously mentioned, the capacitor could be formed on an n-type substrate. The construction of the capacitor would remain the same. The only difference in a p-type and an n-type construction is that the p-typed substrate is connected to ground, while the n-typed substrate is connected to Vdd.
A preferred schematic connection of voltage independent multi-layered capacitor 500 is illustrated in FIG. 6. C SP corresponds to the capacitance between substrate 10 and polysilicon layer 12, C P1 corresponds to the capacitance between polysilicon layer 12 and first metal layer 14, and C 12 corresponds to the capacitance between first metal layer 14, and second metal layer 16. As shown, the positive terminal is connected to plate 38 of C 12 , and plate 36 of C P1 . Plate 34 of C P1 is connected to plate 40 of C 12 , plate 32 of C SP , and the negative terminal. Plate 30 of C SP is also connected to plate 40 of C 12 , plate 32 of C SP , and the negative terminal; furthermore, it is connected to plate 34 of C P1 .
FIG. 7 shows a preferred layout of voltage independent multi-layered capacitor 500 according to the present invention. Measurements are given for a specific embodiment as examples only, and capacitor 500 may have different dimensions. As shown in FIG. 7, the second metal layer 501 of capacitor 500 has the smallest area. It is laid over the first metal layer 503, which has an intermediate area. The polysilicon layer 505 is the largest of the three layers. The different areas of the layers allow for easy connection of the layers with different potentials.
As an example, the dimensions of the layers are a length of 72.4 micrometer with a width of 52.4 micrometer, a length of 76 micrometer with a width of 61 micrometer, and a length of 80 micrometer with a width of 65 micrometer for the second metal layer 501, the first metal layer 503, and the polysilicon layer 505, respectively. As an another example, a capacitor with smaller capacitance has dimensions of a length of 57.4 micrometer with a width of 27.4 micrometer, a length of 61 micrometer with a width of 31 micrometer, and a length of 65 micrometer with a width of 35 micrometer for the second metal layer 501, the first metal layer 503, and the polysilicon layer 505, respectively. These dimensions are provided only as examples of specific embodiments. It will be apparent to anyone of skill in the art that many other dimensions are possible.
FIG. 8 shows a preferred layout of a differential voltage-controlled oscillator which utilizes the current-controlled oscillator according to the present invention. As can be seen, the top and bottom half of the layout is symmetrical with respect to the components in the middle. On each symmetrical side, there are eight identical voltage independent multi-layered capacitors. Referring to the bottom symmetrical side, these eight identical 0.33745 picofarad capacitors are collectively denoted as 2.42 picofarad capacitor 600. In addition, there are two identical 0.13346 picofarad capacitors. These are collectively denoted as 0.266 picofarad capacitor 622.
The arrangement of the capacitors as shown in FIG. 8 allows the easy reduction or addition of capacitance during prototyping. Capacitor 622 is usually bypassed. However, if more capacitance is desired, one or both of the 0.13346 picofarad capacitors could be connected in parallel with capacitor 600 to increase the overall capacitance. In the alternative, one or more of the eight identical 0.33745 picofarad capacitors may be shaved off during prototyping to reduce the capacitance of capacitor 600.
Since capacitor 600 is multi-layered, it could be used in any CMOS fabrication process with multiple metalization layers. Although capacitor 600 comprises eight smaller capacitors, additional metalization layers can be used to construct a single capacitor which utilizes a smaller layout area.
Block 702 of FIG. 8 corresponds to transistor pairs 630, 632 and 830, 832 of FIG. 9. Similarly, resistor block 704 corresponds to resistors 634, 636, and 638 of FIG. 9, while resistor block 706 corresponds to resistors 834, 836, and 838. These resistor blocks and the remaining components shown on FIG. 8 will be discussed with reference to FIG. 9, which shows the layout of FIG. 8 in a schematic diagram.
Referring to FIG. 9, transistor pair 630 and 632 function together as a selecting switch for steering input current i 1 either to ground or to charge capacitor 600. As mentioned, capacitor 622 may be connected in parallel with capacitor 600 to increase the capacitance, hence it may be charged as well if it is not bypassed. As capacitor 600 is charged, comparator 640's output will correspond to its negative input. This output serves as an input to NAND gate 708, whose output serves as an input to NOR gate 710.
NOR gates 710 and 712 function as a RS latch 714 which flips when capacitor 600 is charged so that capacitor 600 can discharge, while capacitor 800 can be charged. NAND gate 708, NOR gate 716, NOR gate 718, and inverter 720 are utilized to override the signal from either comparator 640 or comparator 840 to set or reset latch 714, thereby determining whether capacitor 600 or 800 will be charged. Resistors 634 and 636 provide the time constant at which capacitor 600 is discharged. Resistor 638 is optional, and may be connected in series or in parallel with resistors 634 and 636 depending on the capacitance discharge rate desired.
Since the circuit is symmetrical, resistors 834, 836, and 838 function in a similar manner as resistors 634, 636, and 638. Similarly, transistor pair 830 and 832 have functions corresponding to transistor pair 630 and 632. Comparator 724 functions to amplify the output signal, and provide for a faster transition time. Similarly, inverter 726 and additional buffers may be used to provide for a clearer signal swing to achieve faster transition time.
FIG. 10 shows the simplified schematic block diagram corresponding to the schematic circuit diagram of FIG. 9. Input control 631 corresponds to transistor pair 630 and 632. Similarly, input control 831 corresponds to transistor pair 830 and 832. Capacitor 611 corresponds to capacitor 600 and 622, while capacitor 811 corresponds to capacitor 800 and 822. Discharge unit 635 corresponds to resistors 634, 636, and 638. Likewise, discharge unit 835 corresponds to resistors 834, 836, and 838. "R/S Latch with Reset" 700 corresponds to NAND gate 708, inverter 720, NOR gates 710, 712, 716, and 718. Finally, "Diff Amp & Buffer" 728 corresponds to comparator 724 and invertor 726.
Comparators 640 and 840 function to detect when node voltage 608 or 808 reaches the reference voltage. For example, if the voltage at node 608 reaches the reference voltage, the output signal from comparator 640 will cause RS Latch 700 to turn on discharge unit 635, thereby allowing capacitor 611 to discharge. As discharge unit 635 is turned on, "Diff Amp and buffer" 728 will have an output corresponding to its positive terminal input, hence output 748 will be a logic high.
While capacitor 611 discharges, input control 831 is turned on to charge capacitor 811. When capacitor 811 is charged to the reference voltage, comparator 840 will send an output signal to RS Latch 700, which turns on discharge unit 835 to discharge capacitor 811. At the same moment, input control 631 is turned on to charge capacitor 611 to the reference voltage. As discharge unit 835 is turned on, "Diff Amp and buffer" 728 will have an output corresponding to its negative terminal input. In this case, output 748 will correspond to a logic low. By alternating the charging and discharging of capacitors 611 and 811, oscillation is achieved, as output 748 will oscillate between a logic high and a logic low depending on whether capacitor 611 or 811 is charging. As mentioned, "Diff Amp and buffer" 728 function to ensure a clearer signal swing thereby achieving a faster signal transition time.
The above description is illustrative and not restrictive. Variations of the invention will become apparent to those skilled in the art upon review of this disclosure. The scope of the invention should, therefore, be determined not with reference to the above description, but instead should be determined with reference to the appended claims along with their full scope of equivalents.
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A current-controlled oscillator with first and second differential comparators (640, 840) serving as inputs, first and second voltage independent multi-layered integrated capacitors (600, 800) corresponding to the first and second comparators (640, 840), and a RS latch (700) for switching operation between the two comparators (640, 840) thereby achieving oscillation. The multi-layered integrated capacitors (600, 800) are designed to provide voltage independent capacitance.
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TECHNICAL FIELD
[0001] The present invention relates to honers and sharpeners for blades, and in particular, to devices aid methods for sharpening blades for hand held rotary cutters.
BACKGROUND
[0002] Rotary cutters are used for cutting fabric in quilt making and hobby sewing, among other uses. Such rotary cutters come in many different designs, each of which includes a handle portion and a “wheel blade” or rotary cutting blade. The various designs for rotary cutters include differing handle shapes, for ease of use or user preference, with a rotary cutting blade rotatably mounted near one end. Various designs include differing blade guard features which are intended to reduce the potential for injury to a user.
[0003] The rotary cutting blades for such cutters typically come in three standard sizes, a 28 mm diameter rotary cutting blade, a 45 mm diameter rotary cutting blade, and a 60 mm diameter rotary cutting blade. One known problem with rotary cutters is the relatively high replacement cost of the blades for these popular fabric, craft, and hobby cutting tools. Additionally, as noted in the prior art, many rotary cutting blades lack perfect roundness.
[0004] Known sharpeners for rotary cutting blades include sharpeners for the large rotary blades of commercial cutters for meat slicing and the like, which are used with the motor driven blade of the cutter. Also, known are smaller manual sharpeners for hand held rotary cutters, such as those disclosed in U.S. Pat. Nos. 7,238,096, 5,660,582 and 5,499,943, the disclosures of each of which are incorporated by reference herein. However, these types of manual sharpener require the wheel blade to be removed from the cutter and secured within the device, following which the user rotates a portion of the device by hand to rub the cutting edge of the blade against an abrasive grit. This requires a significant effort on the part of the user, which may be problematic for some customers.
[0005] One attempt to address these shortcomings has resulted in the RBS-61 Rotary Cutter Blade Sharpener available from inventive Circles, LLC. However, such sharpener requires a rotary blade to be bolted to in place on an open top, then a rotating; head positioned thereover which rotates an abrasive disk against the blade, rotating the blade. A complete sharpening requires removing and replacing the blade to sharpen both edges twice, once with a “diamond disc”, and once with an “ultrafine disc”. Such a sharpener is relatively bulky and harder to transport. Further, the continual exposure of the rotary blade during sharpening and the additional handling of the blade required to complete sharpening increase the likelihood of injury to a user.
[0006] Accordingly there exists a need for assemblies and devices that address these problems. A system or assembly that allowed for a rotary blade to be honed or sharpened quickly with reduced chance of injury to a user would be an improvement in the art. Such a sharpener that was easily portable and relatively inexpensive would be further improvement in the art.
SUMMARY
[0007] Apparatus, systems and methods in accordance with the present invention are related to sharpening blades for rotary cutters. In one illustrative embodiment, a power sharpener system secures a rotary cutting blade between upper and lower columns that form a rotating axle in contact with upper and lower sharpening stones, each positioned at an appropriate angle to contact a cutting edge of the rotary blade for sharpening. The upper column may be rotatably attached to an upper cover or lid and the lower column rotatably disposed in a base. After the rotary blade is secured, an electric motor is used to rotate the column, contacting the edges of the blade against the stones to simultaneously sharpen both edges of the blade. In some embodiments, a retractable plate may be disposed around the lower column for placement of the rotary blade thereon and a lifting lever may be used to facilitate blade removal.
DESCRIPTION OF THE DRAWINGS
[0008] It will be appreciated by those of ordinary skill in the art that the elements depicted in the various drawings are not necessarily to scale, but are for illustrative purposes only. The nature of the present invention, as well as other embodiments of the present invention may be more clearly understood by reference to the following detailed description of the invention, to the appended claims, and to the several drawings attached hereto.
[0009] FIG. 1 is a perspective view of an illustrative embodiment of a power sharpening system in an open position in accordance with the principles of the present invention.
[0010] FIG. 2 is a front view of the embodiment of FIG. 1 .
[0011] FIG. 3 is a top view of the embodiment of FIG. 1 .
[0012] FIG. 4 is a side view of the embodiment of FIG. 1 .
[0013] FIG. 5 is a front cutaway view of an alternative embodiment of a power sharpening system in accordance with the principles of the present invention.
[0014] FIG. 6 is a side cutaway view of the embodiment of FIG. 5 ,
[0015] FIG. 7 is a front perspective view of another alternative embodiment off portion of a power sharpener with the present invention.
DESCRIPTION
[0016] For the purposes of promoting an understanding of the principles of the invention, reference will now be made to the embodiment illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended, such alterations and further modifications in the illustrated device, and such further applications of the principles of the invention as illustrated therein being contemplated as would normally occur to one skilled in the art to which the invention relates.
[0017] FIGS. 1 through 4 depict a first illustrative embodiment of a power sharpening assembly 10 in accordance with the principles of the present invention. An outer case 100 surrounds and contains the remaining components of the system 10 and includes an upper cap portion 102 which is connected by a hinge H to a lower portion 110 . Upper cap portion 102 may be generally formed as a rounded sidewall and closed top forming an encircled wall having an open bottom. A securing latch L may extend from the sidewall as a protrusion that interacts with a corresponding latch receiver LR on lower portion 110 .
[0018] A number of structures are disposed in the well of upper cap portion 102 . An upper column 122 is rotatably attached to the upper cap portion 102 by a mounting bracket 124 . As depicted, in FIGS. 1 through 4 , the upper column 122 and mounting bracket 124 may comprise an axle and bearing type of structure. Alternatively, as depicted in FIG. 6 , upper column 122 A may be formed as an outer member 622 with a circular planar bottom having encircling sidewall extending at a right angle from the edges thereof to an outer flange 624 , which is disposed on a hub 623 , on which it can be rotated, and protrudes through a hole in the mounting bracket 124 A face, retained thereon by the flange 624 . A circular pad 123 formed of a resilient material, such as a silicone or rubber may be mounted on the face of the upper column 122 for contacting the surface of an inserted rotary blade. It will be appreciated that although depicted as having a rounded cross section, a structure having any cross sectional shape may be used so long as it can be rotated.
[0019] Structures for aligning the upper cap portion 102 with lower portion 110 when the system 10 is closed are also disposed on the upper cap portion 102 and include alignment rods 130 A and 13 AB extending from the closed top of upper cap portion 102 . These rods may be hollow rod, such as rod 130 which has a lower opening (which may be formed by an extension of only a portion of the rod 130 ) Upon closure, alignment rod 130 may receive a corresponding column located within lower portion 110 within its open bore to facilitate accurate alignment of the upper and lower portions. Alternatively, the rod may be a solid protrusion, having a polygonal, rounded, or other cross sectional shape, which is received in a corresponding receiver in the lower portion 110 .
[0020] Additionally, in some embodiments, the alignment rod 130 interaction with a lower column may engage a cut-off switch to complete a circuit that allows the sharpener 10 to be operated, but prevents operation when the sharpener is open. It will be appreciated that in other embodiments, a cutoff switch which completes a circuit that allows the sharpener 10 to be operated, but prevents operation when the sharpener is open, may be constructed in other manners. For example, in FIG. 1 , a closure tab 145 disposed at the rear surface of the sidewall of upper portion 202 presses push bar 206 into recess of the sidewall at the rear of the front section 200 of tower portion 110 , engaging a switch.
[0021] Additional alignment structures may include one or more alignment flanges 132 , formed as extensions of the outer rim of upper cap portion 102 sidewall that reside inside the sidewall of lower portion 110 upon closure. Alignment flanges 132 may encircle a portion of the upper cap portion 102 and may includes one or more notches that correspond to tabs 152 inside the sidewall of lower portion 110 for increased accuracy of alignment. In addition to facilitating alignment, the flanges 132 may contact retractable plate 150 , pushing it downwards and allowing sharpening of an inserted rotary blade to occur, as discussed in further herein.
[0022] Also disposed in the upper cap portion 102 is upper sharpening stone 140 which is removably disposed in upper stone mounting bracket 142 , which may be formed as a portion of mounting bracket 124 . As depicted, upper sharpening stone 140 may be formed as an elongated member having a square cross section that may be placed in the upper stone mounting bracket 142 , as between a fixed end clip at first end and a movable end clip or lever 143 at the opposite longitudinal end, or as in a recess formed by a first wall or clip at a first end together with opposite walls along the long edges thereof and retained therein by an end clip or lever at the second longitudinal end. Upon installation, one side of the stone is exposed towards the open bottom of upper cap portion 102 , at an angle A measured against a plane parallel to the surface of the face of upper column 122 . Angle A, when measured against the general plane of the base may be from about 5 to about 15 degrees, depending on the embodiment. In the depicted embodiment, the angle is at about 11 degrees and corresponds to the angle of the cutting edge of a rotary cutter blade. Upper sharpening stone 140 may be a natural or synthetic stone suitable for sharpening a blade, as known to those of ordinary skill in the art. It will be appreciated that by using an upper sharpening stone 140 with a square cross-section, as the exposed side of the stone is worn down by use, a user may rotate the stone in the mounting bracket 142 (by removing and replacing the stone) to allow all sides of the stone to be equally used.
[0023] It will be appreciated that, as best depicted in FIG. 2 , the upper stone mounting bracket 142 may be disposed on mounting bracket 124 . In other embodiments, upper stone mounting bracket may be independently disposed in the upper cap portion 102 on a separate bracket.
[0024] Lower portion 110 of outer case 100 includes a rounded front portion 200 , which may be generally formed as a rounded sidewall and a closed bottom forming an encircled will having an open top, and a rear portion 202 which may be formed as an enclosed box of a desired shape attached to the front portion 200 . Latch receiver LR may be disposed on the front outer sidewall of front portion 200 for receiving latch L disposed on upper portion to secure the upper and lower portions in a closed position. Hinge H is attached to the rear portion 202 , which may include a recess in the top thereof for receiving hinge H or the rear surface of upper portion 102 when in an open position. An actuation switch, such as button 204 may be disposed in the rear portion 202 , as may be a receiving socket for a power cord.
[0025] A retractable plate 150 is disposed within the open portion of the front section 200 of lower portion 110 . As depicted in FIGS. 1 and 3 , the upper surface of the retractable plate 150 may be formed as a generally planar surface having a series of rounded downward steps of decreasing size. Each step 152 may be formed by a planar circular flat portion with an outer sidewall rise to the adjoining outer step. The spacing between the steps may correspond to the two standard sizes of rotary cutting blades, for handheld rotary cutters, for example the inner step 152 B may hold a 45 mm diameter rotary cutting blade on the flat portion thereof within its encircling sidewall while ringing step 152 A may hold a 60 mm diameter rotary cutting blade on the flat portion thereof within its encircling sidewall. Rotary cutting blades of differing diameters may be placed on the rotary plate 150 on whichever step 152 they fit into or on the retractable plate above the indicated steps, so long as the diameter falls within the coverage of the sharpening stones.
[0026] A lifting lever generally indicated at 160 in FIG. 1 , may be disposed in the retractable plate 150 to facilitate removal of a rotary blade after sharpening. As depicted lifting lever 160 may be formed as a member having a vertical portion 162 near an edge of retractable plate 150 , which is joined to a horizontal portion 164 corresponding to the upper surface of retractable plate ISO. The horizontal portion 164 of lifting lever 160 lies within an opening in the retractable plate 150 and the surface of the horizontal portion may match the upper surface of retractable plate 150 by completing the steps 152 . Lifting lever 160 may be hingedly attached to the retractable plate 150 , as by a hinge pin near the transition of vertical portion 162 and horizontal portion 164 , in order to allow lever 160 to be rotated by pressing the vertical portion 162 forwards and down, thereby raising the horizontal portion 164 to tip and lift a rotary blade disposed thereover.
[0027] As best depicted in cross-sectional views of FIGS. 5 and 6 , system 10 includes a number of features at least partially disposed in the interior of lower portion 110 . A lower column 220 is disposed in a central hole in retractable plate 150 to expose the top surface 222 thereof. As with upper column 122 , a circular pad 223 formed of a resilient material, such as a silicone or rubber may be mounted on the face of the lower column 220 for contacting the surface of an inserted rotary blade. It will be appreciated that although depicted as having a rounded cross section, a structure having any cross sectional shape may be used so long as it can be rotated. In some embodiments, the face of either lower column 220 or upper column 122 may include a projection that pass through the central hole of an inserted rotary blade and enters a corresponding receptacle on the opposite column upon closure to facilitate alignment.
[0028] The top surface 222 of lower column 220 may be disposed coplanar with the top surface of the retractable plate 150 or at a lower point to enable a user to place a rotary blade on the retractable plate. Where a projection ( 228 . FIG. 1 ) is present on the top surface of lower column 220 , it may project past the retractable plate 150 to facilitate alignment.
[0029] From top surface 222 to a junction point 226 underneath the retractable plate 150 , lower column 220 may have a first portion with a relatively thicker cross section that corresponds to the central hole in retractable plate 150 . From junction point 226 to a lower end, the lower column 220 may comprise a shaft having a relatively narrower cross section (in comparison to the upper portion) which may be disposed in a receiver 230 which may comprise a column disposed on the bottom surface of the lower portion 110 that has a bore in which the shaft rotates.
[0030] Extending from the thicker first portion of lower column 220 near junction point 226 is a radial flange 232 which enables the rotation of lower column 220 to be driven. In depicted embodiment, a medial section of the radial flange 232 extends laterally outward from the column 220 and a slanted portion 234 extends upwards at an angle from the medial section. As best depicted in FIG. 5 , the outer surface of the slanted portion 234 may include a series of ridges 236 , which are spaced apart at regular intervals to allow the rotation to be driven. A medial shelf 240 which may include a lower shaped guide portion 242 or a separate shelf and guide may be used to maintain the column 220 in proper position.
[0031] As best depicted in FIG. 6 , an electric motor M having a shaft S is used to drive a gear element G 1 , having a slanted portion G 2 and a series of ridges G 3 that correspond to the slanted portion 234 and spaces between the ridges 236 of the medial flange 232 to rotate the lower column 220 . Presently, some embodiments use a nine volt motor which rotates the column 220 at a speed of approximately 600 RPM, although it will be appreciated that a motor having a different voltage or rotating the column at a different speed may be used, provided such motor and speed are sufficient to sharpen an inserted rotary blade. It will be appreciated that the motor may be provided power through a cord plugged into a receiving socket disposed in the case 100 , which may be attached through a transformer to a standard electrical outlet, or that a suitable battery or battery series may be used as known to those of skill in the art.
[0032] Beneath its generally planar upper surface, retractable plate 150 has support structures that allow it to retract into bottom portion 110 when top portion 102 is closed and elevate when top portion 102 is opened. On either side of the retractable table 150 , a columnar leg 156 may extend downwards from the upper planar member. As depicted each leg 156 may be a hollow column formed from a surrounding sidewall 154 and may have an open or closed bottom. The lower end of each leg 156 is received in a receptacle 250 formed by a wall 252 projecting upwards from the bottom of the bottom portion 110 and the sidewall of the bottom portion 110 . The legs 156 are spaced outwards of the medial flange 230 of the lower column. A resilient member such as a spring may be disposed in the front portion of the bottom portion in contact with the retractable plate to urge the plate to an elevated position when the system 10 is open. For example, in some embodiment, such resilient members may be at least partially disposed in the receptacles 252 to provide an upwards force on the legs 156 .
[0033] Also disposed in the lower portion 110 is lower sharpening stone 340 which is removably disposed in lower stone mounting bracket 342 . Stone opening 157 is present in retractable table 150 and allows retractable table 150 to retract past the lower stone and bracket during operation. As depicted, lower sharpening stone 340 may be formed as an elongated member having a square cross section that may be placed in the upper stone mounting bracket 342 , as between a fixed end clip at first end and a movable end clip or lever 343 at the opposite longitudinal end, or as in a recess formed by a first wall or clip at a first end together with opposite walls along the long edges thereof and retained therein by an end clip or lever at the second longitudinal end. Upon installation, one side of the stone is exposed towards the open upper end of lower portion 110 , at an angle B measured against a plane parallel to the surface of the face of lower column 220 . Angle B, when measured against the general plane of the base may be from about 5 to about 15 degrees, depending on the embodiment. In the depicted embodiment, the angle is at about 11 degrees and corresponds to the angle of the cutting edge of a rotary cutter blade. Lower sharpening stone 340 may be a natural or synthetic stone suitable for sharpening a blade, as known to those of ordinary skill in the art. It will be appreciated that by using an lower sharpening stone 340 with a square cross-section, as the exposed side of the stone is worn clown by use, a user may rotate the stone in the mounting bracket 342 (by removing and replacing the stone) to allow all sides of the stone to be equally used.
[0034] It will be appreciated that upper stone 140 and lower stone 340 may be disposed at any desired angle with respect to one another that facilitates placement in a system 10 in accordance with the present invention. For example, in the embodiment depicted in FIGS. 1 through 4 , the stones are offset from one another in an angle of approximately 90 degrees measured around the rotational axis of the system, while in the embodiment depicted in FIGS. 5 and 6 , the stones are offset from one another in an angle of approximately 180 degrees measured around the rotational axis of the system.
[0035] FIG. 7 depicts an alternative mechanism for a sharpener system in accordance with the present invention which has a rotary blade RB disposed in the axle formed by upper column 722 and lower column 720 , and uses sharpening stones having a circular cross section and planar lower and upper faces. Such stones, 740 and 840 are mounted in mounting brackets 742 and 842 having a circular stone holding portion. In some embodiments of this type, the stones may be rotated by rotation of, or in, the mounting brackets during sharpening in order to obtain even wearing on the top surface of the stone. In other embodiments, a user may manually rotate the stones between sharpening as desired to obtain even wear. In either type of embodiment, the stones may be removed from the mounting brackets and replaced to expose the former lower surface as the new upper surface to allow both planar sides of the stone to be equally used.
[0036] In operation, a user inserts a rotary blade for a hand held rotary cutter which needs to be sharpened into an open system 10 in accordance with the present invention by placing the rotary blade on or over the top surface 22 of the lower column 220 , as by placing the blade on the retractable plate 150 within a suitable step 152 centered over the lower column 220 . The upper portion 102 or cap of the system 10 is then closed, by rotating the upper portion on hinge H and engaging latch L with latch receiver LR. The alignment structures of the upper and lower portions engage to provide a proper alignment that brings the rotational axis of upper column 122 in alignment with that of lower column 220 , as the face of upper column 122 engages the upper surface of the rotary blade. Where present, the retractable plate 150 is retracted as it is pushed downwards by the structures in the upper portion 102 and cutoff switch 206 is engaged to allow the motor M to be engaged.
[0037] The inserted rotary blade is now held in a rotating axle formed by the upper column 122 and lower column 220 and the cutting edge thereof is in contact with the upper and lower sharpening stones, at an appropriate angle for sharpening. The user then actuates button B to engage the motor M, causing the rotating axle to rotate and sharpening the blade. In some embodiments, actuation of the button B engages an automatic cycle, in which the blade is rotated against the stones for a fixed amount of time set in a control circuit to sharpen or hone the blade as desired. For example, a shorter sharpening cycle may be selected, or a longer honing cycle may be used where the cutting edge is nicked or the blade has strayed from the ideal planar shape to an unsuitable degree. In other embodiments, the button may simply engage the motor while pressed allowing the user individual control over the process.
[0038] After the sharpening process is complete, the user opens the system 10 by releasing latch L from latch receiver LR and rotating top portion 102 upwards. Lifting lever 160 may then be used to tip up the exposed rotary blade for removal from the system 10 and replacement in a hand held rotary cutter.
[0039] While the present invention has been shown and described in terms of preferred embodiments thereof, it will be understood that this invention is not limited to any particular embodiment and that changes and modifications may be made without departing from the true spirit and scope of the invention as defined and desired to be protected.
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Apparatus, systems and methods related to sharpening blades for rotary cutters. In one illustrative embodiment, a power sharpener system secures a rotary cutting blade between upper and lower columns that form a rotating axle in contact with upper and lower sharpening stones, each positioned at an appropriate angle to contact a cutting edges of the rotary blade for sharpening. The upper column may be rotatably attached to an upper cover or lid and the lower column rotatably disposed in a base. After the rotary blade is secured, an electric motor is used to rotate the column, contacting the edges of the blade against the stones to simultaneously sharpen both edges of the blade. In some embodiments, a retractable plate may be disposed around the lower column for placement of the rotary blade thereon and a lifting lever may be used to facilitate blade removal.
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This is a continuation of application Ser. No. 108,573 filed Dec. 31, 1979, now abandoned, which is a continuation of application Ser. No. 919,123 filed June 26, 1978, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to high protein, microbiologically stable, intermediate moisture food products in chunk form which are particularly useful as a pet or animal food.
2. Description of the Prior Art
Pet food products in general are divided into three general classes. They include the so-called dry pet food products, usually in meal or granular form which contain less than 15% moisture, most commonly about 10% moisture. The dry products are packaged and stored in bags and are resistant to spoilage if kept dry.
The high moisture products containing 65-75% moisture are generally sold as canned products and require retorting (cooking) in the canning operation to prevent spoilage.
The more recent intermediate moisture food products are those which contain between about 15 and 45% moisture. These products are in general stabilized by the use of soluble additives to produce a water activity (A w ) sufficient to prevent bacteriological growth and consequent spoilage of the food products when packaged in moisture impermeable, flexible bags or wrappings. The bacterial growth and consequent product spoilage is precluded by additives such as sugar or low molecular weight polyhydroxy alcohols, including, for example, propylene glycol and glycerol. While the use of these soluble additives is effective to control conventional bacteriological growth, it is also necessary to control fungi, yeast and mold which can proliferate on systems which have been stabilized against bacteriological attack. The control of such molds, yeast and fungi is achieved by the addition of an antimycotic agent such as, for example, potassium sorbate, or the like.
Patents relating to the use of sugar stabilizers and antimycotic agents for intermediate moisture pet foods include Burgess et al., U.S. Pat. No. 3,202,541, No. 3,482,985, No. 3,615,652; Buck et al., U.S. Pat. No. 3,653,908, No. 3,489,574 and No. 3,516,838. Zukerman, U.S. Pat. No. 4,022,915, describes an intermediate moisture food product stabilized by the use of 5 to 15% polyhydroxy alcohol. The Zukerman method involves the hot processing and expansion of a mixture of cooked farinaceous and proteinaceous materials admixed with polyhydroxy alcohol and extruded under pressure to produce a low bulk density product which is formed into chunks, coated with fat and packaged.
SUMMARY OF THE INVENTION
The present invention relates to an improved method of preparing an intermediate moisture, proteinaceous food product preferably having a moisture content of from about 25 to 35% (by weight), water activity (A w ) of from about 0.75 to 0.85, characterized by microbiological stability under ordinary shelf storage conditions, more particularly when packaged in essentially moisture impermeable, flexible packaging such as plastic (polyethylene) bags or coated transparent plastic film packaging.
More particularly, the invention relates to a method for preparing a microbiologically shelf stable, extruded proteinaceous food product having a moisture content of between about 25 and 35% by weight and a water activity (A w ) of between about 0.75 and 0.85 which comprises:
(a) cooking a slurry of water, meat, fat, salt, antimycotic agents and a polyhydroxy alcohol at a temperature of at least 185° F. for a period of at least 15 minutes to pasteurize the admixture and form a homogeneous, pumpable admixture;
(b) cooling the admixture to less than about 100° F.;
(c) adding the cooled slurry to a dry admixture of particulate proteinaceous vegetable material and cereal grain material components and blending the same to produce a homogeneous blend containing between about 25 and 35% by weight moisture at a temperature below about 100° F.;
(d) extruding the blended product through a die of predetermined diameter and comminuting the extruded stream of blended product into chunks of predetermined size and shape;
(e) coating the chunks of extruded product with an aqueous solution of vegetable gum and antimycotic agent; and
(f) passing the coated chunks through a drying zone to dry the applied coating to a shiny finish.
The product is characterized by having a total protein content of from about 15 to 35 weight percent, preferably from 20 to 30 weight percent. The protein component of the product is derived from both animal and vegetable sources. Animal or "meat protein" sources include meats or meat by-products and includes poultry and fish.
The vegetable protein source components includes proteinaceous oil seed vegetable materials of a high protein content, including from that known group, soybean derived materials such as soy flour (full fat or defatted), defatted or full fat dehulled soya grits, peanut meal, cottonseed meals and rapeseed meals or the like. These vegetable proteins, in addition to the protein component, contain a sizable amount of carbohydrate. The vegetable protein components are preferably in a partially processed particulate form, i.e., grits, flakes, flours or small chunks. Textured vegetable proteins are also usable. The vegetable protein component used should be essentially free of adventitious contamination (i.e., bacteria, etc.) since it is blended into the product after the pasteurization step which is applied only to the meat slurry. Protein concentrates or isolates which are derived from vegetable proteins may also be used to supplement or replace a minor part (i.e., 10% or less) of the proteins listed above. Since these concentrates are frequently in a liquid or semi-liquid form and have a great part of their naturally occuring carbohydrate and fiber component removed, they are a more concentrated source of protein, but their processing results in a product having less body. Accordingly, the natural solid meat or vegetable protein materials are preferred in this invention since they provide firmness and integrity to the product. Toasted soya grits such as defatted and dehulled flakes or grits (40/80 mesh) which are relatively free from bacterial contamination are particularly preferred. These soya grits generally contain about 50% protein (dry basis) and about 10% moisture and the balance carbohydrate. Vegetable proteins are preferably used to provide up to 85-95% of the protein in the final product.
Partially textured vegetable protein materials such as those produced by the Levinson process described in U.S. Pat. No. 2,162,729 and sold by the H. B. Taylor Division of National Can Corporation under the name TEXTRASOY are particularly useful. Another useful product described by Levinson and Basa in U.S. Pat. No. 3,966,977 is a textured vegetable protein material which has an enhanced protein content, the texture and mouth feel of meat and contains polyhydroxy alcohol stabilizers in a soft, relatively high moisture product.
The fats or oil components of the product made herein may be of animal or vegetable origin such as lard, corn oil or the like, and in part contributed by the meat. Fat is present in amounts of from about 3-10%.
The product contains carbohydrates in amounts of from 20 to 40%, preferably 25 to 35%, by weight. The carbohydrates include sugar, which has the dual function of acting as a nutrient carbohydrate, as well as a preservative. The carbohydrates as starch are as a part of the vegetable protein material (soya grits) and in part by the cereal grain component. The cereal grain components are preferably partially processed materials such as rolled or cracked grains which have been heat treated, i.e., toasted. Particularly useful are breakfast cereal by-products or waste fines from the manufacture of breakfast cereals. They are usually derived from corn, wheat, rice or oats and often contain as much as 15 to 20% by weight of sugar, as well as starch. While sugar is useful as a stabilizer for the semi-moist compositions of this invention, the use of sugar as such should be limited in the diet of pets. Thus, the sugar employed is preferably in amounts from 2% up to, but less than 10%, preferably 2% to 6% by weight, and preferably less than the amount of polyhydroxy alcohol used as a bacteriostatic preservative.
The polyhydroxy alcohols employed to prevent bacterial growth are used in amounts of from 5 to 15%, preferably 5 to 10%. The stability of the product is measured in terms of water activity (A w ) and generally products which have an A w of 0.75 to 0.85 are sufficiently stable for shelf storage without canning or refrigeration. The total water activity is the composite effect obtained from solubles such as polyhydroxy alcohols, sugars such as sucrose, and salt. The preferred polyhydroxy alcohols are edible, food grade materials such as propylene glycol, glycerol, sorbitol or the like. As noted above, sugars may be used in lieu of a portion of the polyhydroxy alcohol, i.e., less than half.
Antimycotic agents are employed to control and prevent the growth of yeast, mold or fungus on or in the stabilized products. Stabilization of the product with sugars and/or polyhydroxy alcohols while adequate to prevent bacterial attack, must be supplemented with antimycotic or antifungal materials such as potassium sorbate or calcium propionate in amounts of from about 0.1 to about 0.2 or 0.4, or more, by weight of product.
The products of the present invention are extruded through a die but are generally of normal density, i.e., not expanded or popped. The extrudate emerging in a continuous stream from the extrusion die head is cut into segments of predetermined length (i.e., 1/2 to 1 inch). These chunk forms, however, while having adequate integrity for handling and processing as stabilized, finished products, are preferably further treated in accord with the process of the present invention to provide a coating on the chunks which acts to improve their integrity and appearance. The coating applied is an aqueous vegetable gum solution, preferably of gum arabic (acacia), although other gums may be used, such as locust bean gum, or the like. The applied gum coating provides the chunk products with a shiny barrier coat which not only helps to prevent crumbing of the surface, but also aids in holding the chunks together and to maintain the initial predetermined moisture level in the chunks. The gum solution at 5-10% solids is heated to 165°-180° before application and contains a small amount of antimycotic agent (0.2 to 0.3%) to inhibit surface growth of mold or yeasts.
The gum coating may be applied by a variety of means including spraying or pan coating and tumbling to provide an even coating over essentially the entire surface of the chunks. The coating contributes 4 to 6% of the chunk weight.
After coating with the gum solution, the chunks are dried in an oven, preferably on a belt which passes through a gas fired, forced hot air circulating oven for a time and at a temperature sufficient to drive off the water component of the coating. When dry, the chunks have a shiny appearance, are not tacky to the touch, do not adhere together, and are essentially at ambient room temperature or a little above.
The dried coated chunks are then packaged in flexible packaging materials such as bags made of polyethylene film or coated cellophane or multi-ply laminated papers or bags. The flexible packaging materials are preferably relatively moisture impermeable and thus maintain the predetermined moisture content of the product which is required for the desired soft texture. The packaged products are shelf stable or, more particularly, are microbiologically stable and do not support bacterial or yeast, mold or fungal growth even after the package is opened. The coating is particularly useful in that it acts as a barrier coat which helps to prevent the chunks from drying out or absorbing atmospheric moisture when the package is opened at the time of use or the bag is imperfectly sealed.
While the herein described products are essentially neutral, i.e., a pH of 6-8, the pH of the product may be adjusted for a cat food to a pH in the range of 5 to 6 by the addition of food grade acids such as phosphoric or acetic acids.
BRIEF DESCRIPTION OF THE DRAWINGS
Reference is made to the attached drawing wherein a flow sheet of the method described herein is illustrated schematically by a series of block diagrams representing various processing zones. The steps (zones) illustrated include:
1. Meat slurry preparation zone.
2. Meat pre-cooker and pasteurization zone.
3. Intermediate meat slurry cooling zone.
4. Mixer and dry addition (cereals and vegetable protein) zone.
5. Extrusion zone.
6. Gum coating application zone.
7. Drying zone.
8. Packaging zone.
The first processing step involves the formation of a "meat slurry", namely, mixing meat or meat by-products with polyhydroxy alcohols and other solubles and minor ingredients, including flavors, colors, salt, antimycotics, vitamins, fats and the like with water. The objective is to provide thorough mixing as well as penetration of stabilizing solubles into the meat component which, by experience, is the most susceptible to spoilage by virtue of normal contamination with bacteria.
The blended slurry is then, or simultaneously with mixing, heated in a "pre-cooker" zone (which may be the same vessel), with agitation, to pasteurizing temperatures above 185° F., preferably 185°-195° F. for a period sufficient to effect pasteurization, i.e., 15 to 20 or 25 minutes. The final pasteurized hot product in a pumpable, liquid slurry form, i.e., 40-60% free liquid (50-70% total moisture) is pumped to a cooling zone and permitted to cool to ambient conditions, i.e., generally less than 100° F., preferably 50°-70° F.
A mixture of comminuted vegetable protein materials such as toasted soya grits is blended together with the particulate cereal products, i.e., breakfast cereal fines, and the cooled, pasteurized meat slurry is added to the dried particulate blend and further mixed to form a homogeneous admixture having a moisture content of 25 to 35%, preferably 25-32% moisture at temperatures of 50°-75° F.
The homogeneous mixture is then passed to an extrusion zone and forced through an extrusion die to form an extrudate stream of the desired dimensions, such as about 1/2 to 1 inch diameter. The temperature may rise slightly in the extrusion step, i.e., from 70°-75° F. to 80° or 85° F., but there is no heat applied to the mix during extrusion, there is no expansion of the product as it emerges from the die, and the product is of the normal density of its components. As the extrudate emerges from the die, it is cut into convenient lengths by a rotary knife so that discrete chunks of about 1/2 to 3/4 inch "diameter" are obtained. The die orifice can be circular, but other shapes such as cross, oval, square, may be used.
The chunks of extrudate are then further processed by gum coating, drying and packaging as described above.
For a more complete understanding of the present invention, reference is made to the following specific embodiments.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
EXAMPLE 1
1. Meat Slurry Preparation
a. Cooking
The following ingredients are mixed in a 250 gallon, round bottom, steam-jacketed stainless steel cooking kettle, equipped with a Lightening mixer and an automatic, temperature controller.
______________________________________Ingredients Pounds % Slurry % Total______________________________________1. Water 218 38.93 18.002. Meats (By-Products) 125 22.32 10.333. Propylene Glycol 100 17.86 8.264. Animal Fat (or Veg. Oil) 75 13.40 6.205. Iodized Salt 12 2.14 1.006. Caramel Color 101/2 1.88 .867. Defluorinated Phosphate.sup.(1) 6 1.07 .508. Iron Oxide (Red) 21/2 0.45 .219. Potassium Sorbate 2 0.36 .1710. Calcium Propionate 2 0.36 .1711. Beef Flavoring 2 0.36 .1712. Liquid Smoke 2 0.36 .1713. Vitamin Premix 21/2 0.45 .2114. Titanium Dioxide 1/2 0.09 .04 TOTAL SLURRY 560 lbs. 100% 46.29%______________________________________ .sup.(1) A calcium phosphate. Mono or dicalcium phosphate may be used as source of calcium and phosphorus.
The above meat slurry is cooked and pasteurized with continuous agitation at temperatures between 185° and 195° F., from between about 15 and 25 minutes.
b. Cooling
The hot pasteurized meat slurry is then pumped from the kettle to a cooling station where the temperature drops to between about 50° to 70° or 75° C. (room temperature).
2. Dry Mix
The following dry ingredients are dry blended in a Baker-Perkins mixer of about 1500 to 1800 pound capacity.
______________________________________Ingredients Pounds % Dry % Total______________________________________1. Toasted Soy Grits, 40/80 Mesh 400 61.54 33.052. Toasted Cereals* (Cereal By- Products) 250 38.46 20.66 TOTAL DRY MIX 650 lbs. 100% 53.71______________________________________ *Toasted cereals or bakery byproducts chiefly corn and wheat containing 1 to 20% sugar.
3. Total Batch Preparation
a. The cool meat slurry is pumped over the dry mix in the Baker-Perkins mixer and the entire mixer contents are thoroughly mixed together for between about 15 and 20 minutes to produce a homogeneous blend containing between about 25 and 32% by weight moisture at a temperature of about between 50° and 75° F. The total mix weight was 1210 lbs.
4. Extrusion
The batch of the blended admixture is passed into a compression and an extrusion chamber of a Bonnot Extruder and through a 1/2 inch die. The extrudate is cut into 3/8-5/8 inch lengths by a rotary knife placed at the die face. The extruded product contains between 25 and 32% moisture at a temperature between about 65° and 75° F.
5. External Gum Application
A 10% aqueous gum acacia solution containing from 0.20 and 0.30% potassium sorbate as a mold inhibitor is heated to about between 160° and 180° F. and is sprayed on the surfaces of the chunks of extruded product at a rate of about between 2 and 4% of the finished product. The chunks are tumbled during spraying to provide an even coating.
The application of gum acacia solution to the surface of the chunks of extruded product provides a very thin, uniform external film after drying. The external film:
a. improves the product integrity and minimizes the fines generated in handling;
b. retards moisture migration from inside the chunk to the surrounding space inside the package;
c. contributes a shiny and more meaty appearance to the product; and
d. produces a desired meat-like product texture.
6. Drying Process
Immediately after the application of the gum coating, the product is passed through a drying zone (70°-80° F.) to dry the coating and form an external film. The product temperature after the drying step is still essentially at ambient room temperature.
7. After drying the product is ready for packaging in sealed, plastic (polyethylene film) bags
The final food product has a moisture content of about 31%; protein, 22%; fat, 8.3%; propylene glycol, 8.3%; sugar, 3.6%; and carbohydrate (total), 29%.
EXAMPLE 2
1. Meat Slurry Preparation
a. Cooking
The following ingredients are mixed in a 250 gallon, round bottom, steam-jacketed stainless steel cooking kettle, equipped with a Lightening mixer and an automatic temperature controller.
______________________________________Ingredients Pounds % Slurry % Total______________________________________1. Water 100 16.89 7.902. Meats (By-Products) 300 50.68 23.703. Propylene Glycol 100 16.89 7.904. Animal Fat (or Veg. Oil) 50 8.45 3.955. Iodized Salt 13 2.20 1.036. Caramel Color 10 1.69 .797. Defluorinated Calcium Phosphate 6 1.01 .508. Iron Oxide (Red) 21/2 0.42 .209. Potassium Sorbate 2 0.34 .1610. Calcium Propionate 2 0.34 .1611. Beef Flavoring 2 0.34 .1612. Liquid Smoke Flavor 2 0.34 .1613. Vitamin Premix 2 0.34 .1614. Titanium Dioxide 1/2 0.08 .04 TOTAL SLURRY 592 100% 46.72______________________________________
The above meat slurry is cooked and pasteurized with continuous agitation at temperatures between 185° and 195° F. from between about 15 and 25 minutes.
b. Cooling
The hot pasteurized meat slurry is then pumped from the kettle to a cooling station where the temperature is permitted to fall to between about to to 70° or 75° F.
2. Dry Mix
The following dry ingredients are dry blended in a Baker-Perkins mixer of about 1500 to 1800 pound capacity.
______________________________________Ingredients Pounds % (Dry) % (Total)______________________________________1. Toasted Soy Grits, 40/80 Mesh 300 44.44 23.682. Toasted Cereals* (Bakery By- Products) 375 55.56 29.59 TOTAL DRY MIX 675 100% 53.27______________________________________ *Toasted cereals/bakery byproducts contain 15-20% sugar.
3. Total Batch Preparation
The cool meat slurry is pumped over the dry mix in the Baker-Perkins mixer and the entire mixer contents are thoroughly mixed together for between about 15 and 20 minutes to produce a homogeneous blend containing between about 25 and 32% by weight moisture at a temperature of about between 50° and 75° F. (Total weight approximately 1267 lbs.)
4. Extrusion
The batch of the blended admixture is passed into a compression and an extrusion chamber of a Bonnot Extruder and through a 1/2 inch die. The extrudate is cut into 3/8-5/8 inch lengths by a rotary knife placed at the die face. The extruded product contains between 25 and 32% moisture at a temperature between about 65° and 75° F.
5. External Gum Application
A 10% aqueous gum acacia solution containing from 0.20 and 0.30% potassium sorbate as a mold inhibitor is heated to about between 160° and 180° F. and is sprayed on the surfaces of the chunks of extruded product at a rate of about between 2 and 4% of the finished product. The chunks are tumbled during spraying to provide an even coating.
The application of gum acacia solution to the surface of the chunks of extruded product provides a very thin, uniform external film after drying.
6. Drying Process
Immediately after the application of the gum coating, the product is passed through a drying zone (70°-80° F.) to dry the coating and form an external film. The product temperature after the drying step is still essentially at ambient room temperature.
7. After drying the product is ready for packaging in sealed, plastic (polyethylene film) bags
The final food product has a moisture content of about 30%; protein, 21%; fat, 8%, propylene glycol, 8%; sugar, 5.3%, carbohydrate (total) 31%.
The packaged product of Example 2 was held on shelf-storage (room temperature) for about 11/2 years and then tested to determine the condition of the product insofar as stability (microbiological) was concerned. The following results were obtained:
______________________________________Total Plate Count: 7300/gramYeast, Mold andFungi Count: <10/gramMoisture Content: 33.2%Water Activity (A.sub.w): 0.85______________________________________
From the foregoing, it was concluded that the product of the process has excellent long-term shelf stability from a microbiological viewpoint.
EXAMPLE 3
1. Meat Slurry Preparation
a. Cooking
The following ingredients are mixed in a 250 gallon, round bottom, steam-jacketed stainless steel cooking kettle, equipped with a Lightening mixer and an automatic temperature controller.
______________________________________ % (Of TotalIngredients Pounds Products)______________________________________1. Water 218 18.022. Meats (By-Products) 125 10.333. Propylene Glycol 100 8.264. Animal Fat (or Veg. Oil) 75 6.205. Iodized Salt 12 0.996. Caramel Color 10 0.837. Defluorinated CalciumPhosphate 6 0.058. Iron Oxide (Red) 21/2 0.219. Potassium Sorbate 2 0.1710. Calcium Propionate 2 0.1711. Beef Flavoring 11/2 0.1212. Liquid Smoke Flavor 3 0.2513. Vitamin Premix 21/2 0.2114. Titanium Dioxide 1/2 0.04TOTAL SLURRY 560 lbs. 46.28%______________________________________
The above meat slurry is cooked and pasteurized with continuous agitation at temperatures between 185° and 195° F. from between about 15 and 25 minutes.
b. Cooling
The hot pasteurized meat slurry is then pumped from the kettle to a cooling station where the temperature is permitted to fall to between about 50° and 70° or 75° F.
2. Dry Mix
The following dry ingredients are dry blended in a Baker-Perkins mixer of about 1500 to 1800 pound capacity.
______________________________________Ingredients Pounds %______________________________________1. Toasted Soy Grits 500 41.322. Cereal By-Products (15-20% sugar) 150 12.40 Total Dry Mix 650 53.72 Total Meat Slurry 560 46.28 Total Batch 1210 Lbs. 100%______________________________________
3. Total Batch Preparation
The cool meat slurry is pumped over the dry mix in the Baker-Perkins mixer and the entire mixer contents are thoroughly mixed together for between about 15 and 20 minutes to produce a homogeneous blend containing between about 25 and 32% by weight moisture at a temperature of about between 50° and 75° F.
4. Extrusion
The batch of the blended admixture is passed into a compression and an extrusion chamber of a Bonnot Extruder and through a 1/2 inch die. The extrudate is cut into 3/8-5/8 inch lengths by a rotary knife placed at the die face. The extruded product contains between 25 and 32 percent moisture at a temperature between about 65° and 75° F.
5. External Gum Application
A 10% aqueous gum acacia solution containing from 0.2 and 0.3% potassium sorbate as a mold inhibitor is heated to about between 160° and 180° F. and is sprayed on the surfaces of the chunks of extruded product at a rate of about between 2 and 4% of the finished product. The chunks are tumbled during spraying to provide an even coating.
The application of gum acacia solution to the surface of the chunks of extruded product provides a very thin, uniform external film after drying.
6. Drying Process
Immediately after the application of the gum coating, the product is passed through a drying zone (70°-80° F.) to dry the coating and form an external film. The product temperature after the drying step is still essentially at ambient room temperature.
7. Packaging
After drying, the product is ready for packaging in sealed, plastic (polyethylene film) bags.
The final coated food product after drying contained about 31% moisture; protein, 29%; fat, 8.3%, propylene glycol, 8.3%; sugar, 2.1%; and carbohydrate (including sugar), 25%.
EXAMPLE 4
1. Meat Slurry Preparation
a. Cooking
The following ingredients are mixed in a 250 gallon, round bottom, steam-jacketed stainless steel cooking kettle, equipped with a Lightening mixer and an Automatic temperature controller.
______________________________________ % (TotalIngredients Pounds Product)______________________________________1. Water 100 7.892. Meats (By-Products) 300 23.683. Propylene Glycol 100 7.894. Animal Fat (or Veg. Oil) 50 3.955. Iodized Salt 12 0.956. Caramel Color 10 0.797. Defluorinated Calcium Phosphate 6 0.478. Iron Oxide (Red) 21/2 0.209. Potassium Sorbate 2 0.1610. Calcium Propionate 2 0.1611. Beef Flavoring 1 0.0812. Liquid Smoke Flavor 4 0.3213. Vitamin Premix 2 0.1614. Titanium Dioxide 1/2 0.04 Total Slurry 592 Lbs. 46.72%______________________________________
The above meat slurry is cooked and pasteurized with continuous agitation at temperatures between 185° and 195° F. from between about 15 and 25 minutes.
b. Cooling
The hot pasteurized meat slurry is then pumped from the kettle to a cooling station where the temperature is permitted to fall to between about 50° and 70° to 75° F.
2. Dry Mix
The following dry ingredients are dry blended in a Baker-Perkins mixer of about 1500 to 1800 pound capacity.
______________________________________Ingredients Pounds %______________________________________1. Toasted Soy Grits 450 35.522. Cereal By-Products (15-20% sugar) 225 17.76 Total Dry Mix 675 53.28 Total Meat Slurry 582 46.72 Total Batch 1267 lbs. 100%______________________________________
3. Total Batch Preparation
The cool meat slurry is pumped over the dry mix in the Baker-Perkins mixer and the entire mixer contents are thoroughly mixed together for between about 15 and 20 minutes to produce a homogeneous blend containing between about 25 and 32% by weight moisture at a temperature of about between 50° and 75° F.
4. Extrusion
The batch of the blended admixture is passed into a compression and an extrusion chamber of a Bonnot Extruder and through a 1/2 inch die. The extrudate is cut into 3/8-5/8 inch lengths by a rotary knife placed at the die face. The extruded product contains between 25 and 32 percent moisture at a temperature between about 65° and 75° F.
5. External Gum Application
A 10% aqueous gum acacia solution containing from 0.20 and 0.30 percent potassium sorbate as a mold inhibitor is heated to about between 160° and 180° F. and is sprayed on the surfaces of the chunks of extruded product at a rate of about between 2 and 4% of the finished product. The chunks are tumbled during spraying to provide an even coating.
The application of gum acacia solution to the surface of the chunks of extruded product provides a very thin, uniform external film after drying.
6. Drying Process
Immediately after the application of the gum coating, the product is passed through a drying zone (70°-80° F.) to dry the coating and form an external film. The product temperature after the drying step is still essentially at ambient room temperature.
7. Packaging
After drying, the product is ready for packaging in sealed, plastic (polyethylene film) bags.
The coated product after drying contained about 30% moisture; protein, 28%; fat, 8%; propylene glycol, 8%; sugar, 3%; carbohydrate (total), 28%.
While the foregoing examples illustrate certain preferred embodiments of the process of the present invention, it is also to be understood that other modifications and variations in the method may be employed without departing from the basic scope and concept thereof. For example, as noted above, the required bacteriostasis is provided predominantly by the polyhydroxy alcohol and sugar components. It is known that either sugar or polyhydroxy alcohol may be used as bacteriostatic agents, however, it is preferred that when sugar is employed as a bacteriostatic agent that it is in a minor amount with respect to the total of bacteriostatic agent, i.e., the aggregate of polyhydroxy alcohol and sugar. The reduction of sugar results in a product which has minimal dietary tooth decay risk for pets.
The product of the process described herein, as noted above, has a normal bulk density and is not expanded or puffed during the extrusion process but is, nonetheless, soft and easily masticated by the pet and therefore appetizing and appealing.
The vegetable gum coating applied to the chunks not only enhances the appearance of the product but, in addition, provides a barrier coat which essentially stabilizes the moisture content of the individual chunks in the package to maintain the desired plasticity and softness of the chunk after the package is opened. The barrier coat also, by virtue of its containing a small amount of antimycotic, minimizes the possibility of mold or fungus growth on the surface of the chunks after they are exposed to the atmosphere or inadvertently exposed to mold spores during the packaging operations. Finally, the vegetable gum coating maintains the integrity of the individual chunks, minimizing either an agglomeration of the chunks in the package and minimizing granulation, breakage or the like of the chunks in the package during handling and prior to use by the consumer.
As noted above, the only pasteurization that is employed is with respect to the "meat slurry" which is both pasteurized and treated with the polyhydroxy alcohol and the antimycotic agents. The pasteurized meat slurry is admixed with the dry components, i.e., vegetable protein and cereal products to form a homogeneous blended product prior to extrusion. The dry blended materials are not pasteurized as such since they are incorporated after the pasteurization step and are not subjected to pasteurizing temperatures in the extrusion step. The bacteriostatic agents in the slurry are physically blended into the dry mix and by virtue of their migration into the dry mix particles extend their bacteriostatic effect to the added dry materials. Since the physical mixing is carried out in a relatively short period, the penetration of the liquids carrying the bacteriostatic agents into the dry particles of the cereal and vegetable protein component is probably not complete when the product is extruded, formed into chunks and coated. This is especially significant when the dry particulate components are hard materials that have been processed in such a way that surface bacteria are occluded within the particles during previous processing. However, the chunks when formed and coated undergo further migration of moisture and bacteriostatic agents until an equilibrium is established within each chunk and by virtue of the complete migration of bacteriostatic agents uniformly throughout the chunks, a chunk with satisfactory shelf storage properties is provided which does not require refrigeration or special packing (canning) to prevent spoilage.
In the production of intermediate moisture food products, cooking or pasteurization is customarily carried out to reduce existing bacterial populations and the bacteriostatic agents used preclude growth of residual and other adventitious contact or air borne bacteria as result from further processing.
The initial contamination of the starting materials depends in large part on their previous history. Thus, meat scraps and meat by-products are usually highly contaminated, but toasted cereal and vegetable proteins with a moisture content of 10-12% maximum have only minimal bacterial contamination. Accordingly, it has been found that it is not required that the cereal grain and vegetable protein materials be pasteurized to achieve a storage stable product, thereby resulting in a substantial savings in processing and energy costs in the production of an entirely satisfactory and acceptable product which is an important object of this invention.
Unless otherwise indicated, all percentages expressed herein are percentages by weight.
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A method of producing an extruded, microbiologically stable, intermediate moisture food product having a moisture content between about 25 and 35% by weight, a protein content between about 15 and 35% by weight, an antimycotic agent and a water activity (A w ) between about 0.75 and 0.85, which has an extended shelf life when stored in moisture-proof packages and does not require hermetic packaging or refrigeration.
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CROSS REFERENCE AND PRIORITY
Priority Paragraph
[0001] This patent application is a U.S. National Phase of International Patent Application No. PCT/AT2015/050068, filed Mar. 17, 2015, which claims priority to Austrian Patent Application No. A 263/2014, filed 7 Apr. 2014, the disclosure of which are incorporated herein by reference in their entirety.
FIELD
[0002] Disclosed embodiments relate to a movable footboard for the doors of vehicles, in particular of rail carriages.
BACKGROUND
[0003] Rail carriages are intended in the description and the claims to be understood to be all rail-bound vehicles for passenger transport whether these be trams, underground trains, high-speed trains, local trains or passenger trains. Disclosed embodiments is intended in particular for such applications but can also advantageously be used with other vehicle doors.
[0004] With such vehicles, there is in many cases a problem that, when stopping in a station, there is between the floor, actually the so-called footrail, which constitutes the door-side end region thereof, on the one hand, and the platform, on the other hand, a gap in a horizontal direction and in many cases also a height difference. Various proposals have already been submitted for providing bridges for this gap either together with the opening of the door or independently thereof, but all these attempts involve different disadvantages and there inevitably also remains after a footboard has been extended a height difference between the upper floor edge of the carriage and the adjacent upper footboard edge.
[0005] Another type of bridging comprises a so-called ramp which is always extended by the same length, comes to rest with the front thereof on the platform and is then raised with the carriage-side end until a consistent level is produced. The great disadvantage lies in the dangers which arise during the pushing-out action over the platform and in some cases also in the contact region with the tread step.
[0006] A lowering or pivoting of the footrail onto the extended footboard has also been proposed, but as a result of the structural height of the footrail there is no actual balancing of the levels in this instance and in this instance the risk of jamming on the one hand and disruption as a result of contamination on the other hand is too great to permit general use or even implementation.
SUMMARY
[0007] Disclosed embodiments may solve or at least reduce this problem, consequently to provide an extendable footboard in which in the extended state ready for operation, even with different extension extents, the height difference between the upper floor edge (footrail) and the upper footboard edge is significantly reduced or eliminated.
[0008] Disclosed embodiments, by the measures and features set out herein, for example, the footboard has on the surface thereof accessible or passable elements which can be raised, thus reduce or eliminate the height difference.
BRIEF DESCRIPTION OF FIGURES
[0009] Disclosed embodiments is explained in greater detail below with reference to the drawings, in which:
[0010] FIG. 1 shows a footboard according to Disclosed embodiments in a partially extended position,
[0011] FIG. 2 shows the footboard in a raised position ready for use,
[0012] FIG. 3 shows the situation of FIG. 2 in a variant,
[0013] FIG. 4 is a bottom view of a footboard according to Disclosed embodiments,
[0014] FIG. 5 shows a first variant of the lifting mechanism,
[0015] FIGS. 6 and 7 show variants of the lifting mechanism as views similar to FIG. 5 in three different positions,
[0016] FIG. 8 shows an embodiment of Disclosed embodiments, and
[0017] FIGS. 9 and 10 show two details, and
[0018] FIG. 11 shows another detail.
DETAILED DESCRIPTION
[0019] A footboard which is generally designated 1 is arranged below a footrail 2 of a carriage body which is not otherwise illustrated in greater detail in the door region. The footboard 1 can be displaced in a substantially horizontal direction transversely relative to the travel direction parallel with the double-headed arrow 3 . The displacement is carried out between a completely retracted position in which the footboard 1 does not protrude beyond the clearance profile and an extended position in which the footboard 1 is moved as close to a platform 4 as is technically possible. FIG. 1 shows an intermediate position of the footboard 1 and there can clearly be seen the height differences between the upper floor edge 5 , the surface 6 of the footboard 1 and the upper platform edge 7 .
[0020] FIG. 2 shows the situation in the state ready for operation in a view similar to that of FIG. 1 : the footboard 1 is in the extension direction of the arrow 3 extended so far that as many of the movable transverse profiles 8 - 12 thereof as possible can be lifted in the manner shown. The mechanism by means of which the lifting is carried out is explained in greater detail below.
[0021] The illustrated position of FIG. 2 shows that, when the footboard 1 is further pushed out, only a portion of the transverse profile 11 would protrude below the footrail 2 so that it would not be possible to lift the transverse profile 11 . For this reason, the pushing-out action terminates in the illustrated position, under some circumstances slightly further out, in order to divide the remaining gap 13 over two regions in an appropriate manner in accordance with the prevailing philosophy of the rail operator or the legal situation or the standards which can be applied.
[0022] As a result of the lifting of the transverse profiles 8 , 9 and 10 in the form of a pivot movement, it is possible for the accessible face which is formed by the transverse profiles to be continued in the region of the upper floor edge 5 without any height offset. This is particularly important and advantageous for access to this face, for use with wheelchairs, pushchairs, and the like.
[0023] The remaining gap 13 is always smaller than the length of the transverse profiles in the pushing-out direction and consequently negligibly small in comparison with current solutions.
[0024] FIG. 3 shows a variant of FIG. 2 in which the footboard 1 is arranged so as to be able to be adjusted in terms of height, for example, so as to be able to be pivoted as illustrated, whereby the height difference 14 between the end of the transverse profile 8 and the upper platform edge 7 can be reduced or eliminated. The horizontal line 15 represents this in a striking manner.
[0025] FIG. 4 is a bottom view of the footboard 1 from which the construction is clearly evident. At the free end of two longitudinal struts 17 , the foremost transverse profile 8 is secured so as to be able to be pivoted about a longitudinal axis 16 which is at least substantially parallel with the travel direction. Below the transverse profile 8 there protrudes a pair of pivot struts 18 , which are also pivotably supported about the longitudinal axis 16 , from the free edge 19 toward the carriage body, the pivot struts 18 are securely connected to the next transverse profile 9 . The same applies to a pair of additional pivot struts 20 and the transverse profile 10 and so on (without any reference numeral) until the last transverse profile 12 . Of course, it is possible to provide in each case only one pivot strut or also more than two.
[0026] As a result of this construction, when one of the transverse profiles 8 to 12 is lifted via the configuration of the pivot struts 18 to 20 , etcetera, away from the free edge 19 , each of the transverse profiles which are located therebetween is lifted whilst the profiles which are located further away therefrom at the carriage body side continue to remain resting on the longitudinal struts 17 . Five transverse profiles are illustrated; there may be more or fewer; at least two are necessary in order to be used in an advantageous manner.
[0027] This operating method becomes clear when viewed together with FIG. 5 , which in the first illustration thereof shows a side view with all the transverse profiles resting on the longitudinal struts 17 , the second illustration shows a schematic section in which the construction of the transverse profiles 8 to 12 can be seen clearly and the third illustration shows how the transverse profile 10 is raised by a rotary element 21 and, by means of the pivot struts 20 thereof, also pivots, and consequently raises, the transverse profiles 8 and 9 which are closer to the free edge 19 than the transverse profile 10 about the pivot axle 16 .
[0028] FIG. 6 shows in a purely schematic manner how the rotary element 21 is rotated by means of a linear drive 22 in such a manner that in this instance it raises the transverse profile which is located in the region thereof, in this instance the transverse profile 10 .
[0029] It is clear that the rotary element 21 , the bearing thereof and associated linear drive 22 are arranged so as to be secured to the carriage body in order to in each case raise the transverse profile which is located in the correct position with respect to the footrail 2 or the front edge thereof.
[0030] FIG. 9 shows a mechanism which is very suitable for this movement. A linear drive 22 which can be moved linearly back and forth in the pushing-out direction has at the front end region thereof a folding axis 28 which is substantially parallel with the longitudinal axis 16 . There is pivotably supported about this folding axis 28 a rotary element 21 which is under the force of a torque in a counter-clockwise direction and which, during the pushing-out movement, moves along below a guiding portion until it has moved past it and folds upward as a result of the action of the torque.
[0031] As the second illustration of FIG. 9 shows, the rotary element engages in the lifting portion 27 of the associated transverse profile 8 - 12 and lifts it upward, as illustrated in greater detail in FIG. 11 .
[0032] FIG. 10 shows a variant in which in place of the guiding portion 29 there is arranged on the carriage body a guiding rail 30 , in which a pin 31 of the rotary element 21 engages; they are actually guiding elements which are provided at both sides of the rotary element. The rotary element 21 is in turn pivotably connected to the linear drive 22 . FIG. 11 shows a configuration of the connection between the rotary portion 21 and lifting portion 27 , which configuration is advantageous to use. A flattened pin 32 of the rotary portion 21 whose angular position on the rotary portion 21 correlates to the angular position thereof at the time of the engagement strikes a catch face 33 of the lifting portion and when the linear drive 22 moves further ( FIG. 9, 10 ) is pushed into a circular recess 34 . When the pin 32 reaches the end of the recess 34 , the horizontal movement comes to an end and the pin 32 moves as a result in a vertical direction, wherein, as a result of the rotation of the pin, it is secured in the recess 34 in a positive-locking manner.
[0033] FIG. 7 shows a variant of FIG. 6 relating to the lifting mechanism, in this instance, in place of a pure rotational movement of a rotary element 21 , an expansion movement of an expansion element 23 is again brought about by means of a linear drive 22 . In this instance, the connection between the rotary element 21 and lifting portion 27 can also be carried out as described above.
[0034] FIG. 8 shows, also in a purely schematic manner, one possibility for the reduction or elimination of the height difference 14 ( FIG. 2 ) between the free end of the footboard and the upper platform edge: a guide 24 for the footboard 1 is in turn pivotably supported about a guiding axis 25 which extends parallel with the longitudinal carriage axis. Using a pivot mechanism, for example, a movable dual wedge 26 , or a linear drive such as a spindle or a hydraulic or pneumatic cylinder/piston unit, the guide 24 and consequently the footboard 1 can be pivoted about the guiding axis 25 and can thus compensate for the height difference 14 . The double-headed arrow 26 indicates this movement; how it is limited is dependent on the respective vehicle and the provisions of the rail administration.
[0035] Disclosed embodiments is not limited to the embodiment illustrated and described, but instead can be modified in different manners. It is thus possible not to arrange the lifting mechanism with the rotary element 21 or the expansion element 23 in a duplicate manner and at the lateral edge of the footboard 1 , but instead centrally and only in single form; the division of the remaining horizontal gap 13 at the side of the platform 4 or at the side of the floor 2 can be carried out differently from the way set out, but this then requires an adaptation of the position or the extent of the lifting action of the lifting mechanism in order not to unintentionally form a height difference, even a small height difference, in the region of the upper floor edge since the engagement location of the lifting mechanism with respect to the transverse profile then changes in accordance with the remaining gap width.
[0036] The construction of the lifting mechanism may deviate from the illustrated examples; it is possible to provide a fixed hydraulic or pneumatic piston/cylinder unit which presses the respective transverse profile upward in a purely non-positive-locking manner, and the like.
[0037] It is possible to use as materials, substances and components all those which are known in the prior art for retractable steps or folding steps; in the knowledge of Disclosed embodiments and in the knowledge of the field of the object and the vehicle to be equipped there are no problems in this regard for the person skilled in the art.
[0038] In summary, it can consequently be set out that Disclosed embodiments substantially relates to a movable footboard for a door of a vehicle, in particular a rail vehicle, having a footboard 1 which can be extended below the footrail 2 at least substantially transversely relative to the travel direction. In order to improve the connection between the footboard and footrail, there is provision for there to be provided at the end region of the footboard 1 remote from the vehicle on at least one longitudinal strut 17 of the footboard 1 a pivot axle 16 which extends at least substantially parallel with the travel direction and about which there are pivotably supported at least two pivot struts 18 , 20 which each carry a transverse profile 8 - 12 . In this instance, each of the pivot struts, as illustrated, may be divided into two aligned pivot struts in order to improve the mechanical and dynamic situation; there are also provided in most cases more than two such pivot struts in order to be able to provide more than two transverse profiles 8 - 12 . Furthermore, each of the pivot struts is only securely connected to the transverse profile 8 - 9 which is associated therewith, whilst the other transverse profiles are freely positioned thereon. Finally, there is provided a lifting mechanism 21 , 22 , 23 which is secured to the vehicle and which lifts only the transverse profile 8 - 12 which is located directly in front of the footrail 2 .
LIST OF REFERENCE NUMERALS
[0000]
1 . Footboard
2 . Footrail
3 . Double-headed arrow
4 . Platform
5 . Upper floor edge
6 . Surface
7 . Upper platform edge
08 - 12 . Transverse profiles
13 Gap
14 Height difference
15 Horizontal
16 Pivot axle
17 Longitudinal struts
18 Pivot struts
19 Free edge
20 Pivot struts
21 Rotary element
22 Linear drive
23 Expansion element
24 Guide
25 Guiding axis
26 Arrow
27 Lifting portion
28 Folding axis
29 Guiding portion
30 Guiding rail
31 Pin
32 Flat pin
33 Catch face
34 Recess
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A movable footboard for a door of a rail vehicle comprises a footboard extendable below a tread strip at least substantially transversely to the direction of travel. To minimize the level difference between the footboard and the tread strip a pivot shaft extends at least substantially parallel to the direction of travel on at least one longitudinal bar of the footboard at the end region of the footboard away from the vehicle, about which pivot shaft at least two pivoting bars are pivotably supported, which pivoting bars each bear a transverse profile element, each of the pivoting bars being rigidly connected to the transverse profile element associated with the pivot bar, while the other transverse profile elements lie freely on said pivot bar, and a lifting mechanism is fastened to the vehicle and lifts the transverse profile element located directly in front of the tread strip.
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This application is related to and claims priority from provisional U.S. Patent Application, Serial No. 60/023,756, filed on Aug. 12, 1996, the disclosure of which is incorporated by reference. This application is also related to U.S. patent application Ser. No. 08/761,063, filed Dec. 5, 1996, and International Application No. PCT/US96/19514, filed Dec. 5, 1996, the disclosures of each of which are expressly incorporated herein.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to the methods and apparatus for controlling fluid flow in microfluidic systems. In, particular, the invention provides microvalves for controlling fluid flow from microreservoirs into transfer channels using capillary valving mechanisms. The capillary valving mechanisms of the invention are based on changes in cross-sectional area and geometry of orifices, reservoirs and microchannels and surface treatment of reservoirs and channels. Specific embodiments of the microvalves of the invention are provided to control fluid flow in microchip-based chemical Microsystems using pumping means and in centrifugal rotors and microplatforms as disclosed, for example in International Application WO97/21090. This invention provides microvalving means for use in apparatus useful for performing microanalytic and microsynthetic analyses and procedures, such as microminiaturization of genetic, biochemical and chemical processes related to analysis, synthesis and purification of biological, chemical, environmental and other compounds.
2. Summary of the Related Art
In the field of medical, biological and chemical assays, mechanical and automated fluid handling systems and instruments are known in the prior art.
U.S. Pat. No. 4,279,862, issued Jul. 21, 1981 to Bertaudiere et al. disclose a centrifugal photometric analyzer.
U.S. Pat. No. 4,381,291, issued Apr. 26, 1983 to Ekins teach analytic measurement of free ligands.
U.S. Pat. No. 4,515,889, issued May 7, 1985 to Klose et al. teach automated mixing and incubating reagents to perform analytical determinations.
U.S. Pat. No. 4,676,952, issued Jun. 30, 1987 to Edelmann et al. teach a photometric analysis apparatus.
U.S. Pat. No. 4,745,072, issued May 17, 1998 to Ekins discloses immunoassay in biological fluids.
U.S. Pat. No. 5,061,381, issued Oct. 29, 1991 to Burd discloses a centrifugal rotor for performing blood analyses.
U.S. Pat. No. 5,122,284, issued Jun. 16, 1992 to Braynin et al. discloses a centrifugal rotor comprising a plurality of peripheral cuvettes.
U.S. Pat. No. 5,160,702, issued Nov. 3, 1993 to Kopf-Sill and Zuk discloses rotational frequency-dependent "valves" using capillary forces and siphons, dependent on "wettability" of liquids used to prime said siphon.
U.S. Pat. No. 5,171,695, issued Dec. 15, 1992 to Ekins discloses determination of analyte concentration using two labeling markers.
U.S. Pat. No. 5,173,193, issued Dec. 22, 1992 to Schembri discloses a centrifugal rotor for delivering a metered amount of a fluid to a receiving chamber on the rotor.
U.S. Pat. No. 5,242,803, issued Sep. 7, 1993 to Burtis et al. disclose a rotor assembly for carrying out an assay.
U.S. Pat. No. 5,409,665, issued Apr. 25, 1995 to Burd discloses a cuvette filling in a centrifuge rotor.
U.S. Pat. No. 5,413,009, issued Jul. 11, 1995 to Ekins discloses a method for analyzing analytes in a liquid.
U.S. Pat. No. 5,472,603, issued Dec. 5, 1995 to Schembri discloses an analytical rotor comprising a capillary passage having an exit duct wherein capillary forces prevent fluid flow at a given rotational speed and permit flow at a higher rotational speed.
Anderson, 1968, Anal. Biochem. 28: 545-562 teach a multiple cuvette rotor for cell fractionation.
Renoe et al., 1974 Clin. Chem. 20: 955-960 teach a "minidisc" module for a centrifugal analyzer.
Burtis et al., 1975, Clin. Chem. 20: 932-941 teach a method for a dynamic introduction of liquids into a centrifugal analyzer.
Fritsche et al., 1975, Clin. Biochem. 8: 240-246 teach enzymatic analysis of blood sugar levels using a centrifugal analyzer.
Burtis et al., 1975, Clin Chem. 21: 1225-1233 teach a multipurpose optical system for use with a centrifugal analyzer.
Hadjiioannou et al., 1976, Clin. Chem. 22: 802-805 teach automated enzymatic ethanol determination in biological fluids using a miniature centrifugal analyzer.
Lee et al., 1978, Clin. Chem. 24: 1361-1365 teach a automated blood fractionation system.
Cho et al., 1982, Clin. Chem. 28: 1956-1961 teach a multichannel electrochemical centrifugal analyzer.
Bertrand et al., 1982, Clinica Chimica Acta 119: 275-284 teach automated determination of serum 5'-nucleotidase using a centrifugal analyzer.
Schembri et al., 1992, Clin Chem. 38: 1665-1670 teach a portable whole blood analyzer.
Walters et al., 1995, Basic Medical Laboratory Technologies, 3rd ed., Delmar Publishers: Boston teach a variety of automated medical laboratory analytic techniques.
Recently, microannlytical devices for performing select reaction pathways have been developed.
U.S. Pat. No. 5,006,749, issued Apr. 9, 1991 to White disclose methods apparatus for using ultrasonic energy to move microminiature elements.
U.S. Pat. No. 5,252,294, issued Oct. 12, 1993 to Kroy et al. teach a micromechanical structure for performing certain chemical microanalyses.
U.S. Pat. No. 5,304,487, issued Apr. 19, 1994 to Wilding et al. teach fluid handling on microscale analytical devices.
U.S. Pat. No. 5,368,704, issued Nov. 29, 1994 to Madou et al. teach microelectrochemical valves.
International Application, Publication No. WO93/22053, published Nov. 11, 1993 to University of Pennsylvania disclose microfabricated detection structures.
International Application, Publication No. WO93/22058, published Nov. 11, 1993 to University of Pennsylvania disclose microfabricated structures for performing polynucleotide amplification.
Columbus et al., 1987, Clin. Chem. 33: 1531-1537 teach fluid management of biological fluids.
Ekins et al., 1994 Ann. Biol. Clin. 50: 337-353 teach a multianalytic microspot immunoassay.
Wilding et al., 1994, Clin. Chem. 40: 43-47 disclose manipulation of fluids on straight channels micromachined into silicon.
One drawback in the prior art microanalytical methods and apparati has been the difficulty in designing systems for moving fluids on microchips through channels and reservoirs having diameters in the 10-100 μm range. Microfluidic systems require precise and accurate control of fluid flow and valving to control chemical reactions and analyte detection. Conventional pumping and valving mechanisms have been difficult to incorporate into microscale structures due to inherent conflicts-of-scale. These conflicts of scale arise in part due to the fact that molecular interactions arising out of mechanical components of such valves, which are negligible in large (macroscopic) scale devices, become very significant for devices built on a microscopic scale.
One such phenomenon associated with microscale devices is termed "stiction". Stiction is functionally defined as the adhesion of two components under static conditions. Stiction may be due to a variety of causes, such as electrostatic charge transfer, chemical or hydrogen bonding or precipitation of adherent chemicals while the parts are in contact. In order to overcome stiction, a disproportionately large amount of mechanical or electrical energy must be applied. However, the application of such energy and the accompanying force on the microvalve can completely overwhelm the delicate structural and electrical features of the devices. In addition, the manufacture of complex valves and associated circuitry is challenging and results in prohibitively high manufacturing costs.
Systems that use centripetal force to effect fluid movement in microstructures address the need for a pumping mechanism to effect fluid flow, but do not solve these valving needs. The present invention permits precise and accurate control of valving, flow and metering of fluids in microstructural platforms, including both microchip-based and centrifugal microplatform-based technologies, using structures that take advantage of surface tension and capillarity.
SUMMARY OF THE INVENTION
The present invention provides centrifugal rotors and microsystems platforms, as disclosed in International Application WO97/21090 having solid-state microvalves that control fluid flow in the rotor or microsystems platform. The invention provides such microvalves wherein fluid flow on a centrifugal rotor or microsystem platform is motivated by centripetal force of the rotating rotor or platform and controlled by the arrangement, dimensions and surface characteristics of the fluid-handling components (including capillary microchannels and fluid reservoirs) of the rotor or platform. The invention particularly provides arrangements of such fluid-handling components to provide for precise delivery of metered amounts of a fluid, preferably a fluid comprising a biological sample, to a fluid reservoir on the rotor, after application to the rotor of a relatively imprecise or excess amount of said biological sample. The invention also provides arrangement of such fluid-handling components on centrifugal rotors or microsystems platforms wherein a fluid volume contained in one fluid reservoir of the rotor or platform is displaced from the reservoir by centripetally-motivated movement of a second fluid volume from a second fluid reservoir.
In a first embodiment is provided a centrifugal rotor or microsystems platform for providing centripetally-motivated fluid micromanipulation, whereby a precisely metered amount of a fluid sample, most preferably comprising a biological sample, is aliquotted on the rotor or platform from a less precisely applied sample volume. In this embodiment of the invention, said rotor or platform is a rotatable platform, comprising a substrate having a first flat, planar surface and a second flat, planar surface opposite thereto, each surface comprising a center about which the platform is rotated. In said centrifugal rotor or microplatform is provided a first surface that comprises the following components in combination:
1. An entry port comprising a depression in the first surface having a volumetric capacity of about 1 to about 150 μL and that is accessible to an operator for application of a fluid sample, most preferably a fluid comprising a biological sample. The entry port is fluidly connected with
2. A first metering capillary and
3. A second overflow capillary each capillary fluidly connected with the entry port. Each capillary defines a cross-sectional area of about 0.02 mm to about 1 mm in diameter, and each capillary extends radially from the center of the platform, defining a first end proximally arrayed towards the center of the platform and fluidly connected with the entry port, and a second end distally arrayed from the center of the platform, and wherein the proximal end of each capillary defines a curved opening. The first metering capillary also defines a volume of the fluid when filled from the opening at the first end of the capillary to the second end of the capillary. Each capillary comprises a material that is "wettable" by the fluid, particularly fluid comprising a biological sample, so that fluid placed into contact with the first end of each capillary at the entry port flows by capillary action on the rotor or platform at rest (i.e., without rotation of the rotor or the platform) through each capillary to the second end of the capillary, which forms a capillary junction that prevents further fluid flow in the absence of the application of centripetal force applied by rotating the rotor or platform.
The first metering capillary is further fluidly connected with
4. A first fluid chamber having a depth in the surface of the platform that is equal to or greater than the depth of the metering capillary. The first fluid chamber is positioned radially more distant from the center of the platform than the entry port, and the difference in cross-sectional area between the first metering capillary and the first fluid chamber produces the capillary junction at the second end of the first metering capillary that prevents further fluid flow in the absence of the application of centripetal force applied by rotating the rotor or platform.
The second overflow capillary is further fluidly connected with
5. An overflow chamber having a depth in the surface of the platform equal to or greater than the depth of the overflow capillary. The overflow chamber is positioned radially more distant from the center of the platform than the entry port or the first fluid chamber, and the difference in cross-sectional area between the second overflow capillary and the overflow chamber produces the capillary junction at the second end of the second overflow capillary that prevents further fluid flow in the absence of the application of centripetal force applied by rotating the rotor or platform.
In this arrangement, fluid placed onto the disk at the entry port flows by capillary action to the junction of the metering capillary and the first fluid chamber, and excess fluid flows by capillary action to the junction of the overflow capillary and the overflow chamber. Rotation of the platform at a first rotation speed motivates fluid displacement in the overflow capillary into the overflow chamber but does not fluid displacement in the metering capillary. In this way, rotation of the platform at the first rotational speed drains the fluid from the entry port into the overflow chamber, leaving a precisely defined amount of the fluid in the first metering capillary. Thereafter, rotation of the platform at a second rotation speed that is greater than the first rotational speed motivates fluid displacement of the volume of the fluid in the metering capillary into the first chamber, thereby delivering a precisely-determined amount of the fluid, most preferably a fluid comprising a biological sample, to the first fluid chamber.
In preferred embodiments, the platform also comprises air displacement channels whereby air displaced by fluid movement is vented to the surface of the platform.
In a preferred embodiment, the rotatable platform has a diameter of about 20 mm to about 400 mm. In a preferred embodiment, the entry port is from about 0.25 mm to about 1 mm deep. In a preferred embodiment, the entry port is positioned from about 1 cm to about 20 cm. In a preferred embodiment, the first metering capillary has a cross-sectional dimension of from about 0.02 mm to about 0.75 mm. In a preferred embodiment, the first metering capillary is from about 5 mm to about 100 mm long. In a preferred embodiment, the first metering capillary comprises a volume from about 1 μL to about 150 μL. In a preferred embodiment, the first metering capillary is radially extends from about 10 mm to about 200 mm from the center of the platform. In a preferred embodiment, the second overflow capillary has a cross-sectional dimension of from about 0.02 mm to about 0.75 mm. In a preferred embodiment, the second overflow capillary is from about 5 mm to about 100 mm long. In a preferred embodiment, the second overflow capillary is radially extends from about 10 mm to about 200 mm from the center of the platform. In a preferred embodiment, the first fluid chamber is from about 0.25 mm to about 1 mm deep. In a preferred embodiment, the first fluid chamber comprises a volume of about 1 μL to about 150 μL. In a preferred embodiment, the first fluid chamber is radially extends from about 15 mm to about 115 mm from the center of the platform. In a preferred embodiment, the first rotational speed is from about 10 rpm to about 500 rpm. In a preferred embodiment, the second rotational speed is from about 100 rpm to about 200 rpm. In a preferred embodiment, a volume of from about 1 μL to about 150 μL is delivered to the first fluid chamber at the second rotational speed.
In the practice of the invention is also provided a method for moving a fluid in a microsystem platform of the invention. In this embodiment, the invention provides a method having the steps of
1. Applying an amount of a fluid sample, most preferably a biological fluid sample to the entry port of the rotatable microsystem platform, the sample comprising a volume of about 1 to about 100 μL. In preferred embodiments, the biological fluid sample is a blood drop.
2. Rotating the platform at a first rotation speed for a time sufficient to displace the fluid in the entry port and the overflow capillary into the overflow chamber.
3. Rotating the platform at a second rotation speed that is greater than the first rotational speed to displace a volume of the fluid sample in the metering capillary into a first fluid chamber. In a preferred embodiment, the first rotational speed is from about 10 rpm to about 500 rpm.
In a preferred embodiment, the second rotational speed is from about 100 rpm to about 200 rpm.
In a preferred embodiment, a volume of from about 1 μL to about 150 μL is delivered to the first fluid chamber at the second rotational speed.
In a second embodiment of the invention is provided a centrifugal rotor or Microsystems platform for providing centripetally-motivated fluid micromanipulation, wherein a volume of a fluid sample, most preferably comprising a biological sample, in a fluid chamber of the rotor or platform is approximately completely displaced in the chamber by replacement of the volumetric capacity of the chamber with an amount of a displacement fluid. In such embodiments of the invention, said rotor or platform is a rotatable platform, comprising a substrate having a first flat, planar surface and a second flat, planar surface opposite thereto, each surface comprising a center about which the platform is rotated. In said centrifugal rotor or microplatform is provided a first surface that comprises the following components in combination:
1. An entry port comprising a depression in the first surface having a volumetric capacity of about 1 to about 150 μL and that is accessible to an operator for application of a fluid sample, most preferably a fluid comprising a biological sample. The entry port is fluidly connected with
2. A first microchannel which defines a cross-sectional area of about 0.02 mm to about 1 mm in diameter that extends radially from the center of the platform and defines a first end proximally arrayed towards the center of the platform and is fluidly connected with the entry port, and a second end distally arrayed from the center of the platform. A capillary junction is formed between the proximal end of the microchannel and the entry port that prevents further fluid flow in the absence of the application of centripetal force applied by rotating the rotor or platform. Fluid placed into contact with the first end of the capillary at the entry port does not flow into the microchannel unless centripetal force is applied to the fluid by rotating the rotor or platform.
The first microchannel is further fluidly connected with
3. A first fluid chamber having a depth in the surface of the platform equal to or greater than the first microchannel and positioned radially more distant from the center of the platform than the entry port. The entry port, microchannel and first fluid chamber are arrayed on the surface of the platform so that rotation of the platform at a first rotational speed motivates displacement of the fluid in the entry port through the first microchannel and into the first fluid chamber.
The rotor or platform further comprises
4. A second fluid chamber containing a volume of a displacement fluid, that is fluidly connected with
5. A second microchannel, wherein the second microchannel extends radially from the center of the platform and defines a first end proximally arrayed towards the center of the platform and a second end distally arrayed from the center of the platform. The second microchannel is fluidly connected with the second fluid chamber at the first end of the microchannel and the second microchannel is fluidly connected with the first fluid chamber at the second end of the microchannel. Rotation of the platform at the first rotation speed does not motivate flow of the displacement fluid through the second microchannel. The second microchannel comprises a material that is not "wettable" by the displacement fluid, so that fluid placed into contact with the first end of the capillary at the second fluid chamber does not flow into the microchannel unless centripetal force is applied to the fluid by rotating the rotor or platform at a higher rotational speed than the first rotational speed. Alternatively, the difference in cross-sectional area of the microchannel and the second fluid chamber is sufficient to form a capillary junction at the first end of the microchannel, so that fluid does not flow into the microchannel unless centripetal force is applied to the fluid by rotating the rotor or platform at a higher rotational speed than the first rotational speed.
The platform further comprises
6. A third fluid chamber comprising a displacement fluid that is fluidly connected with
7. A third microchannel, wherein the third microchannel extends radially from the center of the platform and defines a first end proximally arrayed towards the center of the platform and a second end distally arrayed from the center of the platform, wherein the third microchannel is fluidly connected with the third fluid chamber at the first end of the microchannel and wherein the third microchannel is fluidly connected with the first fluid chamber at the second end of the microchannel. Rotation of the platform at the first rotation speed does not motivate flow of the fluid sample through the third microchannel.
Rotation of the platform at the second rotational speed motivates flow of the displacement fluid from the second fluid chamber, through the second microchannel and into the first fluid chamber, wherein flow of the displacement fluid into the first fluid chamber forces the fluid in the first fluid chamber through the third microchannel and into the third fluid chamber. In preferred embodiments, displacement fluid flow into the first fluid chamber is laminar and without turbulence, that is, the displacement fluid forces the fluid, most preferably a biological sample fluid, out of the first fluid chamber and into the third microchannel without mixing of the sample fluid and the displacement fluid.
In a preferred embodiment, the rotatable platform has a diameter of about 20 mm to about 400 mm. In a preferred embodiment, the entry port is from about 0.25 mm to about 1 mm deep. In a preferred embodiment, the entry port is positioned from about 1 cm to about 20 cm. In a preferred embodiment, each of the fluid chambers is from about 0.25 mm to about 1 mm deep. In a preferred embodiment, each of the fluid chambers comprises a volume of about 1 μL to about 150 μL. In a preferred embodiment, each of the fluid chambers radially extends from about 15 mm to about 115 mm from the center of the platform. In a preferred embodiment, the first rotational speed is from about 10 rpm to about 500 rpm. In a preferred embodiment, the second rotational speed is from about 100 rpm to about 2000 rpm. In a preferred embodiment, a volume of from about 1 μL to about 150 μL is displaced from the first fluid chamber into the third fluid chamber by laminar displacement fluid flow from the second fluid chamber to the first fluid chamber at the second rotational speed.
In the practice of the invention is also provided a method for moving a fluid in a microsystem platform of the invention. In this embodiment, the invention provides a method having the steps of
1. Applying an amount of a fluid sample, most preferably a biological fluid sample to the entry port of the rotatable microsystem platform, the sample comprising a volume of about 1 to about 1 μL. In preferred embodiments, the biological fluid sample is a blood drop.
2. Rotating the platform at a first rotation speed for a time sufficient to displace the fluid in the entry port into the first fluid chamber.
3. Rotating the platform at a second rotation speed that is greater than the first rotational speed to displace the displacement fluid through the second microchannel and into the first chamber. The displacement fluid is introduced into the first chamber by laminar flow, wherein the displacement fluid does not mix with the fluid, most preferably a fluid comprising a biological sample, in the first fluid chamber. Movement of the displacement fluid by laminar flow into the first fluid chamber forces the fluid in the first fluid chamber, most preferably a fluid comprising a biological sample, through the third microchannel and into the third fluid chamber.
In a third embodiment is provided a centrifugal rotor or microsystems platform for providing centripetally-motivated fluid micromanipulation, whereby a precisely metered amount of a fluid sample, most preferably comprising a biological sample, is aliquotted on the rotor or platform from a less precisely applied sample volume, and wherein a volume of a fluid sample, most preferably comprising a biological sample, in a fluid chamber of the rotor or platform is approximately completely displaced in the chamber by replacement of the volumetric capacity of the chamber with an amount of a displacement fluid. In such embodiments of the invention, said rotor or platform is a rotatable platform, comprising a substrate having a first flat, planar surface and a second flat, planar surface opposite thereto, each surface comprising a center about which the platform is rotated. In said centrifugal rotor or microplatform is provided a first surface that comprises the following components in combination:
1. An entry port comprising a depression in the first surface having a volumetric capacity of about 1 to about 150 μL and that is accessible to an operator for application of a fluid sample, most preferably a fluid comprising a biological sample. The entry port is fluidly connected with
2. A first metering capillary and
3. A second overflow capillary each capillary fluidly connected with the entry port. Each capillary defines a cross-sectional area of about 0.02 mm to about 1 mm in diameter, and each capillary extends radially from the center of the platform, defining a first end proximally arrayed towards the center of the platform and fluidly connected with the entry port, and a second end distally arrayed from the center of the platform, and wherein the proximal end of each capillary defines a curved opening. The first metering capillary also defines a volume of the fluid when filled from the opening at the first end of the capillary to the second end of the capillary. Each capillary comprises a material that is "wettable" by the fluid, particularly fluid comprising a biological sample, so that fluid placed into contact with the first end of each capillary at the entry port flows by capillary action on the rotor or platform at rest (i.e., without rotation of the rotor or the platform) through each capillary to the second end of the capillary, which forms a capillary junction that prevents further fluid flow in the absence of the application of centripetal force applied by rotating the rotor or platform.
The first metering capillary is further fluidly connected with
4. A first fluid chamber having a depth in the surface of the platform that is equal to or greater than the depth of the metering capillary. The first fluid chamber is positioned radially more distant from the center of the platform than the entry port, and the difference in cross-sectional area between the first metering capillary and the first fluid chamber produces the capillary junction at the second end of the first metering capillary that prevents further fluid flow in the absence of the application of centripetal force applied by rotating the rotor or platform.
The second overflow capillary is further fluidly connected with
5. An overflow chamber having a depth in the surface of the platform equal to or greater than the depth of the overflow capillary. The overflow chamber is positioned radially more distant from the center of the platform than the entry port or the first fluid chamber, and the difference in cross-sectional area between the second overflow capillary and the overflow chamber produces the capillary junction at the second end of the second overflow capillary that prevents further fluid flow in the absence of the application of centripetal force applied by rotating the rotor or platform.
In this arrangement, fluid placed onto the disk at the entry port flows by capillary action to the junction of the metering capillary and the first fluid chamber, and excess fluid flows by capillary action to the junction of the overflow capillary and the overflow chamber. Rotation of the platform at a first rotation speed motivates fluid displacement in the overflow capillary into the overflow chamber but does not fluid displacement in the metering capillary. In this way, rotation of the platform at the first rotational speed drains the fluid from the entry port into the overflow chamber, leaving a precisely defined amount of the fluid in the first metering capillary. Thereafter, rotation of the platform at a second rotation speed that is greater than the first rotational speed motivates fluid displacement of the volume of the fluid in the metering capillary into the first chamber, thereby delivering a precisely-determined amount of the fluid, most preferably a fluid comprising a biological sample, to the first fluid chamber.
The rotor or platform also comprises
6. A second fluid chamber containing a volume of a displacement fluid, that is fluidly connected with
7. A first microchannel, wherein the first microchannel extends radially from the center of the platform and defines a first end proximally arrayed towards the center of the platform and a second end distally arrayed from the center of the platform. The second microchannel is fluidly connected with the second fluid chamber at the first end of the microchannel and the microchannel is fluidly connected with the first fluid chamber at the second end of the microchannel. Rotation of the platform at the firs or second rotational speeds does not motivate flow of the displacement fluid through the first microchannel. A capillary junction is formed between the proximal end of the first microchannel and the second fluid chamber that prevents displacement fluid flow in the absence of the application of centripetal force applied by rotating the rotor or platform at a higher rotational speed than the first or second rotational speed.
The platform further comprises
8. A third fluid chamber that is fluidly connected with
9. A second microchannel, wherein the second microchannel extends radially from the center of the platform and defines a first end proximally arrayed towards the center of the platform and a second end distally arrayed from the center of the platform, wherein the second microchannel is fluidly connected with the third fluid chamber at the first end of the microchannel and wherein the microchannel is fluidly connected with the first fluid chamber at the second end of the microchannel. Rotation of the platform at the first or second rotation speeds does not motivate flow of the fluid sample in the first fluid chamber through the second microchannel.
Rotation of the platform at the third rotational speed motivates flow of the displacement fluid from the second fluid chamber, through the second microchannel and into the first fluid chamber, wherein flow of the displacement fluid into the first fluid chamber forces the fluid in the first fluid chamber through the third microchannel and into the third fluid chamber. In preferred embodiments, displacement fluid flow into the first fluid chamber is laminar, that is, the displacement fluid forces the fluid, most preferably a biological sample fluid, out of the first fluid chamber and into the third microchannel without mixing of the sample fluid and the displacement fluid.
In preferred embodiments, the platform also comprises air displacement channels whereby air displaced by fluid movement is vented to the surface of the platform.
In the practice of the invention is also provided a method for moving a fluid in a microsystem platform of the invention. In this embodiment, the invention provides a method having the steps of
1. Applying an amount of a fluid sample, most preferably a biological fluid sample to the entry port of the rotatable microsystem platform, the sample comprising a volume of about 1 to about 100 μL. In preferred embodiments, the biological fluid sample is a blood drop.
2. Rotating the platform at a first rotation speed for a time sufficient to displace the fluid in the entry port and the overflow capillary into the overflow chamber.
3. Rotating the platform at a second rotation speed that is greater than the first rotational speed to displace a volume of the fluid sample in the metering capillary into a first fluid chamber.
4. Rotating the platform at a third rotation speed that is greater than the first and second rotational speeds to displace the displacement fluid through the first microchannel and into the first chamber. The displacement fluid is introduced into the first chamber by laminar flow, wherein the displacement fluid does not mix with the fluid, most preferably a fluid comprising a biological sample, in the first fluid chamber. Movement of the displacement fluid by laminar flow into the first fluid chamber forces the fluid in the first fluid chamber, most preferably a fluid comprising a biological sample, through the second microchannel and into the third fluid chamber.
Preferred embodiments are as above for the metering and displacement embodiments considered separately.
In a fourth embodiment of the invention is provided a centrifugal rotor or Microsystems platform for providing centripetally-motivated fluid micromanipulation, wherein a volume of a fluid sample, most preferably comprising a biological sample, in a first fluid chamber of the rotor or platform is delivered in a stream of droplets into a second fluid chamber on the rotor or platform. In such embodiments of the invention, said rotor or platform is a rotatable platform, comprising a substrate having a first flat, planar surface and a second flat, planar surface opposite thereto, each surface comprising a center about which the platform is rotated. In said centrifugal rotor or microplatform is provided a first surface that comprises the following components in combination:
1. An entry port comprising a depression in the first surface having a volumetric capacity of about 1 to about 150 μL and that is accessible to an operator for application of a fluid sample, most preferably a fluid comprising a biological sample. The entry port is fluidly connected with
2. A first microchannel which defines a cross-sectional area of about 0.02 mm to about 1 mm in diameter that extends radially from the center of the platform and defines a first end proximally arrayed towards the center of the platform and is fluidly connected with the entry port, and a second end distally arrayed from the center of the platform. The first microchannel is further fluidly connected with
3. A first fluid chamber having a depth in the surface of the platform equal to or greater than the first microchannel and positioned radially more distant from the center of the platform than the entry port. Rotation of the platform at a first rotational speed motivates displacement of the fluid in the entry port through the first microchannel and into the first fluid chamber.
The platform further comprises
4. A second microchannel, wherein the second microchannel extends radially from the center of the platform and defines a first end proximally arrayed towards the center of the platform and a second end distally arrayed from the center of the platform. The second microchannel is fluidly connected with the first fluid chamber at the first end of the microchannel and the second microchannel is fluidly connected at the second end of the microchannel with
5. A second fluid chamber having a depth in the surface of the platform equal to or greater than the second microchannel and positioned radially more distant from the center of the platform than the first fluid chamber.
The second end of the second microchannel comprises a surface that is non-wetting, or alternatively the second end of the second microchannel defines an opening into the second fluid reservoir. Rotation of the platform at the first rotation speed does not motivate flow of the displacement fluid through the second microchannel. Rotation of the platform at a second rotational speed that is greater than the first rotational speed motivates flow of the fluid from the first fluid chamber, through the second microchannel and into the second fluid chamber. As a consequence of the properties of the second end of the second microchannel, flow of the fluid into the second fluid chamber comprises a stream of droplets from about 0.1 to about 10 μL in volume. In addition, each of the microchannels and the fluid chambers also comprise air displacement channels whereby air displaced by fluid movement is vented to the surface of the platform.
In the practice of the invention is also provided a method for moving a fluid in a microsystem platform of the invention. In this embodiment, the invention provides a method having the steps of
1. Applying an amount of a fluid sample, most preferably a biological fluid sample to the entry port of the rotatable microsystem platform, the sample comprising a volume of about 1 to about 100 μL. In preferred embodiments, the biological fluid sample is a blood drop.
2. Rotating the platform at a first rotation speed for a time sufficient to displace the fluid in the entry port into the first fluid chamber.
3. Rotating the platform at a second rotation speed that is greater than the first rotational speed to displace the displacement fluid through the second microchannel and into the second fluid chamber wherein the flow of the fluid from the second end of the second microchannel into the second fluid chamber comprises a stream of droplets having a volume of from about 0.1 μL to about 10 μL.
It is an advantage of the centrifugal rotors and microsystems platforms of the invention that an imprecise amount of a fluid comprising a biological sample can be applied to the rotor or platform and a precise volumetric amount of the biological sample is delivered to a fluid reservoir comprising a reaction vessel or other component of the rotor of platform for performing chemical, biochemical, immunological or other analyses. It is an advantage of the centrifugal rotors and microsystems platforms of the invention that metering of said precise amount of a biological fluid sample, for example, a drop of blood, is provided as an intrinsic property of the metering capillary channel of the rotor or platform, thereby avoiding variability introduced by centripetal metering of the sample into a reaction reservoir. It is a further advantage of the centrifugal rotors and microsystems platforms of the invention that an operator can avoid having to precisely measure an amount of a fluid comprising a biological sample for application to the rotor or microsystem platform, thereby permitting end-users, including consumers, having a lower level of sophistication to use a medically diagnostic or other embodiment of the rotor or microsystem platform of the invention.
It is an advantage of the centrifugal rotors and microsystems platforms of the invention that fluid movement into and out of fluid reservoirs on the rotor or platform is precisely determined by displacement of a first fluid, such as biological sample, from a fluid reservoir by a second fluid contained in a second reservoir on the rotor or platform. It is also an advantage of the centrifugal rotors and Microsystems platforms of the invention that approximately complete replacement of the volumetric capacity of a first reservoir can be achieved by using fluid displacement as disclosed herein, thereby providing for maximum recovery of a first fluid sample upon displacement by a second fluid, or maximum delivery and replacement of the first fluid by the second fluid. This aspect of the invention is advantageous for providing sequential chemical or biochemical reaction steps wherein mixing of the reagents is not desired.
It is a further advantage of the centrifugal rotors and microsystems platforms of the invention that fluid movement into and out of fluid reservoirs on the rotor or platform is accomplished by providing a stream of droplets at the end of a microchannel or capillary, wherein fluid is delivered into a fluid chamber thereby. Such embodiments are particularly advantageous for enriching or concentrating a mixture comprising particulate material, advantageously including cells, in a method for centrifugally separating or concentrating such particulates in a mixture from the solution in which the particulates are suspended. Such embodiments are also particularly advantageous where thorough mixing of the fluid in the chamber is required.
Specific preferred embodiments of the present invention will become evident from the following more detailed description of certain preferred embodiments and the claims.
DESCRIPTION OF THE DRAWINGS
FIG. 1a illustrates the relationship between pressure and position on a rotating platform of the invention, and
FIG. 1b shows the contact angles and behavior of fluids on wetting and non-wetting surfaces.
FIG. 2a is a schematic drawing of the dimensional and pressure relationships between capillaries and chambers of different cross-sectional dimensions.
FIG. 2b illustrates capillary junction geometries for wetting and non-wetting surfaces.
FIGS. 3a and 3b illustrate geometries for droplet formation from a capillary.
FIG. 4 is a schematic of the pressure relationships in a chamber on a rotating platform of the invention.
FIG. 5A is a graph and
FIG. 5B is a schematic diagram of the arrangement of a channel on a disk of the invention as described with relation to Equation 13.
FIG. 6A is a graph and
FIG. 6B is a schematic diagram of the arrangement of a channel on a disk of the invention as described with relation to Equations 20 and 21.
FIG. 7A is a graph and
FIG. 7B is a schematic diagram of the arrangement of a channel on a disk of the invention as described with relation to Equation 22.
FIGS. 8A, 8B and 8C are graphs and
FIG. 8D is a schematic diagram of the arrangement of a channel on a disk of the invention as described with relation to Equation 23.
FIG. 9 is a schematic of the time-dependent fluid movement in a Microsystems platform constructed of a nonwetting material.
FIG. 10 illustrates schematically the geometry of droplet formation for enriching particulates in a suspension.
FIGS. 11A through 11E are schematic diagrams of the different structural and functional layers of a disk of the invention configured for DNA sequencing.
FIG. 12 is a schematic diagram of a platform of the invention comprising a metering capillary as described in Example 2.
FIG. 13 is a schematic diagram of a platform of the invention comprising fluid displacement by laminar flow as described in Example 3.
FIG. 14 is a schematic diagram of the spectrophotometric chamber described in Example 4.
DETAILED DESCRIPTION OF THE INVENTION
For the purposes of this invention, the term "sample" will be understood to encompass any chemical or particulate species of interest, either isolated or detected as a constituent of a more complex mixture, or synthesized from precursor species.
For the purposes of this invention, the term "fluidly connected" will be understood to mean micromanipulation apparatus" is intended to include analytical centrifuges and rotors, microscale centrifugal separation apparati, and most particularly the Microsystems platforms and disk handling apparati of International Application No. WO97/21090.
For the purposes of this invention, the terms "capillary", "microcapillary" and "microchannel" will be understood to be interchangeable and to be constructed of either wetting or non-wetting materials where appropriate.
For the purposes of this invention, the term "fluid chamber" will be understood to mean a defined volume on a rotor or Microsystems platform of the invention comprising a fluid.
For the purposes of this invention, the term "entry port" will be understood to mean a defined volume on a rotor or microsystems platform of the invention comprising a means for applying a fluid to the rotor or platform.
For the purposes of this invention, the term "capillary junction" will be understood to mean a junction of two components wherein one or both of the lateral dimensions of the junction are larger than the corresponding dimensions the capillary. In wetting or wettable systems, the such junctions are where the valving occurs, because fluid flow through the capillaries is stopped at such junctions. In non-wetting or non-wettable junctions, the exit from the chamber or reservoir is where the capillary junction occurs. In general, it will be understood that capillary junctions are formed when the dimensions of the components change from a small diameter (such as a capillary) to a larger diameter (such as a chamber) in wetting systems, in contrast to non-wettable systems, where capillary junctions form when the dimensions of the components change from a larger diameter (such as a chamber) to a small diameter (such as a capillary).
For the purposes of this invention, the term "biological sample" or "biological fluid sample" will be understood to mean any biologically-derived analytical sample, including but not limited to blood, plasma, serum, lymph, saliva, tears, cerebrospinal fluid, urine, sweat, plant and vegetable extracts, semen, and ascites fluid.
For the purposes of this invention, the term "air displacement channels" will be understood to include ports in the surface of the platform that are contiguous with the components (such as chambers and reservoirs) on the platform, and that comprise vents and microchannels that permit displacement of air from components of the platforms and rotors by fluid movement.
For the purposes of this invention, the term "capillary action" will be understood to mean fluid flow in the absence of rotational motion or centripetal force applied to a fluid on a rotor or platform of the invention.
For the purposes of this invention, the term "capillary microvalve" will be understood to mean a capillary comprising a capillary junction whereby fluid flow is impeded and can be motivated by the application of pressure on a fluid, typically by centripetal force created by rotation of the rotor or platform of the invention.
The microplatforms of the invention (preferably and hereinafter collectively referred to as "disks"; for the purposes of this invention, the terms "microplatform", "Microsystems platform" and "disk" are considered to be interchangeable), are provided to comprise one or a multiplicity of microsynthetic or microanalytic systems. Such microsynthetic or microanalytic systems in turn comprise combinations of related components as described in further detail herein that are operably interconnected to allow fluid flow between components upon rotation of the disk. These components can be fabricated as described below either integral to the disk or as modules attached to, placed upon, in contact with or embedded in the disk. The invention also comprises a micromanipulation device for manipulating the disks of the invention, wherein the disk is rotated within the device to provide centripetal force to effect fluid flow on the disk. Accordingly, the device provides means for rotating the disk at a controlled rotational velocity, for stopping and starting disk rotation, and advantageously for changing the direction of rotation of the disk. Both electromechanical means and control means, as further described herein, are provided as components of the devices of the invention. User interface means (such as a keypad and a display) are also provided, as further described in International Application WO97/21090.
Fluid (including reagents, samples and other liquid components) movement is controlled by centripetal acceleration due to rotation of the platform. The magnitude of centripetal acceleration required for fluid to flow at a rate and under a pressure appropriate for a particular microsystem is determined by factors including but not limited to the effective radius of the platform, the position angle of the structures on the platform with respect to the direction of rotation and the speed of rotation of the platform.
The capillary microvalves of the invention is based on the use of rotationally-induced fluid pressure to overcome capillary forces. Fluids which completely or partially wet the material of the microchannels (or reservoirs, reaction chambers, detection chambers, etc.) which contain them experience a resistance to flow when moving from a microchannel of narrow cross-section to one of larger cross-section, while those fluids which do not wet these materials resist flowing from microchannels (or reservoirs, reaction chambers, detection chambers, etc.) of large cross-section to those with smaller cross-section. This capillary pressure varies inversely with the sizes of the two microchannels (or reservoirs, reaction chambers, detection chambers, etc., or combinations thereof), the surface tension of the fluid, and the contact angle of the fluid on the material of the microchannels (or reservoirs, reaction chambers, detection chambers, etc.) . Generally, the details of the cross-sectional shape are not important, but the dependence on cross-sectional dimension results in microchannels of dimension less than 500 μm exhibit significant capillary pressure. By varying the intersection shapes, materials and cross-sectional areas of the components of the microsystems platform of the invention, "valve" are fashioned that require the application of a particular pressure on the fluid to induce fluid flow. This pressure is applied in the disks of the invention by rotation of the disk (which has been shown above to vary with the square of the rotational frequency, with the radial position and with the extent of the fluid in the radial direction). By varying capillary valve cross-sectional dimensions as well as the position and extent along the radial direction of the fluid handling components of the microsystem platforms of the invention, capillary valves are formed to release fluid flow in a rotation-dependent manner, using rotation rates of from 100 rpm to several thousand rpm. This arrangement allows complex, multistep fluid processes to be carried out using a pre-determined, monotonic increase in rotational rate.
The instant invention provides arrangements on the microsystems platforms of the invention to provide three types of capillary microvalving applications. The invention provides capillary metering of precise amounts of a volume of a fluid sample from the application of a less precise volume of a fluid sample at an entry port on the microsystem platform. These embodiments of the invention provide for delivery of precise amounts of a sample such as a biological fluid sample without requiring a high degree of precision or accuracy by the operator or end-user in applying the fluid to the platform, and is advantageous in embodiments of the microsystems platforms of the invention that are used by consumers and other relatively unsophisticated users. The invention also provides laminar flow-dependent replacement of a fluid in a first chamber by a second displacement fluid in a second chamber on the platform. These embodiments of the invention provide approximately complete replacement of a fluid in one chamber on the platform with fluid from another, and thereby provide means for practicing sequential chemical reactions and other sequential processes on the platform under conditions wherein mixing of the two fluids is disadvantageous. The invention also provides platforms comprising microchannel junctions with fluid chambers and reservoirs wherein fluid transfer through the microchannel and into the fluid chamber is effected in a dropwise manner, whereby the fluid in a microchannel is transferred into the fluid chamber as a stream of droplets. These embodiments of the invention provide means for enriching a suspension or mixture of a particulate material in a solution, by providing enriched droplets containing a higher density of the particulate than in the original suspension or mixture, when subjected to centripetal acceleration. Advantageous particulate material include cells, for example.
In embodiments of the invention providing laminar flow of fluids, one fluid replaces another without appreciable mixing of the two fluids. Flow is laminar if the Reynolds number, R, is less than 2200, wherein the Reynolds number is calculated by the equation:
R=ρua/μ
wherein ρ is the density of the fluid, μ is the viscosity of the fluid, u is the mean fluid velocity and a is a characteristic dimension (such as the cross-sectional diameter of a circular channel). For aqueous solutions, where ρ is 1 g/cm 3 , μ is 0.01 dyne-sec/cm, the mean fluid velocity must be greater than 220 cm/sec for a chamber having a cross-sectional dimension of 1 mm. Typically, the mean fluid velocity is less than 10 cm/sec, so that the flow of fluid in the chambers of the rotors and platforms of the invention will be laminar.
A. Theoretical
All fluids can be characterized by interactions with solid substrates and gasses. These interactions are further characterized by interfacial tension, or the energy per unit area at the interface of the fluid with another substance. One result of interfacial tension is capillary action (see Adamson, 1976, Physical Chemistry of Surfaces, 3d ed., Wiley & Sons: New York). Under "wetting" conditions, the liquid and solid experience mutual attraction. In such cases, liquids may flow from a large reservoir into a smaller, more narrow tube, in order to maximize the area of the solid/liquid interface. Flow through the tube is inhibited if the tube opens to a sufficiently large diameter that the area of solid/liquid contact would decrease by additional flow. Conversely, under non-wetting conditions, liquids resist flow through a small diameter tube (see Gerhart & Ross, 1985, Fundamentals of Fluid Mechanics, Addison Wesley Publishing: Reading, Mass.). Flow can be initiated into a non-wettable tube by applying pressure to the fluid. If a fluid encounters a constriction in the tube, capillarity requires even the greater pressure to be applied. The above considerations relating the use of capillarity to manipulate fluid flow are elaborated in the discussion below.
Physical surface features of fluid containing solids are known to affect the behavior of fluids (see Columbus & Palmer, 1987, Clinical Chemistry 33; 1531). By the proper design of surface features and selection of materials, structures can be designed to allow fluid flow only when sufficient pressure is applied to the liquid. This force can be supplied using pumping means, gravity, or preferably, centripetal force due to rotation of microfabricated structures on centrifugal rotors and microplatforms provided as described herein and in International Patent Application, Publication No. WO97/21090.
The invention disclosed herein includes microvalve structures that allow:
starting and stopping liquid flow;
precise metering of liquid flow; and
fluid partitioning, whereby particulates are concentrated prior to release.
Variables that affect the performance of these microvalve structures include:
size and shape of fluid reservoirs, channels and orifices;
hydraulic pressure exerted on the fluid (in centripetal embodiments, pressure is determined by platform radius and rotation rate); and
fluid surface tension and interfacial energy of the interface between the fluid and the materials of the fluid flow system.
B. Illustrative Examples
a. Capillary Forces
In general, capillary forces are understood to arise due to the effects of interfacial energy, i.e., the energy if interactions between materials, particularly fluids and especially liquid materials, at their interface with other materials (usually solids). For example, the interfacial energy per unit area the interface between a liquid material and its vapor is termed the surface tension of the liquid (γ). One manifestation of surface tension is observed at a curved liquid-vapor interface. There exists across such and interface a pressure drop ΔP wherein
ΔP=Force/Area=γ(1/R.sub.1 +1/R.sub.2) (1)
where R 1 and R 2 are the principal radii of the curvature of the interface. These radii are defined by the spheres which would be tangent to the surface at any point. The sphere having the smallest radius tangent to the surface at such point had the first radius of curvature, R 1 . The sphere having the largest radius tangent to the surface at such point had the second radius of curvature, R 2 .
An example is a liquid-vapor interface which is locally spherical; the radii of curvature are then equal to each other and to a sphere of radius r, and Equation 1 yields a pressure drop
ΔP=2γ/r (2)
from the liquid side of the interface to the vapor side. This is illustrated in cross-section in FIG. 1a. The physical implication is that such a surface would expand into the vapor, increasing the radii of curvature and decreasing the pressure drop. It will be recognized that a saddle-shaped surface (where the radii of curvature arc equal in magnitude but opposite in sign) has no pressure drop, as shown by application of Equation 1.
Another interface of interest is that between a liquid and a solid. The energy difference between the liquid-solid interface and the liquid-vapor interface can be expressed by an equation involving the surface tension of the liquid, γ, and the contact angle, Θ c , of the contact line where the liquid-solid, liquid-vapor and solid-vapor interfaces meet. This relationship is shown in FIG. 1b, where the relationships between these interfaces are illustrated for a non-wetting )left side of the Figure) and wetting (right side of the Figure) interaction between solid and liquid are illustrated. The behavior of the liquid in either case is determined by the equation:
γ.sub.sv -γ.sub.is =γ cos Θ.sub.c (3)
where γ sv is the energy per unit area of the solid-vapor interface, γ is is the energy per unit area of the liquid-solid interface, and γ is the energy of the liquid-vapor interface (equal to the liquid surface tension). For contact angles Θ c greater than 90°, the liquid does not wet the solid, and "beads" on the solid surface. For contact angles Θ c less than 90°, the liquid wets the solid, and spreads onto the solid surface. This behavior is illustrated in the Figure, where the contact angle formed between the liquid, solid and vapor is shown in exaggerated detail for each alternative contact angle.
In the present invention, Equation (1), which describes the pressure drop supported across a liquid-vapor interface, and Equation (3), which expresses differences in interfacial energies, are employed to determine the arrangement of surfaces comprising the microvalve structures and contours and change in the surface area of the solid structures that promote or inhibit fluid flow. These parameters are also used to provide fluid metering devices as described herein.
a. Capillarity at the Junction of Vessels With Different Cross-Sectional Areas
In the present invention, the contact angle is manipulated by the choice of the arrangement of the surfaces comprising the microvalve structures and combined with changes in surface area of the solid structures to either promote or inhibit fluid flow. Fluid flow can be "active" (i.e., promoted by the application of pressure or centripetal force), or "passive" (i.e., promoted or inhibited solely by the capillary forces according to the principles discussed above). To illustrate these principles with clarity and simplicity, the capillary orifices and channels or tubes discussed herein comprise circular cross-sectional areas. It will be understood that the precise shape of the capillary orifice affects the applied pressures at which the microvalves of the invention permit fluid flow, and that the manner in which pressure is thus affected is the minimum interfacial energy of the fluid/surface and fluid/vapor interfaces at the junction between the channel, tube or orifice and the reservoir.
One example of fluid flow as practiced by the microvalve structures of the invention is shown in FIGS. 2a and 2b. FIG. 2a shoes two reservoirs (R) having arbitrary cross-sectional area A R and cross-sectional perimeters PR connected by a tube (T) of smaller cross-sectional area A T and perimeter P T , so that P R /A R <P T /A T . (The tube is provided for illustration; the analysis and discussion provided herein are equally applicable to an orifice of the same cross-sectional area. Further, the reservoirs can be different, provided that the dimensions of the orifice are smaller that those of either reservoir.) A volume of fluid is introduced into one reservoir, and is free to partition between the reservoirs and the connecting tube as a result of capillary forces; air holes may be placed appropriately to remove air displaces by fluid flow. The capillary forces experienced by the liquid as it is introduced into the tube is expressed by a pressure, the magnitude of which is given by the following equation:
P.sub.C =Force/Area=γ{(-P.sub.R /A.sub.R)cos Θ.sub.R +(P.sub.T /A.sub.T)cos Θ.sub.T } (4)
where Θ R and Θ T are the contact angles between the liquid and the surface of the reservoir and the tube, respectively. For circular reservoirs and channel, the contact angle provides a radius of curvature whose magnitude of curvature is smaller within the tube that within the reservoir, resulting in pressure differences between these two interfaces that leads to fluid flow.
The cross-sectional areas and perimeters of importance are those at the contact line(s) between solid, liquid and vapor. These parameters may be a function of the position of the interfaces of the reservoir(s) and tube(s); and example of this dependence of the contact angle on surface shape configuration include funnel-shaped tubes and spherical reservoirs. For most cross-sectional shapes, the ratio of P i /A i varies as a inverse of the average cross-sectional diameter of the reservoir or tube. This means that the volume of the reservoir or tube of smaller average diameter makes the larger contribution to the pressure define in Equation (4) (e.g., the component of smaller average diameter in FIGS. 2a and 2b is a tube).
Because Equation (4) is the pressure that resists fluid flow in the direction of the tube (to the right in FIG. 2a), a pressure P* of greater magnitude and opposite direction must be applied across the interface at the tube entrance; this pressure can be applied to the fluid in the reservoir on the left of the Figure. The magnitude of such a pressure P* is given by the following equation:
P*=γ{(P.sub.R /A.sub.R) cos Θ.sub.R -(P.sub.T /A.sub.T) cos Θ.sub.T} (5)
If the applied pressure is greater than the opposing pressure arising from capillary forces, fluid will flow from the left reservoir into the tube. For a non-wetting fluid emerging from the orifice, the maximum resisting force occurs when the liquid-vapor interface points along the edges of the tube or orifice; hence, this is the resisting force or pressure that must be overcome:
P*=γ{(P.sub.R /A.sub.R) cos Θ.sub.R +(P.sub.T /A.sub.T)}(6)
(where P R and A R refer to the left-hand reservoir in the Figure). In this arrangement, Equation (5) defines the pressure necessary to initiate fluid flow into the microvalve. Equation (6) defines the pressure that must be applied to cause flow into the right-hand reservoir.
If both contact angles are greater than or equal to 90°, the pressure at the interface is negative (i.e., points to the left in FIG. 2a). In order to force liquid from the reservoir into the tube, a pressure of at least the same magnitude must be applied on the fluid in the opposite direction (to the right in the Figure). If the pressure is greater than P* as given in Equation (6), the fluid will further flow from the tube into the second (right) reservoir. If the contact angles are less than 90°, the pressure at the interface is positive (i.e., it points to the right in FIG. 2a). In this case, fluid is drawn into the tube by capillary action, filling the tube until an interface is formed at the junction of the tube with the second large reservoir at the end of the tube (i.e., on the right in FIG. 2a). At this interface, the liquid assumes a configuration wherein there is no pressure difference across the left-hand and right-hand interfaces (given by Equation (1)) (i.e., the pressures are equal). To move fluid into the right-hand reservoir, a pressure must be applied as given by Equation (5).
The pressure necessary for flow into the second reservoir in the case of a wetting solution can be increased through the use of inlets into the second reservoir that are shaped conically (e.g., similar to the tip of macroscopic pipette). Alternatively, micron-sized textures as described in Columbus (Id.) can be used, or a combination thereof For conical-shaped inlets, Equation (6) gives the pressure necessary for flow, as described above in the case of a non-wetting solution, but with the radius of curvature determined by the outer radius of the conical surface.
In practice, wetting fluids emerging from capillaries are more susceptible to the effects of pressure fluctuation, vibrations and other such phenomenon, which can result in premature wetting of the exit area. This is because the wetting fluid is retained at the junction of the tube and a fluctuation driving fluid into the reservoir results in a smaller capillary force than was exerted when the fluid was at the junction. A non-wetting fluid is retained at the entry to a tube or channel; a fluctuation driving fluid into the tube results in the same capillary force as at the junction, and hence the fluid interface may be pushed back by capillary forces once the cause of the fluctuation has subsided.
One means for controlling pressures necessary for flow are provided by textures in the surface material, such as concentric rings around the exit port: such textures have increased resistance to flow along the surface relative to a smooth surface so that a fluid droplet may form with a 90° angle as described above in the case of a non-wetting solution. In this case, Equation (6) gives the minimum pressure necessary for flow.
Equations (4), (5) and (6) define microvalve principles and a construction method for making microvalves for controlling fluid flow in Microsystems and microplatforms. Succinctly, channels of varying cross-sectional area are used in combination with applied pressures to "valve" fluids through certain control points in the microplatform or other microsystem. A simple example of such a microvalving arrangement is a succession of chamber connected by tubes or channels so that initiation of flow in each tube is achieved by stepwise increases in applied pressures. Non-limiting examples of shapes of "valving" orifices useful in the microvalves of the invention are illustrated in FIG. 2b.
b. Capillary Forces and the Creation of Droplets at a Tube Orifice
Another aspect of the disclosed invention is the dropwise release of fluid from a channel, tube or simple orifice between reservoirs or chambers. A droplet of a fluid will detach from the end of a tube containing the fluid when the force on the droplet (in a direction away from the tube or orifice) is greater that the force of the surface tension holding the droplet on the he tube (discussed more fully in Adamson, ibid.). This relationship is described by the following equations:
F=ρVα.sub.c =k(2πrγ) (7a)
or, solving for the volume V of the droplet
V=k(2πrγ)/ρα.sub.c (7b)
wherein a c is the acceleration which the free droplet would experience due to the applied force (e.g., pressured or gravity); V is the volume of the detached droplet; ρ is the liquid density; r is the approximate radius of the tube from which the drop "falls" (defined as the inner radius for a non-wetting surface, and the outer radius of a tube tip for a wetting surface); and k is a geometry-dependent coefficient related to γ/V 1/3 ranging in magnitude from 0.5 to 1. The value of k appropriate for the conditions under consideration is determined self-consistently between values of k which are tabulated as a function of different values of γ/V 1/3 . This requires an iterative approach. An initial "guess" for the value of k is made, and then Equation (7b) is used to calculate V. This value of V is then used to look up an appropriate value for k in the aforesaid Table. If the value of k determined from the Table is different from the original assumption, the correct value must lie therebetween, and an internmediate approximation is made and the analytical process repeated. This process is continued until a value of k is determined that is consistent with the calculated value as described above. For example, a choice of k is determined that is consistent with the calculated value as described above. For example, a choice of k=0.75 might lead to value of γ/V 1/3 =0.1, which tabulated values of k indicate are appropriate for k=0.95. The value of k is then adjusted and the calculation repeated iteratively until the actual value of k for a given instance is determined. The other symbols have the meanings and values described above in previous equations. Release of a droplet from the end of a tube is illustrated in FIGS. 3a and 3b. FIG. 3a shows the release of a droplet under the influence of a force (such as pressure or gravity); the droplet is shown to be released when a sufficient volume is achieved in response to the applied force; release occurs when the surface tension holding the droplet is insufficient to counter the force pulling the droplet away from the end of the tube. It is recognized that the shape of the orifice determines to a degree the volume of the detached droplet for a given tube cross-sectional area and applied acceleration (pressure), and that droplet formation and the magnitude of the requisite pressure also depends on whether the surface is wetting or no-wetting. FIG. 3b shows orifice shapes that facilitate droplet formation for both wetting and non-wetting.
c. Use of Centripetal Acceleration to Apply Pressure to a Liquid
One means for providing a applied force to motivate fluid flow is the application of a centripetal force; this means is particularly important on centrifugal rotors and in microplatform systems as disclosed in International Application WO97/21090. In microplatform arrangements, a reservoir and connecting channels are arrayed on a microplatform, preferably a circular shaped disk, at a radial distance R from the center of rotation. Such an arrangement is shown if FIG. 4, wherein the reservoir is characterized by the radial distance from the center of the disk (R), its extent along that radius (L) and the rotation rate f in revolutions per second. The pressure at the outer radius of the fluid due to centripetal acceleration is given by the following equation:
P=4π.sup.2 ƒ.sup.2 ρLR (8)
where ρ is the fluid density. It can be seen that the pressure at the outer extent of the reservoir will differ from the pressure at the inner extent of the reservoir by 4π 2 ƒ 2 ρLR.
The driving force for fluid motion or creating fluid pressures is the force on matter which results from centripetal acceleration. A device may rotate at an angular rate of f in revolutions/sec and angular frequency
ω=2πƒ (9)
The centripetal acceleration (or acceleration oriented along the radius at a radial distance R from the center of the uniformly-rotating disk) is
α.sub.c =ω.sup.2 R (10)
A mass m in such uniform circular motion is subject to a centripetal force
F.sub.c =mα.sub.c =mω.sup.2 R (11)
which is directed inward along the radius to the center of rotation. If the mass is held fixed at this radius, the device causing rotation supplies this force; this is the origin of the static pressure in liquid columns discussed below. If the mass is placed on top of a trap-door above a radially-oriented tube, and the trap-door opened, the inertia of the mass will cause it to accelerate down the tube; this is the basis for driving fluids radially outward on a rotating disk.
Rotation may create a static pressure in a non-flowing fluid. Assume a column of liquid extending from an inner radius R 0 . The tube may be along the radius or inclined at an angle to the radius. Let the pressure at position R 0 be defined as P 0 , which is for example atmospheric pressure. The excess pressure due to rotation of the liquid at Position R such that R 0 <R is found by integrating the centripetal force per unit area for liquid of density p from position R 0 to R:
P-P.sub.0 =∫ρα.sub.c =ρω.sup.2 /2×(R.sup.2 -R.sub.0.sup.2) (12)
If the tube is filled, extending from the center, then this pressure is
P-P.sub.0 =(2.834×10.sup.-4)pƒ.sup.2 R.sup.2(13)
in pounds per square inch (psi) where R=radial position in cm, ρ=density in gm/cm 3 , and f=frequency in revolutions/sec. Thus, the pressure (or the amount of centripetal force on a fluid) varies directly with the density of the fluid, and as the square of the radial position from the center of rotation as well as the square of the frequency of rotation.
To determine the velocity of liquid in motion in channels on a rotating disk, the equation of motion for the fluid must be solved. An element of fluid of radius a and length dR filling the circular channel has a mass dm subject to acceleration:
dm=πρα.sup.2 dR (14)
The equation of motion for this fluid element is force=(mass) X (acceleration). The forces are centripetal forces, capillary forces due to differences in interfacial energies between the fluid and vapor and fluid and solid surfaces, and dissipative forces due to the viscosity of the liquid and nonuniformity of flow. Capillary forces are ignored; it is understood that centripetal force and/or external pressure may need to be applied to force liquid into channels which are not wetted. As an over-estimate of these dissipative forces, both the force for fully-developed laminar flow of a Newtonian fluid (F L ) and that due to non-uniform flow (F D ) are included:
F=mα
F.sub.c +F.sub.L +F.sub.D =dmα.sub.R (15)
F.sub.c +F.sub.L +F.sub.D =(ρπα.sup.2 dR)α.sub.R(15)
where a R is the acceleration of the fluid mass element along the radius and
F.sub.c =(ρπα.sup.2 dR)ω.sup.2 R
F.sub.L =-(8μπα.sup.2 dR)u
F.sub.D =-(2ρπα.sup.2 dR)u.sup.2 (16)
where μ is the viscosity and u is the radial velocity of the fluid. These last two expressions are standard-mechanics expressions for fully-developed and completely undeveloped laminar flow, such as at channel entrances/exits or at the ends of a flowing droplet. Also note that for tubes or channels inclined at an angle θ with respect to the radius F C would be replaced by (F C ) X cos θ. The final equation becomes
(ρπα.sup.2 dR)ω.sup.2 R-(8μπR)u-(2ρπα.sup.2 u.sup.2 dR)=(ρπα.sup.2 dR)(du/dt) (17)
where the radial acceleration of the fluid is defined by α R -(du/dt). This is a differential equation for the fluid flow velocity.
This equation is solved for specific examples. Consider a droplet of fluid of length L moving in a radial channel of greater length than the droplet.
Because the fluid in the droplet all moves at the same velocity, dR may be replaced by L and R by the average position of the droplet, <R>=(R+L/2).
Dividing out common factors:
(ω.sup.2 (R+L/2)/2)-(8μ/ρα.sup.2)u-2(u.sup.2 /L)=(du/dt)(18)
This equation must be solved numerically. An approximation may be made which has been justified through comparison with numerical solutions. It consists of this: the negative terms on the left-hand-side almost entirely cancel the positive term. Then the right-hand-side can be set to 0 and a solution can be made to the resultant equation for the "terminal velocity" at position R, u 0
(ω.sup.2 (R+L/2)/2)-(8μ/ρα.sup.2)u-2(u.sub.0.sup.2 /L)=0(19)
This is a quadratic equation which has the solution
u.sub.0 =-(B+√ B.sup.2 +4AC)/2A (20)
with
A=L/2
B=8μ/ρα.sup.2 (21)
C=(ω.sup.2)(R+L/2)/2)
In conventional units these become A=2/L, B=320μ/ρD 2 and C=(19.74)ƒ(2R+L) with u 0 =fluid velocity in cm/sec; L=droplet length in cm; μ=viscosity in poise; ρ=fluid density in gm/cm 3 ; D=2a=tube diameter in cm; and R=radial position of the fluid droplet in cm. As described, this expression gives the approximate velocity of a droplet of fluid in a tubular channel, the volume of the droplet resulting in droplet length being shorter than the channel length. This estimate assumes both viscous and non-viscous losses. The velocity of a fluid droplet will increase with increasing density and droplet volume (length), and decrease with increased viscosity. The velocity will increase with increased channel diameter, rotational velocity, and radial position.
Fluid flow velocity in a filled channel connecting a full chamber at position Ro and receiving reservoir at position R 1 is calculated by defining L in equation (19) and subsequent equations as the channel length, L=R 1 -R 0 . Then equation (21) with the definitions following equation (21) are used to calculate the flow velocity in the filled chamber as a function of radius.
The rate of fluid-flow is the product of velocity and channel area:
Q=u.sub.0 πα.sup.2 =u.sub.0 πD.sup.2 /4 (22)
where Q=flow in mL/sec; u 0= velocity in cm/sec (calculated from equations 20 and 21); and D=tube diameter in cm.
The time required to transfer a volume V from a reservoir to a receptacle through a tube or channel of length L depends on whether V is such that the tube is filled (length of a "droplet" of volume V in the tube would be longer than the tube itself) or unfilled by volume V. In the former case, this time is approximately the volume V of the fluid divided by the rate of flow Q; in the latter case it is approximately this calculated time multiplied by the ratio of the tube length to the resultant droplet length:
Dt=V/Q if L≦(4V/πD.sup.2)
Dt=(V/Q)×(4πD.sup.2 L/4V), if L>(4V/πD.sup.2) (23)
wherein Dt is the same time in seconds for fluid of volume V in mL flowing at rate Q in mL/sec to flow from a filled reservoir to a receptacle through a tube of length L and diameter D in cm. The rate of flow Q is calculated from eq. (22) and by extension equations (20) and (21) and the definitions of the parameters following equation (21). The time Dt increases with increasing volume transferred and decreases with increasing flow-rate.
Fluid characteristics such as pressure and velocity are related to physical parameters of the disk, such as disk radius and speed of rotation, as described above. These relationships are illustrated in FIGS. 5A, 5B, 6A, 6B, 7A, 7B, and 8A through 8D, derived from the above equations for water at room temperature, with p=1 gm /cm 3 andμ=0.001 poise. These figures delineate the most relevant parameters of fluid movement on a rotating disk.
FIG. 5A illustrates the relationship between static pressure in a fluid-filled tube 30 cm in length as a function of radial distance (R) and rotation rate (f), calculated from Equation 13. The arrangement of the tube on a rotating disk is shown in FIG. 5B. It can be seen that pressures of between 0 and 10,000 psi can be generated in the tube at rotational speeds of 0 to 10,000 rpm. Pressures of this magnitude are conventionally used, for example, to drive high pressure liquid chromatography (HPLC).
FIG. 6A shows the radial velocity of droplets having volume of 1, 10 and 100 μL droplets moving in an empty, 30 cm long tube with a diameter of 1 mm, calculated from Equations 20 and 21. The rube is aligned to extend along the radius of the disk from the center, and the disk is rotated at speeds of 100, 1,000 or 10,000 rpm. The arrangement of the tube on a rotating disk is shown in FIG. 6B. These velocities may be used to calculate the transfer time for fluid droplets. For example, a 1 μL droplet flows at approximately 20 cm/sec when at a position 2 cm from the center of a disk rotating at 1,000 rpm. Hence, the time to flow through a 1 cm tube can be calculated to be about 0.05 seconds. (For tubes oriented non-radially at an angle of 45° to the direction of rotation, the velocity drops by a factor of 30%.)
FIG. 7A illustrates flow rates in a 5 cm fluid-filled tube of different diameters. The tubes are each placed on a rotating disk and connects two radially oriented reservoirs, shown in FIG. 7B. According to Equation 22, flow rates are a function of radial position of the tube (which vary in this example from 2-30 cm), the tube diameter (10 μm, 100 μm, or 1,000 μm), and rotation frequency (100, 1,000 or 10,000 rpm). (As above, for tubes with a non-radial orientation of 45°, the velocity drops by a factor of 30%). Droplet velocities shown in FIG. 7A were calculated by Equation 11 and flow rates determined using Equation 12.
In FIGS. 8A, 8B and 8C, the time required to transfer 1, 10, and 100 μL droplets, respectively, through a 5 cm tube is shown. The tube connects two radially oriented reservoirs as illustrated in FIG. 8D. Transfer times are a function of radial position of the tube (0-30cm), tube diameter (10 μm, 100 μm, or 1,000 μm), and rotation frequency (100, 1,000 or 10,000 rpm). The curves shown in FIGS. 8A, 8B and 8C were calculated using Equation 23.
Taken together, these formulate and graphs describe the interrelationship of disk radii and rotation speeds, channel lengths and diameters, and fluid properties such as viscosity and density in determining fluid velocities and flow rates on the disk. The assumptions behind these derivations include viscous losses due to Poiseuille (non-turbulent) flow, with the addition of losses due to non-uniform flow of droplets and at tube inlet and outlet ports. These formulae and graphs provide lower limits for velocities and flow rates. Fluid velocities can range from less than 1 cm/sec to more than 1,000 cm/sec, and fluid flow rates from less than 1 pL/sec to tens of mL/sec for rotation rates ranging from 1 to 30,000 rpm. By combining channel diameters and positions on the disk, it is possible to carry out fluid transfer over a wide range of time scales, from milliseconds to hours and tens of hours for various processes.
C. Particular Examples of the Invention
1. Devices Using Centripetal Acceleration and Capillary Forces to Effectuate Fluid Flow
Concerning the use of centripetal force to cause fluid flow in a system influenced by capillary forces, equations (5) and (8) indicate that fluid flow will begin when:
4π.sup.2 ƒ.sup.2 ρLR>γ{(P.sub.R /A.sub.R) cos Θ.sub.R -(P.sub.T /A.sub.T) cos Θ.sub.T} (24
As discussed above, Equation (24) is equivalent to Equation (6) (describing non-wetting fluid flow into a reservoir) when cos Θhd T=1.
According to this equation, flow will not begin until a critical frequency, ƒ*, is achieved (for any particular R, L, contact angles and cross-sectional area and perimeters. This frequency increases with decreasing radial position (as measured from the center of rotation), decreasing L (i.e., smaller reservoirs in the radial direction), and decreasing A T . The choice of appropriate combinations of these variables, and materials (governing contact angles with the liquid) results in a wide varieties of critical frequencies at which fluid flow is effected.
It will be recognized that parameters in equation (24) are subject to variability inherent in analyte fluids or due to the manufacturing processes used to manufacture a centrifugal rotor or microsystems platform. This implies that there are a range of frequencies f* that exist over which fluids will flow in different copies of the same device. A properly designed centrifugal rotor or Microsystems platform manufactured according to this invention will incorporate such variations to provide reproducible fluid movement. For example, if two processes of a centrifugal rotor or Microsystems platform are to occur sequentially at frequencies f1* and f2*, the centrifugal rotor or Microsystems platform is designed according to the invention so that variability in f1* and f2* allows no overlap between the two frequencies. If f1* is 500 rpm±50 rpm, f2* cannot be 525 rpm±50 rpm because both fluids would flow, or a fluid would flow through both rotor or platform structures, at the same rotational rate. Thus, proper rotor or platform design would provide an f2* value of 700 rpm±50 rpm in a rotor or platform having an f1* value of 500 rpm±50 rpm. In this way, a centrifugal rotor or microsystems platform according to the invention can be rotated at 600 rpm providing fluid flow of a first fluid, or through a first component structure in the rotor or microsystems platform, and the rotational rate can be increased to 800 rpm to provide fluid flow of a second fluid, or through a second component structure in the rotor or microsystems platform.
Variations effecting fluid flow can also be present due to properties of the fluid, such as surface tension and density; the contact angle between the fluid and the material of the rotor or platform; and in the dimensions of the component structures (such as microchannels, capillaries, reservoirs, etc.) of the rotor or platform. In view of the definition of f* above, whatever parameter comprising f* having the largest relative variations will dominate (i.e., have the greatest influence) on the variations in f*. (Relative variations are defined for the purposes of this invention as the variation in a parameter a, termed Δa, normalized to the average or specified value of the parameter, or Δa/a) For example, variations in cross-sectional area of microchannels will have a much greater effect on variations of f* than variations in the cross-sectional area of reservoirs, due to the larger relative contribution of a small variation in a generally much smaller cross-sectional area.
The contribution of fluid densities, particularly of biological fluid samples, to the variation in rotational frequency required to effect a particular fluid flow are typically minimized by the addition of diluents having a standard density (such as water or simple buffered solutions such as phosphate buffered saline, known in the art and having a density of approximately 1 g/cm 3 ). Fluid density variations will be understood to contribute to variations in f* by only a few percent.
Surface tension variations of biological fluids are small, because these fluids are primarily comprised of water containing significant contributions of other constituents; for example, blood comprises particulates such as blood cells and platelets, as well as serum proteins, sugars, ions and other metabolites. These constituents may affect surface tension by adsorbing preferentially to the fluid surface on the rotor or microsystem platform. The concentrations of such constituents necessary to saturate a surface are very small. Because the bulk concentrations in the liquids are much larger than is necessary to saturate surfaces, variations in those bulk concentrations do not affect the amount adsorbed to the surface and hence the surface tension. Typical variations in surface tension are on the order of approximately 1-2%.
For the same reason, contact angle variations are recognized to be small contributors to variation in f* values. Additionally, adsorption of components in a fluid, particularly a complex biological sample, to a newly-presented surface during fluid flow on a rotor or Microsystems platform, will be understood to present an additional design consideration. For example, if blood is introduced into a plastic capillary, blood proteins will adsorb to the plastic surface over a period of 1-20 minutes (see Feijen et al., 1979, in Advances in Cardiovascular Physics, vol. 3 (Ghista et al., eds), S. Karger, Basel). This adsorption will effect the wettability and contact angle of the surface.
Variations in the dimensions of the manufactured centrifugal rotor or Microsystems platform will be understood to comprise contributions primarily in the capillaries and microchannels of said rotors and platforms. Manufacturing tolerances for conventional injection molding can routinely be held to about±13 μm, and very precise injection molding can reduce this variability to about±7 μm. For applications which require capillaries smaller than about 100 μm in diameter, manufacturing methods with even greater dimensional tolerances are preferred, such that the relative tolerances remain small. For example, precision diamond milling for the production of a mold for injection molding provides tolerances of about±1 μm, and this tolerance can be easily maintained using such molds in an injection/compression or coining machine. Similarly, deep lithographies such as LIGA may be used to create mold masters featuring component sizes in the range of 100s of μms and holding tolerances within about±1 μm. The creation of a mold is then made through transfers in ways known to those skilled in the art. Conventional photolithography may be used to produce even smaller structures, on the order of 10 microns (μms) in size, with tolerances in the range of ±0.1 μm. A new technique, termed micromilling uses microscopic tools on the order of tens of microns in size to mill patterns into plastic substrates with tolerances of ±0.1 μm, which patterns may then be transferred to a mold insert. These and other methods known to those with skill in the art can be used to prepare the rotors and microsystems platforms of the invention whereby variability in the components of the rotor or platform are minimized to produce more uniformity in the performance of the rotors or platforms.
Variations in contact angle may be controlled by treatment of the biological fluid, the surface, or both (See Benvenutti & Del Maso, 1989, in Polymers: Their Properties and Blood Compatibility, Kluwer Academic Publishers: Dordrecht). For example, surfaces can be pre-incubated with a solution of serum albumin to "pre-block" the surface with a homogeneous protein solution and thereby prevent adsorption of serum proteins from blood samples. (Benvenutti & Del Maso, Id.) The presence of these proteins on the surface thus stabilizes the contact angle when the surface is in contact with a complex, protein-containing solution such as blood. Fluid treatment can alternatively be effected by the addition of a component that binds to the surface in preference to adsorption of biological fluid components. Additional modifications include heparinization of the surface, or the addition of heparin to the biological fluid, for example, in blood to prevent coagulation; addition of heparin is, of course, required in embodiments of methods of using the rotors and microsystems platforms of the invention directed towards, for example, separation of blood components.
Another consideration affecting variation in contact angle is nonhomogeneity in the surface due to variations of the surface "roughness" at the microscopic level. These variations produce hysteresis in the contact angle over a range through which the contact angle varies. The contribution of hysteresis is significant because the maximum contact angle in this range will determine the pressure (and hence rotational speed) at which fluid flow will occur through a capillary structure. This range will be a characteristic of the manufacturing process, and will be understood to contribute variation in cos Θ of no more than approximately 1-2%.
The dominant source of variation in f* is that which has the largest variation. Variations in contact angle and surface tension are on the order of 1-2%. If variations in the capillary cross-sectional dimensions are greater than 1-2%, frequency variations will arise due to these variations in dimension, and will be related by the equation: Δf*/f*=(Δa/a) 1/2 .
In the construction of the microsystems platforms and rotors of the invention, it will be recognized that a fluid-impermeable lid or cover over the first platform surface is necessary, because fluid must be confined to a capillary junction in order for centripetal and capillary forces to be useful in controlling fluid flow. Methods by which such lids or surface coverings can be attached to the surface of the platforms or rotors of the invention include screen-printable ultraviolet light cure-utilizing utilizing methods, pressure-sensitive sealing methods, or heat-cured glues or epoxies. Also useful are spin coating such adhesives from a solution onto the lid material using conventional photolithography; the use of self-adhering films or heat-sealable films; as well as ultrasonic welding. Dimensional tolerances required for such lid-welding methods are expected to provide a minimum of about±2.5 μm, while certain of these methods will advantageously produce even better tolerances.
In one non-limiting example, a volume of 100 μL of water is sequentially moved from a reservoir near the center of a rotating disk towards the edge of the disk. All parts are manufactured from a single material having a contact angle of 100 ° (>90°, therefore non-wetting with water). The surface tension of water is γ=72 dyne/cm 2 and the density is ρ=1 g/cm 3 . Rectangular reservoirs and tubes having width W and thickness T are arranged along the radial direction of the disk. Reservoirs having the dimensions listed in the Table below are located at radial positions R, having the following critical frequencies:
TABLE I______________________________________R(cm) W.sub.R (cm) T.sub.R (μm) W.sub.T (μm) T.sub.T (μm) f(rpm)______________________________________2 1 0.1 150 150 9293.5 1.5 0.1 110 110 10065 2 0.1 80 80 1142______________________________________
where water flows from each reservoir into the tube connecting it with the next reservoir at the given frequency and when P R =2.2 cm, A R =0.1 cm 2 , T T =0.06 cm and A T =2.25×10 -4 cm 2 ; when P R =3.2 cm, A R =0.15 cm 2 , T T =0.044 cm and A T =1.21×10 -4 cm 2 ; and when P R =0.5 cm, A R =0.5 cm 2 , T T =0.032 cm and A T =0.64.×10 -4 cm 2 .
FIG. 9 illustrates this sequence of fluid motion. In this example, fluid is placed in the first reservoir closest to the center of rotation. By using Equation (6) it is determined that fluid is expected to flow from the first reservoir through the first tube at a rotational frequency of at least 929 rpm but less than 1006 rpm. By rotating the disk at between 929 rpm and 1005 rpm, the fluid flows from the first reservoir into the first tube or channel, and then empties into the second reservoir; this is because the pressure needed to traverse the interface between the first tube and the second reservoir is less that the pressure generated at that point on the disk when the disk is accelerated to at least 929 rpm but less than 1006 rpm. This description is also understood in terms of the equations presented above; fluid will flow when the pressure at this position on the disk and at this rotational rate as expressed by Equation (5) is greater that the pressure due to capillary forces as expressed in Equation (5). Upon flowing into the second reservoir, however, capillary forces halt fluid flow, because the pressure needed to traverse the interface between the second reservoir and the second tube is more that the pressure generated at that point on the disk when the disk is accelerated to at least 929 rpm but less than 1006 rpm. By increasing the rotation rate to 1006 rpm, the fluid is motivated to flow from the second reservoir into the second tube or channel, and then empties into the third reservoir; this is because the pressure needed to traverse the interface between the second tube and the third reservoir is less than the pressure generated at that point when the disk is accelerated to 1006 rpm. Upon flowing into the third reservoir, however, capillary forces again halt fluid flow, because the pressure needed to traverse the interface between the third reservoir and the third tube is more than the pressure needed to traverse the interface between the third reservoir and the third tube is more than the pressure generated at that point on the disk when the disk is accelerated to 1006 rpm. By increasing the rotation rate to 1142 rpm, fluid flows from the third reservoir into the third tube or channel, and then empties into the fourth and last reservoir.
Ranges of tube/channel architecture and rotational speed are greatly increased for surfaces that are more hydrophobic. This principle is illustrated for a microplatform disk as shown in FIG. 9, comprising a material having a contact angle of 110°;
TABLE II______________________________________R(cm) W.sub.R (cm) T.sub.R (cm) W.sub.T (μm) T.sub.T (μm) f(rpm)______________________________________2 1 0.1 250 250 7073.5 1.5 0.1 150 159 8545 2 0.1 100 100 1015______________________________________
where water flows from each reservoir into the tube connecting it with the next reservoir at the given frequency.
Other non-limiting examples include:
1. Microplatforms and other microsystems fabricated of a single material having a contact angle of <90°. Due to the dependence of the pressure in Equations (5) and (7) on trigonometric functions, the sign of the pressures changes, reflecting the fact that the surfaces of the device preferentially wet with fluid. As a result, fluid is drawn by capillary action from the large reservoir into the tube of smaller cross-sectional area. If fluid motion into the second reservoir results in a decrease in the amount of the wetted surface, capillary forces will act to oppose further flow, forming a capillary action valve analogous to those discussed above. Pressure must then be applied to initiate further flow. Reservoir and tube geometry (such as sharp exit tips on the channel) are use to ensure the need for positive pressure for the fluid to enter the second reservoir. Thus, arrangement of the component geometries, and choice of material and contact angles, permit selective and differential fluid flow between reservoirs and reaction chambers via connecting channels.
2. Centrifugal rotors, microplatfonms and Microsystems arc also fabricated comprising material having contact angles <90° and other material having contact angles >90°. For example, using aqueous solutions a fluid reservoir may be hydrophilic (contact angle <90°), whereas a tube or channel is fabricated from a material having a contact angle >90° (thereby requiring positive pressure to be applied to motivate fluid flow from the reservoir into the channel).
3. Reservoirs and channels are also provided in certain embodiments of the invention having variable cross-sectional area and/or perimeter in the direction of fluid flow (e.g., radially in a microplatform disk system). As fluid flow, the position of solid-liquid-vapor contact also move; as the cross-sectional areas change, the pressures defined in Equation (1) change as well, changing the magnitude of total capillary forces. An advantage of such design is that the rate of fluid flow in the channel can be more precisely controlled. For example, channels can arrayed on a platform whereby the force opposing fluid flow increases with distance form the center of the platform, thereby requiring increased rotational speed to overcome such forces as fluid flows through the system.
4. Relatively large-scale (i.e., micron-size) imperfections are provided on the interior of tubes or reservoirs, to provide directionality of fluid flow, to limit fluid velocity, or to otherwise control flow. (See Columbus and Palmer, 1987, Clinical Chemistry) 33 1531.
b. Devices Using Centripetal Acceleration and Capillary Forces to Meter Fluid
The invention provides means for producing aliquots of a fluid from a reservoir or other fluid chamber or channel. Such aliquots are provided by a combination of centripetal acceleration and capillary action and are dependent on the geometry of the ends of the reservoirs and channels. The provision of aliquots is illustrated by the following example. Pressure is applied to a fluid to motivate the formation of a droplet at an opening to a reservoir or at the end of a channel, as described by Equation (6) above. The volume of a droplet formed at a given pressure is then calculated using Equations (7) and (8) as follows:
ρVα.sub.c =ρVω.sup.2 R=k(2πrγ)
V=(krγ)/(2πρƒ.sup.2 R) (25)
For a tube or channel having a diameter of 200 μm (corresponding to a radius of 100 μm), droplets with a volume of 1 μL are released when subjected to an acceleration of 5 g (for a value of the constant k=1). Acceleration of this magnitude is achieved by rotation at 470 rpm for a reservoir or channel positioned 2 cm from the center of rotation. Because droplets form at a finite rate (a rate determine by the geometry of the fluidics system, the contact angle (determined by the material from which the microsystem is fabricated), and the fluid density), rotational speed can be adjusted to the critical frequency for a time sufficient for a single droplet to be delivered, followed thereafter by a reduction in rotational speed.
Droplets form at a finite rate determined by the geometry of the fluidics system, the contact angle, surface tension, fluid density and pressure supplied by rotation of the disk. The relationship between droplet formation and these parameters can determined (see Adamson, Id.)
c. Devices Using Centripetal Acceleration and Capillary Forces to Produce and Deliver Enriched Droplets
The invention also provides means for producing aliquots of a fluid from a reservoir or other fluid chamber or channel, wherein the droplet contains a concentration of particulates contained in the fluid. This aspect of the invention is illustrated in FIG. 10 for a simple fractionation aliquot dispensing system made from non-wetting material. A solution containing a fluid and particulates (such as cells, for example) is introduced into a conical reservoir that empties through a sharp "tip" or constriction at one end of the direction of fluid flow into a larger chamber, the tip having a small diameter relative to the conical reservoir. Rotation at a frequency below the critical frequency necessary for movement of fluid through the orifice as a droplet results in concentration of the particulates at the end of the conical reservoir, i.e., at the position of the sharp tip. (This is analogous to conventional centrifugation performed at a microscopic scale.) A droplet containing a concentration of the particulates is then produced by increasing the rotation rate to the critical frequency for a time sufficient to produce the droplet. The droplet produced has a volume given by Equation (10); from the volume of the droplet and the concentration of the particulates in both the original fluid and after production of the droplet the concentration of the particulates in the droplet is determined. Alternatively, means such a spectrophotometric means may be used to determine concentration, as described in International Application WO97/21090, incorporated by reference herein.
An advantage of using conical reservoir for a non-wetting fluid levels in the reservoir (because the ratio of the area of the liquid-vapor and liquid-solid interface decreases). As a result, the magnitude of the pressure required to produce a droplet (and the critical frequency) increases with the production of a droplet. This ensures that only a single droplet is produced, absent an increase in rotational speed.
It will be recognized that the surface tension of the fluid will vary depending on the concentration of particulates, an extreme example being the presence of detergents or surfactants in the solution. Detergents and surfactants decrease surface tension to a reproducible value when present in very dilute quantities, producing no important impediment to operation of the device. Particulates affect surface tension through a colligative effect (reducing surface tension as concentration of particulates is increased). This characteristic can be used to increase droplet formation under circumstances where particulates (such as cells) are concentrated or enriched at the exit orifice of a passage: rotation at a speed below the threshold for bulk fluid flow may provide pressure on a concentrated solution comprising particulates sufficient for droplet formation to occur.
It will be recognized that the above theoretical consideration and mathematical formulae will deviate with expected deviations from ideality; such deviation are within the skill of a worker of ordinary skill to determine without undue experimentation. One example of a expected deviation from ideality is a consequence of neglecting the influence of gravity on fluid flow in the above theoretical discussion. The effect of gravity is in turn dependent on the geometry of the microstructure: in axis of rotation being typically vertical, gravity acts perpendicular to the direction of fluid flow and is expected to have a negligible effect over typical fluid densities and viscosities (e.g., using aqueous solutions). Contact angles are affected by adsorption of solution components (such as proteins); it is known, however, that the creation of microscopic irregularities in the reservoir and tube (or channel)wall make such variation in contact angle virtually unimportant (see Columbus and Palmer, ibid.). Orifice shape, fluid density and other variables also influence the specific dynamics of fluid flow. It is also known that surfaces can be treated to prevent adsorption of solution components, using methods such as silation and plasma treatment.
Because the flow restriction devices of the invention do not involve physical "closing" of valves, the following additional consideration exist: evaporation, condensation and aerosol production in liquids valved by the invention. Evaporation is a concern in long-term storage of devices comprising liquids whose fluid flow is to be controlled using the valves of the invention. Condensation issues similarly arise for devices stored comprising dry reagents which must not be prematurely wetted due to adsorption of water or other fluids that condense upon temperate changes or otherwise. Either of these potential difficulties can be addressed by the placement of a thin film of poly(ethylene oxide) or glycerine within the capillaries of the devices comprising the microvalve of the invention, which would provide an effective barrier to water vapor and aerosols. Such barriers are also advantages because bulk fluid flow dissolves the barrier, and the amount of such barrier material used is sufficiently small that its presence in the analytic fluid is inconsequential (e.g., 0.1-1.0 microlitres).
Aerosol production can be reduced using channels having sharp curves (such as "U" tubes) or other curved, serpentine designs.
It will also be recognized that liquid contact with surface material such as certain plastics can cause swelling of the material due to diffusion of the fluid into the material. This is particularly significant in plastic that are wetted by specific fluids such as water. Such swelling could change the cross-sectional areas of the invention. Swelling can be reduced by surface coating, e.g., with silicone oxides or polymer laminates. Swelling can also be an expected part of the design of such systems: assuming that the shelf-life of a product is known, the degree of swelling over the lifetime of the product can be properly estimated and the shape and configuration of the microsystem can be designed to minimize the effects of swelling.
EXAMPLE 1
Fabrication of Microplatform Disks for Chemical Analysis, Synthesis, and Applications
Microplatform disks of the invention are fabricated from thermoplastics such as teflon, polyethylene, polypropylene, methylmethacrylates and polycarbonates, among others, due to their case of molding, stamping and milling. Alternatively, the disks can be made of silica, glass, quartz or inert metal. A fluid handling system is built by sequential application of one or more of these materials laid down in stepwise fashion onto the thermoplastic substrate. FIGS. 11A through 11E are a schematic representation of a disk adapted for performing DNA sequencing. Disks of the invention are fabricated with an injection molded, optically-clear base layer having optical pits in the manner of a conventional compact disk (CD). The disk is a round, polycarbonate disk 120 mm in diameter and 100 pm thick. The optical pits provide means for encoding instrument control programming, user interface information, graphics and sound specific to the application and driver configuration. The driver configuration depends on whether the micromanipulation device is a hand-held, benchtop or floor model, and also on the details of external communication and other specifics of the hardware configuration. This layer is then overlaid with a reflective surface, with appropriate windows for external detectors, specifically optical detectors, being left clear on the disk. Other layers of polycarbonate of varying thickness are laid down on the disk in the form of channels, reservoirs, reaction chambers and other structures, including provisions on the disk for valves and other control elements. These layers can be pre-fabricated and cut with the appropriate geometries for a given application and assembled on the disk. Layers comprising materials other than polycarbonate can also be incorporated into the disk. The composition of the layers on the disk depend in large part on the specific application and the requirements of chemical compatibility with the reagents to be used with the disk. Electrical layers can be incorporated in disks requiring electric circuits, such as electrophoresis applications and electrically-controlled valves. Control devices, such as integrated circuits laser diodes, photodiodes and resistive networks that can form selective heating areas or flexible logic structures can be incorporated into appropriately wired recesses, either by direct fabrication of modular installation onto the disk. Reagents that can be stored dry can be introduced into appropriate open chambers by spraying into reservoirs using means similar to inkjet printing heads, and then dried on the disk. A top layer comprising access ports and air vents, ports or shafts is then applied. Liquid reagents are then injected into the appropriate reservoirs, followed by application of a protective cover layer comprising a thin plastic film.
EXAMPLE 2
Fluid Metering Microsystems Platform
A microsystem platform is constructed as described in Example 1 from components having a contact angle less than 90° for all fluids to be applied to the platform, and having components arrayed on the platform to provide metered fluid delivery to a fluid chamber in a defined volume. A diagrammatic representation of this platform is shown in FIG. 12.
An entry port A having a depth in the platform surface from about 0.25 mm to about 1 mm and lateral dimensions of from about 0.2 cm to about 2 cm is constructed on the platform fluidly connected with a metering capillary B having a cross-sectional diameter of from about 0.02 mm to about 0.75 mm and proximal ends rounded with respect to entry port A. The entry port is also constructed to be fluidly connected with an overflow capillary C having a cross-sectional diameter of from about 0.02 mm to about 0.75 mm and proximal ends rounded with respect to entry port A. The overflow capillary is fluidly connected with an overflow chamber D having a depth in the platform surface greater than the depth of the overflow capillary C and that ranges from about 0.02 mm to about 1 mm. Metering capillary B is fluidly connected to fluid chamber E having a depth in the platform surface greater than the depth of the metering capillary B and that ranges from about 0.02 mm to about 1 mm. Each of the overflow and fluid chambers is also connected with air ports or air channels, such as F, that have dimensions of about 0.02 mm to about 1 mm and permit venting of air displaced by fluid movement on the platform. A capillary junction G is present in the air channel to prevent fluid flow into the air channel.
Entry port A is positioned on the platform from 1 cm to 20 cm from the center of rotation. Metering capillary B extends from entry port A from about 0.5 cm to about 1 cm. The extent of the length of overflow capillary C is at least about 20% greater than the extent of the length of metering capillary B. The position of fluid chamber E is from about 0.5 cm to about 10 cm from the center of rotation, and the position of overflow chamber D is thus from about 1.5 cm to about 11.5 cm from the axis of rotation.
In the use of this platform, an imprecise volume (ranging from 1-150 μL of fluid) of a fluid is applied to the entry port A. In embodiments of the platform comprising air displacement channels, the fluid will wick into air channel F. The presence of the capillary junction G in air channel F prevents fluid flow into the air channel. Fluid also wicks into metering capillary B and overflow capillary C. Fluid flows through the metering capillary B and overflow capillary C at no rotational speed until the fluid reaches capillary junctions at the junction between metering capillary B and fluid chamber E and overflow capillary C and overflow chamber D. Metering capillary B is constructed to define a precise volume from about 1-150 μL of fluid between entry port A and the capillary junction at fluid chamber E, which is designed to be at least the amount of the fluid placed by the user in entry port A.
After sample loading by a user and filling of metering capillary B and overflow capillary C at no rotational speed, the platform is spun at a first rotational speed ranging from 10-500 rpm; the exact value is dependent on the position of the components on the platform. For example, for an entry port A having a depth of 0.6 mm, metering capillary B having dimensions of 0.5 mm×0.5 mm in cross-section and a length of 2.2-3.8 cm from the center of rotation, overflow capillary C having dimensions of 0.5 mm×0.5 mm in cross-section and a length of 5.4 cm from the center of rotation, this first rotational speed is equal to 128 rpm for either water or milk.
Due to the greater distance of the end of overflow capillary C from the center of rotation than the end of metering capillary B, fluid flows through overflow capillary C into overflow chamber D. The platform is spun until all excess fluid is evacuated from entry port A and into overflow chamber D, except the fluid contained in metering capillary B.
At a second rotational speed that is greater than the first rotational speed, typically in the range of 100-2000 rpm, the precise amount of fluid contained in metering capillary B is delivered into fluid chamber E. For example, for an entry port A having a depth of 0.6 mm, metering capillary B having dimensions of 0.5 mm×0.5 mm in cross-section and a length of 2.2-3.8 cm from the center of rotation, overflow capillary C having dimensions of 0.5 mm×0.5 mm in cross-section and a length of 5.4 cm from the center of rotation, this second rotational speed is equal to 400 rpm for either water or milk.
EXAMPLE 3
Fluid Displacing Microsystems Platform
A microsystem platform is constructed as described in Example 1 having a contact angle greater than or less than 90°, and having components arrayed on the platform to provide fluid displacement from a first fluid chamber to a third fluid chamber using a displacement fluid contained in a second fluid chamber.
Three fluid chambers A, B and C are arrayed on the platform as shown in FIG. 13. Each chamber ranges in depth in the surface of the platform from about 0.25 mm to about 1 mm and lateral dimensions of from about 0.2 cm to about 2 cm. A capillary D leading from fluid chamber B has a cross-sectional diameter of from about 0.02 mm to about 0.75 mm. A capillary junction E is fluidly connected with capillary D and has dimensions at least as deep and wider than capillary D. A flow channel F having cross-sectional dimensions of from about 0.02 mm to about 0.75 mm is fluidly connected to capillary junction E and with fluid chamber A. A capillary G is fluidly connected to both fluid chambers A and C and has cross-sectional dimensions of from about 0.02 mm to about 0.75 mm. Also provided on the platform are air ports and channels H and K, optionally comprising capillary junction I to prevent fluid flow through the air channels.
This collection of components is positioned on the platform from about 1 cm to about 20 cm from the center of rotation. In the arrangement of these components, fluid chamber A is radially positioned farther from the center of rotation relative to fluid chamber B. Capillary G comprises a path so that fluid flow passes through the capillary at a point closer to the center of rotation than the inward extent of fluid chamber A. Fluid chamber C may be positioned at the same radius as chamber A or more distantly from the center of rotation.
Fluid chamber B is charged with displacement fluid, typically on manufacture or in preparation of the platform for use. Fluid chamber A usually contains a fluid sample, introduced directly or using metering capillaries as described in Example 2 or otherwise; such combinations of the components of the platforms of the invention are within the skill of those with skill in the art to combine. The volume of displacement fluid in fluid chamber B is typically greater than the volume of sample fluid in fluid chamber A. Upon rotation of the platform at a rotational speed F1, which ranges from about 50-3000 rpm, displacement fluid flows through capillary D, capillary junction E, flow channel F and into fluid chamber A. Because of the dimensions of the components of the platform, fluid flow is laminar. In response to fluid flow of displacement fluid into fluid chamber A, the sample fluid in chamber A flows through capillary G and into fluid chamber C. The geometry of capillary G ensures that fluid chamber A remains filled at all times during displacement of sample fluid into fluid chamber C. Fluid flow proceeds with rotation of the platform until all sample fluid in chamber A is replaced by displacement fluid, and sample fluid is dispensed into fluid chamber C. Because of laminar fluid flow, very little mixing of sample fluid and displacement fluid occurs.
EXAMPLE 4
Increase in Optical Pathlength Using Integral Mirrors in a Rotating Microplatform for Performing Spectrophotometric Measurements
Spectrophotometric measurements in centrifugal rotors or microsystems platforms encounter limitations relating to relatively short pathlengths across such Microsystems platforms or through microanalytical rotors. Since the amount of light absorbed by a solution at any wavelength is directly proportional to both the depth of the absorbing layer (i.e., the spectrophotometric pathlength) and the concentration of the absorbing molecules (the Lambert-Beer law), improvements in spectrophotometric measurement over a range of solution concentrations of absorbing molecules can be addressed through increasing the pathlength through the absorbing solution.
In a microsystem platform according to this invention and as disclosed in International Application No. WO97/21090, the top-to-bottom pathlength is extremely abbreviated, typically ranging from about 0.1 mm to about 1 mm. However, such a platform can also present a relatively wide lateral aspect (see FIG. 12). As a result, spectrophotometric measurement can be improved by increasing the pathlength in the lateral dimension.
This embodiment of the invention is illustrated in FIG. 12. Light from a spectrophotometric light source, typically at a particular wavelength, is shone perpendicularly on the surface of the platform or rotor. The platform or rotor comprises a measurement cell having optically transparent side walls embedded in and perpendicular to the plane of the platform surface. In optical proximity to the transparent sidewalls of the measurement chamber is a first mirror, angled at a 45° angle to the plane of the transparent sidewalls, wherein the mirror is embedded in the surface of the platform or rotor and is either exposed to or covered by an optically-transparent portion of the surface of the platform. The spectrophotometric light source is positioned perpendicularly relative to the plane of the surface of the platform and in a position to illuminate the first mirror. Light is reflected from the first mirror, through the transparent sidewall on a first side of the optical measurement chamber, across the extent of the measurement chamber and through the transparent sidewall on the other side of the optical measurement chamber. Positioned in optical proximity to the transparent sidewalls of the measurement chamber is a second mirror, angled at a 45° angle to the plane of the transparent sidewalls, wherein the mirror is either exposed to or covered by an optically-transparent portion of the surface of the platform. Light emitted through the transparent sidewall of the optical measurement chamber is reflected by the second mirror perpendicularly to the surface of the rotor or microsystem platform and onto a photosensitive light collector, for example, a photoelectric cell, a photodiode or a photomultiplier tube calibrated to measure the absorbance or % transmittance of the reflected light.
The mirrors of this embodiment of the invention can either be manufactured and embedded in the surface of the rotor or platform, or the surfaces of the platform or rotor comprising the mirrors can be integrally molded and metallicized in plastic.
It will be understood that the foregoing discussion emphasizes certain specific embodiments of the invention and that all modifications or alternatives equivalent thereto are within the spirit and scope of the invention as set forth herein.
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The invention provides microvalves for controlling fluid flow from microreservoirs into transfer channels using capillary valving mechanisms for use in apparatus useful for performing microanalytic and microsynthetic analyses and procedures, such as microminiaturization of genetic, biochemical and chemical processes related to analysis, synthesis and purification of biological, chemical, environmental and other compounds.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to Korean Patent Application No. 10-2014-0036970, filed on Mar. 28, 2014, and all the benefits accruing therefrom under 35 U.S.C. §119, the contents of which in its entirety are herein incorporated by reference.
BACKGROUND
[0002] 1. Field
[0003] Disclosed herein is a gene having resistance to furfural, which is a by-product of a hydrolysate derived from lignocellulosic biomass, and a strain comprising the same.
[0004] Description about National Support Research and Development
[0005] This study is conducted by the support of Korea Ministry of Science, ICT and Future Planning under the supervision of Korea Institute of Science and Technology, and research title is development of technique for manufacturing next generation fuel/material by integrated utilization of lignocellulosic biomass (2N36860) (Research management agency: Korea Research Council of Fundamental Science and, Grant Number: CAP-11-1: Creative Allied Program[CAP]).
[0006] 2. Description of the Related Art
[0007] As concerns about global warming and oil resource depletion rise, world bio research fields pay more attention to development of alternative energy sources and alternative materials of petrochemicals. For this, studies into production of bio-fuels and platform chemicals from lignocellulosic biomass by fermentation of microorganism strain are actively going on. The lignocellulosic biomass mainly consists of cellulose, hemicellulose, lignin and the like, and can be converted to renewable fuels, plastics and other various chemicals by fermentation of microorganism.
[0008] In order to use the lignocellulosic biomass to microorganism fermentation, a pre-treatment process for hydrolyzing cellulose to sugar is needed. However, various by-products, which are made during the pre-treatment process, as well as sugars such as glucose and xylose, which can be used by microorganisms, are contained in a hydrolysate, which is made during the pre-treatment for sugar hydrolysis using acid at high temperature and pressure. Examples of the by-products made during the pre-treatment process for sugar hydrolysis are furfural, hydroxymethylfurfural (HMF), acetic acid and the like. Because these have toxicity to microorganisms, there is a problem of decreased productivity on the fermentation process using the hydrolysate. Accordingly, development of a strain having resistance to a toxic material in the hydrolysate is necessary.
[0009] Furfural made from xylose, among the by-product existing in the hydrolysate, is one of important materials inhibiting microorganism fermentation in the hydrolysate, and the toxicity of the hydrolysate has considerable relevance to the concentration of the furfural. The furfural is converted to furfuryl alcohol, which is relatively less toxic than the furfural in cells. In the process, it uses NADH or NADPH, and intracellular amount of the NAD(P)H becomes unbalanced, thereby inhibiting cell growth and fermentation. In addition, it is known that its toxicity becomes severe because it causes genetic mutation, makes cell membrane weak, and interacts with other materials in the hydrolysate such as hydroxymethylfurfural and acetic acid.
REFERENCES OF THE RELATED ART
Patent Document
[0000]
International Patent Publication No. WO2012-135420A2 (2012 Oct. 4)
Korean Patent Publication No. 10-2003-0040605 (2003 May 23)
Non-Patent Document
[0000]
Wang, X., E. Miller, et al., 2011, “Increased furfural tolerance due to overexpression of NADH-dependent oxidoreductase FucO in Escherichia coli strains engineered for the production of ethanol and lactate.” Applied and environmental microbiology 77(15): 5132-5140
Sasano, Y., D. Watanabe, et al., 2012, “Overexpression of the yeast transcription activator Msn2 confers furfural resistance and increases the initial fermentation rate in ethanol production.” Journal of bioscience and bioengineering 113(4): 451-455
SUMMARY
[0014] The present disclosure is directed to providing a gene having resistance to furfural, which is a toxic by-product contained in a hydrolysate derived from lignocellulosic biomass, and a strain containing the same.
[0015] In one aspect, there is provided a furfural-resistant gene containing at least one genetic sequence selected from the group consisting of the cg1661 (SEQ ID No.: 1) and cg1310 (SEQ ID No.: 2) gene, and a furfural-resistant strain containing the same.
[0016] In another aspect, there is provided a screening method of the furfural-resistant gene, which contains: selecting a target gene for identifying the furfural-resistant gene; and after inserting the target gene into a wild type and overexpressing thereof, selecting a gene showing furfural resistance as the furfural-resistant gene.
[0017] The furfural-resistant strain containing the furfural-resistant gene according to the present disclosure shows faster growth speed than the wild type (wild type strain) in the furfural-containing medium. Thus, it may increase production rate of the material, which is produced by the wild type. Accordingly, the problem that microorganism fermentation was difficult because toxic by-products such as furfural are contained in a hydrolysate derived from inedible lignocellulosic biomass may be solved. Thus, it may effectively produce food additives, feed additives and the like such as amino acids from inedible biomass as well as the existing starch-based biomass without growth inhibition or production rate reduction by the toxic materials in a hydrolysate.
[0018] Further, according to the method for producing a strain of the present disclosure, the resistant gene may be selected from relatively small number of target genes. Thus, time, cost and the like for developing the resistant strain may be saved. Further, this method for identifying genes may be broadly applied to methods for identifying various unknown functional genes in addition to the furfural-resistant gene.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] The above and other aspects, features and advantages of the disclosed exemplary embodiments will be more apparent from the following detailed description taken in conjunction with the accompanying drawings in which:
[0020] FIG. 1 is a graph showing growth curve of Corynebacterium glutamicum wild type strain (wild type) in a medium containing furfural of various concentrations (0, 6.5, 13 and 20 mM);
[0021] FIGS. 2 a to 2 c are graphs showing the result of analyzing the concentrations of furfural and furfuryl alcohol in the furfural-containing medium according to the growth of Corynebacterium glutamicum , wherein FIG. 2 a is the case of the medium containing 6.5 mM furfural, FIG. 2 b is the case of the medium containing 13 Mm furfural, and FIG. 2 c is the case of the medium containing 20 mM furfural;
[0022] FIG. 3 is an image schematically showing the process of homology search of FucO in Corynebacterium glutamicum;
[0023] FIG. 4 is a graph comparing relative growth of target gene-transformed strains (pAN6-cg0310, pAN6-cg1310, pAN6-cg1661 and pAN6-cg3374) and a positive control group (pAN6-b2799) in the medium containing 6.5 mM furfural, with growth rate of a negative control group (pAN6) in the medium not containing the furfural, respectively; and
[0024] FIG. 5 is a graph comparing relative growth of target gene-transformed strains (pAN6-cg0310, pAN6-cg1310, pAN6-cg1661 and pAN6-cg3374) and a positive control group (pAN6-b2799) in the medium containing 13 mM furfural, with growth rate of a negative control group (pAN6) in the medium not containing the furfural, respectively.
DETAILED DESCRIPTION
[0025] Exemplary embodiments now will be described more fully hereinafter with reference to the accompanying drawings, in which exemplary embodiments are shown.
[0026] Embodiments of the present disclosure provide a furfural-resistant gene containing at least one genetic sequence selected from the group consisting of cg1661 (SEQ ID No.: 1) and cg1310 (SEQ ID No.: 2) gene.
[0027] The furfural is an organic compound made from by-products during sugar hydrolysis process of various biomass, and has a chemical formula of OC 4 H 3 CHO and a chemical structure of the following formula (I). The furfural is toxic, and therefore, it deteriorates production speed of microorganism and production rate of fermentation product when fermenting microorganism in a hydrolysate of biomass.
[0000]
[0028] Accordingly, embodiment of the present disclosure provides a furfural-resistant strain, which contains the furfural-resistant gene, thereby having excellent growth capability under furfural-containing environment. Specifically, the furfural-resistant strain according to embodiments of the present disclosure is a strain, wherein the furfural-resistant gene containing the cg1661 (SEQ ID No.: 1) and cg1310 (SEQ ID No.: 2) gene is inserted in a wild type. In one embodiment, the wild type is Corynebacterium glutamicum , specifically Corynebacterium glutamicum ATCC 13032 (ACCESSION NC — 006958, VERSION NC — 006958.1 GI:62388892). The insertion of the gene is conducted by inserting the furfural-resistant gene into the wild type using a vector and then overexpressing thereof, and the vector may be, for example, a plasmid such as pAN6. In one embodiment, the furfural-resistant strain is Corynebacterium glutamicum ATCC 13032/pAN6-cg1661 (KCTC 12565BP).
[0029] The furfural-resistant strain according to embodiments of the present disclosure may be grown in a furfural-containing medium. Further, growth of the furfural-resistant strain according to one embodiment in the furfural-containing medium is increased about 1.4 folds or more, more specifically about 1.8 folds or more, compared to a wild type. When the wild type is Corynebacterium glutamicum , the Corynebacterium glutamicum wild type (wild type strain) is hard to be grown in the hydrolysate derived from lignocellulosic biomass due to toxicity of the furfural contained in the hydrolysate. However, the furfural-resistant strain according to embodiments of the present disclosure has furfural resistance by containing the furfural-resistant gene of the present disclosure. Thus, it may be effectively grown in the hydrolysate derived from lignocellulosic biomass, thereby having further increased amino acid productivity, compared to the wild type.
[0030] Accordingly, embodiments of the present disclosure may provide a method for producing amino acids, which contains inoculating the furfural-resistant strain into the hydrolysate derived from lignocellulosic biomass.
[0031] Further, another embodiment of the present disclosure may provide a method for screening the furfural-resistant gene, which contains:
[0032] selecting a target gene for identifying the furfural-resistant gene; and
[0033] after inserting the target gene into the wild type and overexpressing thereof, selecting a gene showing furfural resistance as the furfural-resistant gene.
[0034] In order to select the target gene for identifying the furfural-resistant gene, embodiments of the present disclosure may contains at least one of:
[0035] searching genes, which are expected to have furfural-resistance through literature search, and selecting a gene, which is similar with the gene searched through the literature, among genes of the wild type, as the target gene; and
[0036] analyzing gene expression pattern depending on furfural stress using microarray, and selecting a gene showing high expression level as the target gene.
[0037] In one embodiment, selecting the target gene through literature search may contain searching furfural-resistant genes known in literature, and selecting genes showing high similarity in the wild type by homology search as the target gene. For example, from [Wang, X., E. Miller, et al., 2011, “Increased furfural tolerance due to overexpression of NADH-dependent oxidoreductase FucO in Escherichia coli strains engineered for the production of ethanol and lactate.” Applied and environmental microbiology 77(15): 5132-5140], it may be found that the NADH-dependent oxidoreductase (fucO) converts the furfural to furfuryl alcohol (see the following chemical formula (II)). Then, the genes in the wild type, which are similar with the searched FucO, may be selected as the target gene. At this time, the contents of the literature in its entirety are herein incorporated by reference.
[0000]
[0038] In one embodiment, when the parent strain is Corynebacterium glutamicum , cg1310 (rolM, maleylacetate reductase, SEQ ID No.: 2), which is similar with the genes searched by the literature in Corynebacterium glutamicum genes, may be selected as the target gene.
[0039] In another embodiment, specifically, selecting the target gene using microarray may contain: treating the furfural to the wild type at different concentrations, conducting microarray to mRNA of the wild type, and then selecting genes, whose gene expression change depending on furfural stress, namely, whose expression pattern increased by the furfural, is judged to have relevance to furfural resistance, as the target gene. For example, when using Corynebacterium glutamicum as the wild type, cg0310 (SEQ ID No.: 3), cg3374 (SEQ ID No.: 4), cg1661 (SEQ ID No.: 1) and cg3399 (SEQ ID No.: 5) may be selected as the target gene.
[0040] In embodiments of the present disclosure, a gene having high resistance to the furfural may be finally selected as the furfural-resistant gene, by inserting the selected target gene into the wild types and overexpressing thereof. Specifically, the selected target genes are cloned and inserted into the wild types to obtain target gene-overexpressed strains, and then these strains are cultured in the furfural-containing medium. Then, their growth speed is compared with growth speed of strains with an expression vector (e.g.: pAN6), in which the target gene is not inserted, and the target genes, which are inserted in the strains showing increased growth speed, may be selected as the furfural-resistant genes. For example, when using Corynebacterium glutamicum as the wild type, the target genes cg1310, cg0310, cg3374, cg1661 and cg3399 are genetically recombined and inserted into the wild type, respectively, and overexpressed. Then, a recombinant strain, which substantially shows higher cell growth rate than the wild type, is selected, and the target gene inserted in the recombinant strain is finally selected as the furfural-resistant genes. In one embodiment, the final furfural-resistant gene selected in the above step may contain at least one gene of membrane protein (efflux permease)-type cg1661 and reductase-type cg1310.
[0041] The examples (and experiments) will now be described. The following examples (and experiments) are for illustrative purposes only and not intended to limit the scope of the present disclosure.
Example 1
Confirm of Growth Inhibitory Effect of Furfural in Wild type
[0042] In order to develop a furfural-resistant strain, first of all, Corynebacterium glutamicum is selected as a wild type, and then, growth inhibitory effect of furfural at Corynebacterium glutamicum wild type strain (wild type), which is Corynebacterium glutamicum ATCC 13032, depending on concentration, and concentrations of furfural and furfuryl alcohol in a culture solution depending on cell growth are confirmed.
[0043] Specifically, as the culture solution, 2% glucose as a carbon source is added to a minimal medium, CGXII medium, and furfural of 6.5 mM, 13 mM and 20 mM are added thereto, respectively, to compare growth speed with the case not adding the furfural. At this time, the composition of the CGXII medium is 20 g/L (NH 4 ) 2 50 4 , 5 g/L Urea, 1 g/L KH 2 PO 4 , 1 g/L K 2 HPO 4 , 0.25 g/L MgSO 4 .7H 2 O, 42 g/L MOPS, 10 mg/L CaCl 2 , 0.2 mg/L Biotin, 0.03 g/L Protecatechuic acid, Trace metal (10 mg/L FeSO 4 .7H 2 O, 10 mg/L MnSO 4 .H 2 O, 1 mg/L ZnSO 4 .7H 2 O, 0.2 mg/L CuSO 4 .7H 2 O, 0.02 mg/L NiCl 2 .6H 2 O). Culture is conducted at 30° C. after inoculating the cells (initial OD 600 =1) into the culture solution 50 mL in a 250 mL Erlenmeyer flask. As a result of the culture, as shown in FIG. 1 , it is confirmed that the growth speed of the strain becomes slow as the furfural concentration in the medium is increased, and the growth is reduced at about 50% or more even at the lowest concentration of 6.5 mM, compared with the medium not containing the furfural.
[0044] Further, in order to check the concentration changes of the furfural and furfuryl alcohol in the medium according to the growth of Corynebacterium glutamicum in the medium containing 6.5 mM, 13 mM and 20 mM furfural by the culture time, respectively, the culture solution is analyzed using gas chromatography (GC). At this time, the culture solutions obtained by each collection time are centrifuged at 12,000 rpm for 5 min, and the supernatants are filtered and used for the analysis. The results of the culture solution analysis are shown in FIG. 2 a , FIG. 2 b and FIG. 2 c . As shown in FIGS. 2 a, b and c , it is confirmed that entire furfural added to the medium is introduced into the cells regardless of the concentration and converted to furfuryl alcohol.
Example 2
Selection of Target Gene for identifying Furfural-Resistant Gene
[0045] In order to select a target gene for identifying the furfural-resistant gene, two methods, i.e., a method of searching literatures and a method using microarray are used.
[0046] Method of Searching Literatures
[0047] Because it is confirmed that the furfural added in the medium is converted to the furfuryl alcohol in the cells in Example 1, literature search is conducted to find a furfural reductase. As a result, FucO gene as a furfural reductase using NADH in E. coli is found in [Wang, X., E. Miller, et al., 2011, “Increased furfural tolerance due to overexpression of NADH-dependent oxidoreductase FucO in Escherichia coli strains engineered for the production of ethanol and lactate.” Applied and environmental microbiology 77(15): 5132-5140]. And, in order to find similar genes with the gene in Corynebacterium glutamicum , homology search is conducted using Blastx (http://blast.ncbi.nlm.nih.gov/Blast.cgi). The searching process is schematically shown in FIG. 3 .
[0048] As a result, among the genes, which are expected to have similarity, cg1310 (SEQ ID No.: 2) showing increased expression at microarray is selected as the target gene. And, information about the selected target gene, and expression level of the target gene depending on the furfural concentration in the medium, which is obtained by analyzing gene expression pattern thereof depending on the furfural concentration using microarray, are shown in the following Table 1.
[0000]
TABLE 1
Gene Expression Level
Furfural
Furfural
Furfural
Conc. in
Conc. in
Conc. in
Gene
Gene
Medium:
Medium:
Medium:
No.
Name
Annotated Protein
6.5 mM
13 mM
20 mM
cg1310
rolM
Maleylacetate
1.476
2.872
2.183
reductase
[0049] The gene expression level of the above Table 1 shows the relative mRNA expression level of the target gene cg1310 of the wild type strain, Corynebacterium glutamicum ATCC 13032, grown in the medium containing the furfural, against the wild type strain grown without stress in the medium not containing the furfural. As a result of analysis, compared with the medium not containing the furfural, the mRNA expression level of the target gene is increased in the medium containing the furfural, and the mRNA expression level of the target gene is further increased when the furfural concentration is increased from 6.5 mM to 13 mM.
[0050] Method Using Gene Expression Analysis
[0051] DNA Microarray is used as a method for analyzing gene expression depending on the furfural stress.
[0052] Specifically, among genes corresponding to the module classified at http://www.coryneregnet.de/ of entire genes, and genes, whose corresponding protein names contain at least one of transport, permease and pump, genes showing increased expression level at all furfural concentrations are selected, and then, genes showing about 10 folds or more increased expression level at least one concentration are selected. And, among the selected genes, existing genes, which are known to response to stress, are excluded by literature search, and cg0310 (SEQ ID No.: 3), cg1661 (SEQ ID No.: 1), cg3374 (SEQ ID No.: 4) and cg3399 (SEQ ID No.: 5) are selected as the target gene. These are catalase, efflux pump in the cell membrane, oxidoreductase and permease-type genes. Then, information of the target genes selected by microarray, and expression levels of the target genes depending on the furfural concentration in the medium, which are obtained by analyzing gene expression pattern thereof using microarray, are shown in the following Table 2.
[0000]
TABLE 2
Gene Expression Level
Furfural
Furfural
Furfural
Conc. in
Conc. in
Conc. in
Gene
Gene
Medium:
Medium:
Medium:
No.
Name
Annotated Protein
6.5 mM
13 mM
20 mM
cg0310
katA
catalase
3.219
3.443
10.956
cg1661
—
Arsenite efflux
7.240
3.071
13.186
pump ACR3 or
related permease
cg3374
cye1
Putative NADH-
1.461
3.219
29.016
dependent flavin
oxidoreductase
cg3399
—
Permease of the
4.485
6.529
15.694
major facilitator
superfamily
[0053] The gene expression levels of the above Table 2 show the relative mRNA expression levels of the target genes of the wild type strain grown in the medium containing the furfural, against the wild type strain grown without stress in the medium not containing the furfural. As a result of analysis, compared with the medium not containing the furfural, the mRNA expression levels of each target gene are increased in the medium containing the furfural, and the mRNA expression levels of the target genes are further increased as the furfural concentration is increased.
Example 3
Confirm of Resistant Effect of Target Gens in Furfural-Containing Medium
[0054] A test for confirming resistant effect of the target genes selected in Example 2 is conducted. At this time, among the target genes of Example 2, cg3399 is excluded from this test because it is not grown after culturing in a medium containing 20 mM furfural.
[0055] Specifically, as the target genes of the present disclosure, cg0310, cg1310, cg1661 and cg3374, and b2799 (ACCESSION NP — 417279, VERSION NP — 417279.2 GI:345452723), which is FucO gene of E. coli K-12 MG1655 (L-1,2-propanediol oxidoreductase), as a positive control group are transformed into a wild type strain, Corynebacterium glutamicum ATCC 13032, using a Corynebacterium glutamicum expression vector, pAN6, under the conditions of 25 μF, 200Ω and 2,500 V by electroporation, respectively. As a negative control group, pAN6, which is not inserted with any other genes, is also transformed into a wild type strain with the same method. The pAN6 (Kan′) is a high copy plasmid, and a shuttle vector derived from pEKEx2 for gene expression regulation of Corynebacterium glutamicum/E. coli (P tac , lacI q , pBL1 oriV C.glutamicum , pUC18 oriV E.coli ). This may be confirmed in [Frunzke, J., Engels, V., Hasenbein, S., Gätgens, C., Bott, M., 2008. Co-ordinated regulation of gluconate catabolism and glucose uptake in Corynebacterium glutamicum by two functionally equivalent transcriptional regulators, GntR1 and GntR2. Molecular microbiology. 67, 305-322], and the contents of the literature in its entirety are herein incorporated by reference. After the transformation, cells are selected on BHIS (37 g/L brain heart infusion (Difco), 91 g/L sorbitol) agar plate containing 25 μg/ml Kanamycin. As a result, recombinant strains pAN6-cg0310, pAN6-cg1310, pAN6-cg1661, pAN6-cg3374 and pAN6-b2799 are manufactured, respectively.
[0056] The above pAN6 contains lacI gene. Accordingly, gene expression may be controlled by IPTG induction. Thus, in order to confirm the furfural resistance of the recombinant strains, IPTG is added to the culture at the concentration of 0.5 mM at the time of inoculating the strains for induction, thereby overexpressing the genes. Then, the recombinant strains are cultured in CGXII medium supplemented with 6.5 mM and 13 mM furfural, respectively. And, OD 600 value by the time is compared with OD 600 value of the negative control group in the medium not containing the furfural, and the results are shown in FIG. 4 and FIG. 5 .
[0057] As a result, it is found that the pAN6-cg1310 and pAN6-cg1661 have the highest furfural resistance because they show about 1.5 folds and about 1.8 folds higher cell growth than the negative control group (pAN6) in the medium not containing the furfural. Accordingly, these are decided as the final furfural-resistant genes.
[0058] [Accession No.]
Depositary Authority: Korean Collection for Type Culture (Republic of Korea) Accession No.: KCTC 12565BP Date of Deposit: 2014 Mar. 5.
[0062] While the exemplary embodiments have been shown and described, it will be understood by those skilled in the art that various changes in form and details may be made thereto without departing from the spirit and scope of the present disclosure as defined by the appended claims.
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The furfural-resistant strain containing the furfural-resistant gene according to the present disclosure may be effectively grown in a furfural-containing medium. Accordingly, the problem that microorganism fermentation was difficult because toxic by-products such as furfural are contained in a hydrolysate derived from inedible lignocellulosic biomass may be solved. Further, according to the method for producing a strain of the present disclosure, the resistant gene may be selected from relatively small number of target genes. Thus, time, cost and the like for developing the resistant strain may be saved. Further, this method for identifying genes may be broadly applied to methods for identifying various unknown functional genes in addition to the furfural-resistant gene.
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BACKGROUND OF THE INVENTION
This invention relates to a tufting method of selectively forming cut pile and loop pile in the same row of stitching in a backing fabric.
In U.S. patent of R. T. Card, U.S. Pat. No. 3,084,645, a method and apparatus for tufting cut pile and loop pile in the same row of stitching is disclosed. In that method, selective forming cut pile and loop pile depends on the pressure between a looper and a spring clip which is secured on the side face of the looper and is placed in a clearance between the arranged two loopers.
In U.S. patent of Paul E. Jolley and Robert T. Crumbliss, U.S. Pat. No. 4,134,347, a method and apparatus for tufting even level cut pile and loop pile in the same row of stitching is disclosed. In that method, selective forming cut pile and loop pile depends on selective opening and closing a gate which is constructed with a looper (hook) and a gate member placed in a clearance between the arranged two loopers.
But, so the finer a gauge of stitching row and the narrower a clearance between loopers, it is difficult to place a spring clip and a gate member between loopers, and it makes the gauge parts expensive to mount pivotably a gate member on the side of the looper like as a shears, a pinchers or a nippers, and further, such a gate member makes a tufting machine to be complicated and to be hard to deal with.
SUMMARY OF THE INVENTION
The present invention provides a simple and reliable method for forming tufted fabrics having a pattered arrangement of cut pile and loop pile in any row of stitching by seizing selective loops of pile yarn from a needle at a portion of the adjacent free end of the looper bill or at the inner portion from the free end of the looper bill.
In practicing the principles of the present invention, in each periodic time of cooperative engagement between a plurality of needles and a plurality of loopers, and a plurality of loopers and a plurality of knives that have reciprocal movement driven by conventional means, each looper is controlled and determined respectively and selectively for its cooperative needle to cross slightly or closely. A looper determined to cross a needle slightly seizes a loop of pile yarn carried by a needle through the base fabric at a portion adjacent of the free end of the looper bill, and so, a loop is released very easily from a looper and forms loop pile.
On the other side, a looper determined to cross a needle closely seizes a loop of pile yarn at a portion of the looper bill which is inner from the free end, so a loop cannot be released from a looper and receives engagement with a looper and a knife and forms cut pile.
In the present invention, there are provided a plurality of vertical thin through slits on the front side of the looper block to push in a shank of a looper, and a plurality of loopers are arranged and supported slidingly toward respective needles in these slits. Of course, a looper block is driven reciprocably toward a needle by conventional means such as a link and carries a plurality of loopers toward a plurality of needles to cross slightly them respectively, and loop pile is formed.
When letting a selected looper cross a needle closely to form cut pile, a looper is pushed out from a slit of a looper block by conventional drive means such as a cam, a link and a cylinder through the medium such as a rod, a wire and air etc. Like as above description, in the present invention, it need not the sub-gauge-parts such as a spring clip and a gate member to form cut pile and uncut loop pile selectively in the same row of stitching.
Consequently, it is a primary object of the present invention to provide a simple and reliable method and apparatus for forming tufted fabrics having cut pile and loop pile in the same row of stitching.
It is another object of this invention to provide a fine gauge tufted fabric having cut pile and loop pile in the same row of stitching.
BRIEF DESCRIPTION OF THE DRAWINGS
Further objects and advantages of the invention will be apparent from the following description taken in conjunction with the drawings, wherein:
FIG. 1 is a fragmentary vertical section view taken transversely through a multiple needle tufting machine embodying apparatus constructed in accordance with the principles of the present invention.
FIG. 2 is a fragmentary perspective view of the looper block illustrated in FIG. 1.
FIG. 3 is a fragmentary vertical sectional view of a portion of the tufting machine illustrated in FIG. 1, but enlarged to show the looper and the looper block.
FIG. 4 is an enlarged vertical sectional view of an operative position of the looper relative to the needle, and wherein the looper threads through a loop of pile yarn slightly.
FIG. 5 is an enlarged vertical sectional view of an operative position of the looper relative to the needle, and wherein the looper threads through a loop of pile yarn deeply.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, there is illustrated in FIG. 1 a needle shaft 1, a knife shaft 2 and a looper shaft 3 oscillatorily rotated in timed relationship with each other by conventional drive means such as a cam and lever means from a main shaft (not shown).
In FIG. 1, 4 is a rocking arm secured to the needle shaft 1, and is pivotably connected to a push rod 6 with a connecting link 5. A needle bar 8 is mounted on the lower end of the push rod 6 riding in a bearing in an upper flame 7 to slide longitudinally. So that, when the needle shaft 1 is oscillatorily rotated, a plurality of needles 10 one being shown that are mounted in a needle block 9 and fixed at the bottom of a needle bar 8 to penetrate a base fabric 11 are all reciprocably driven through the medium of the cam 4, the link 5 and push rod 6 and each needle carried a pile yarn 12 to tuft loops on the base fabric 11.
A rocking arm 13 secured to the looper shaft 3 is pivotably connected to an intermediate rocking arm 15 with a connecting rod 14.
The lower end of the rocking arm 15 is clamped to a laterally extending rock shaft 16 mounted rotatively on an pillow bearing 17, and at the upper end of it a looper bar 18 is fixed. A plurality of loopers are arranged removably in a looper block 19 mounted on top of bar 18. So that, when the looper shaft 3 is oscillatorily rotated, a plurality of loopers are reciprocably driven toward a plurality of needles together with the looper block 19 through the medium of the rocking arm 13, the connecting rod 14 and the intermediate arm 15. And at a time when the free end of a looper crosses a needle, its end 58 threads in a loop 21 of pile yarn carried by a needle, and at next time when a needle returns upwardly, the loop 21 is seized by the free end 56 of the bill of the looper (see FIGS. 4 and 5).
Element 22 is a rocking arm secured to the knife shaft 2, and at the front side of the arm a knife bar 26 is fixed, and on the knife bar 26 a plurality of knives 24 extending upwardly are secured to a knife block 25, and the upper end of a knife touches the side of the corresponding looper mounted above it. So that, as the knife bar 26 is reciprocably driven by the knife shaft 2 the knives mounted thereon cooperatively engage with respective loopers 20 to cut the selected loop seized on the various loopers to form cut pile 27 as hereafter described.
In the preferred embodiment, as illustrated in FIGS. 2 and 3, there are three flanges 28, 29 and 30 on the upper side of the looper block 19 paralled to each other and laterally extending, and two paralled channels 31 and 32 are provided between them.
On front flange 28 and middle flange 29, a plurality of vertical thin through slits 34 and 35 are provided at the same regular interval as the gauge of row stitching for a shank 33 of the looper 20 to push in and be slidingly supported.
On a back flange 30, a plurality of small through holes are provided each hole being in a straight line extending from two slits 34 and 35 to pass a wire 36 through.
The back end 38 of the shank 33 of each looper (see FIGS. 3-5) is pushed in the slits 34 and 35 and is pivotably connected with a pin 39 to a connecting piece 40 which is connected to the end of the wire 36. The other end of each wire 36 is connected to a movable cylinder head 43 of a cylinder 42, and the wire 36 is covered slidingly in a flexible sheath 45 from a fixed cylinder head 44 to the back flange 30 of the looper block. So that, each looper 20 is reciprocably driven toward the needle 10 not only with oscillatory movement of the looper shaft 3, looper bar 18 and block 19 but also by reciprocal movement of the cylinder head 43 through the medium of the wire 36 like as pushed out and back for the looper block 19.
Each of the two channels 31 and 32 is covered with lids 46 and 47 respectively. Besides, at the underside of the front lid 46 a laterally extending ridge 49 is provided to stick in the front channel 31, and a recess is provided on the middle portion of the upper end of the looper shank 33 and exposed in the front channel 31, the length c of which recess is longer than the width b of the channel or the ridge. So that, there is provided narrow clearance 50 between the ridge and the recess 48 same as the difference (d=c-b) between the length c of the recess and the width b of the ridge. And so, reciprocating movement of the looper 20 with a corresponding cylinder 42 is limited to this clearance d since a back edge 52 of the ridge engages the back end 53 of the recess of a looper as it is pushed by a cylinder and the front end 54 the ridge engages the front end 55 of the looper recess as it is pulled back by a cylinder.
At the underside of the free end of the looper extends a protuberance 56. The bottom edge 57 of the protuberance 56 is sloping, and the front end 58 of it is lower than the looper's cutting edge 23, and the back end 59 of it is further low than the front end 58. And the length a of protuberance 56 is longer than the clearance d (the distance of looper travel) as before described. (a>d)
Reciprocating movement of the looper 20 is adjusted so that the bill of the looper crosses a needle 10 slightly and the back end 59 of the protuberance 56 does not cross a needle 10 when the looper is driven with only the looper shaft 3, as illustrated in FIG. 4. So that, if the cylinder 42 connected to a looper does not act, the loop 21 of pile yarn is seized at a portion of the bottom edge 57, and at next time when the needle 10 returns upwardly and the looper returns backwardly, the loop 21 released from the free end 58 of the looper and does not receive engagement with the looper 20 and the knife 24, and forms loop pile.
But, as illustrated in FIG. 5, at a time when the bill 58 of the looper 20 driven with the looper shaft 3 crosses the needle 10 and threads into a loop 21, if a looper 20 is pushed out from the looper block 19 by its cylinder 42 and crosses the needle so closely as the back end 59 of the protuberance 56 to cross the needle, the loop 21 is seized at a portion of the cutting edge 23. At the next time when the needle returns upwardly even if the looper 20 returns backwardly with the looper shaft 3 and the cylinder 42, the loop is seized, or hung, on the back edge 61 of the protuberance 56, a loop can not be released from the looper 20. So that when the machine has advanced through one more cycle the seized loop is carried by the movement of the base fabric 11, as shown by the direction of the arrow to the inner part of the cutting edge 23 like the loop shown adjacent the knife in FIGS. 4 and 5. At the next periodic time of tufting, this loop is cut by the engagement of the knife 24 associated with the respective looper to form cut pile 27.
By the above description and drawings it is understood that when a pile yarn 12 is supplied to each needle 10 by any convenient type of yarn feed mechanism and the cylinder 42 is respectively controlled in each row of stitching by well known pattern reading and signaling mechanism, the same pile height of cut pile and loop pile is selectively formed in the same row of stitching.
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In a conventional tufting machine forming cut pile only, a looper is supported in a looper block sliding toward a cooperative needle, and, in each periodic time of tufting reciprocation, it is determined selectively whether a looper is pushed out from a looper block or not and whether a loop of pile yarn is seized thereby at a looper bill releasably or securely. The loop seized releasably is released from a looper and forms loop pile. The loop seized securely is not released from a looper and receives engagement of a looper and a knife to form cut pile. In order to determine selectively whether the looper is pushed out or not, a conventional pattern apparatus can be used.
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BACKGROUND OF THE INVENTION
This invention relates to an improved belt conveyor for signatures, loose sheets, gathered or pamphletized sheets, and the like, having a device for picking them up. Such conveyors are utilized in particular in bookbindery.
Conveyors of this same general type are known per se. They usually comprise a supporting frame and a substantially horizontal feeder belt run, as well as a substantially sloping elevator belt run forming an obtuse angle with the run of the conveyor belts feeding the signatures or the like. Such feeder belts are operated at a substantially lower speed than said elevator belts.
The practical problem is encountered with known conveyors that, owing to the low speed of the feeder belts, a stack of signatures, loose sheets, gathered sheets or the like (hereinafter referred to as "signatures", for simplicity) is subjected to a forward pushing force which is only applied to that side of the signatures which contacts the feeder belts, so that in the proximity of the transition or transfer area from the horizontal feeder belts to the elevator belts, a frictional engagement action is exerted on the bottom portion of the signatures tending to open them fan-like at the top and cause them to slope or lean towards the feeder belts, especially with small size and thick signatures.
The problem is further enhanced by the use of comparatively rigid signatures.
Thus, an operator's presence is required on a continued basis to prevent the signatures from being tilted rearwardly.
Moreover, conventional conveyors have the disadvantage that the signatures are picked up upon completion of the upward transport of the foremost signature, which is due to the substantial lack of impact between the signature following the foremost signature which is being picked up by the elevator belts.
This phenomenon is obviously specially evident in the case of particularly rigid signatures, or signatures of appreciable thickness. This phenomenon reflects, moreover, in a longer time for the formation of the stacks downstream of the elevator belts.
OBJECTS OF THE INVENTION
This invention sets out to provide an improved belt conveyor for signatures, loose sheets, gathered sheets, and the like, including a device for picking them up, which on one hand is capable of obviating the aforementioned drawbacks, and on the other hand, affords automatic operation of such conveyors even when the latter are operated at high operation speeds.
According to the invention, moreover, this improved conveyor, or the signature picking up device, can be produced in a simple manner and from a limited number of parts, the same being also adapted for incorporation in existing conveyor systems by performing a few simple adaptation operations.
SUMMARY OF THE INVENTION
According to one aspect of this invention, the improved conveyor comprises signature entraining means interposed between the feeder belts and elevator belts, means for sensing the presence of the signatures and controlling the actuation of the feeder belts being also preferably provided.
Advantageously, according to the invention, the elevator belts run is provided, on the input side thereof, with a deflecting roller effective to deflect the elevator belts from the oblique lay to a substantially vertical one.
Furthermore, in accordance with this invention, said means of entrainment of the signatures comprise rings located at the deflecting roller on the input end of the elevator belts, said rings being advantageously formed with an outer surface having a high frictional coefficient.
According to the invention, moreover, said rings are provided on that same deflecting roller on the input end of the elevator belts, the rings having a maximum thickness, or protruding areas or points, exceeding that of the elevator belts.
According to a first variation of the invention, the signature entraining means comprise a suction roller having at least two circumferential sectors formed with circumferentially distributed through holes, a tubular inner diaphragm of substantially C-like configuration, suction being applicable at the area where the horizontal feeder belts adjoins the sloping elevator belts.
According to a further variation of the invention, the signature entraining means comprise transverse strips set apart from one another on the outer side of the elevator belts. Obviously, said strips may be replaced with other projections of different geometries, e.g. cylindrical, pyramidal, polygonal, or otherwise.
More features and variations may be inferred from the appended subordinate claims.
BRIEF DESCRIPTION OF THE DRAWINGS
Further details, advantages and variations of this improved belt conveyor for signatures, loose sheets, gathered sheets and the like, and related pick up device, will become apparent from the following description of a preferred embodiment of the invention, as illustrated by way of example in the accompanying drawing, where:
FIG. 1 is a diagramatical side elevation fragmentary view of a conveyor at the transition area from the feeder belts to the elevator belts in a belt conveyor of conventional design;
FIG. 2 shows diagramatically a side elevation sectional view, similar to FIG. 1, of a conveyor according to the invention;
FIGS. 3 and 4 are views similar to FIG. 1, with signatures added, illustrating two successive transport steps of the signatures;
FIG. 5 is a perspective view of a roller provided with entrainment rings according to this invention;
FIG. 5a is an enlarged scale schematical section taken along the line V--V of FIG. 5;
FIG. 6 shows schematically and in perspective a variation of the roller provided with signature entraining means, according to the invention;
FIG. 6a is a schematical cross-sectional view taken along the line VI--VI of FIG. 6; and
FIG. 7 illustrates schematically another variation of this invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Reference is made initially to FIG. 1, where a conveyor of traditional design is illustrated schematically. The conveyor feeder belts are indicated at 1, the same being provided in the form of individual belts in side-by-side relationship, the numeral 2 designating the elevator belts. At 1a and 2a, respectively, there are indicated path deflecting rollers for the belts 1 and 2, located at the area where the signatures 3 are moved upwards. As shown in FIG. 1, the upper runs of the belts 2 extend entirely in the same oblique plane, it forming with the belts 1 an obtuse angle the vertex whereof results from the line of intersection of the upper runs of the belts 1 and 2. Owing to the lower speed of the belts 1 with respect to the belts 2, this known equipment frequently produces, especially with rather "stiff" signatures, a situation whereby the signatures are urged at their lower edges in a direction such that the signatures open fan-like and the rearmost signatures tend to fall flat onto the belts 1. Although this phenomenon is related to the type, rigidity, thickness and size format of the signatures, it is always recognizable, albeit in varying extents, in all conventional conveyors of the type just described. The phenomenon is also due to the fact that, in known conveyors, the signatures are picked up in a spaced apart condition, and in operation, the engagement between the foremost signature and the elevator belts 2 hinders or in practice prevents the signature which follows the foremost one from contacting the belts 2 until the foremost signature has been practically completely removed. This, in turn, makes it impossible to develop high stacking rates, such rates being also related to the type of signatures being handled.
In the inventive arrangement, by contrast, the elevator belts 2 are deflected, prior to their entering the area of the belts 1 and through their deflecting roller 2a, to leave their oblique lay and extend downwards, in the example shown substantially vertically downwards, thereafter they are further deflected by additional rollers along the return run of the belts 2. Thus, at the crossing area between the upper reaches of the belts 1 and 2 there is formed a cleared angle α which allows the pack of signatures 3 to be brought closer to the elevator belts 2.
Furthermore, according to this invention, there are provided entrainment rings, two in number in the example shown, which are attached fixedly, e.g. by cementing them, to a specially provided roller which forms the cited deflecting roller 2a in the example shown. The rings 4 have a larger thickness dimension than the belts 2, that is to say that the outer surfaces of the rings 4 protrude outwardly from the outer sides of the belts 2, said outer surfaces being advantageously a roughened one. This protruding arrangement of the rings 4 results in the foremost of signatures 3 contacting said rings 4 immediately, thereby as soon as the foremost signature 3 has been moved upwards beyond the rings 4, the following signature abuts those same rings 4, so that the signatures 3 can now be rapidly moved upwards in overlapped relationship with one another. Positive abutment of the signature which follows the foremost signature against the rings 4 is ensured by the forward movement imparted by the belts 1 to the pack of signatures 3.
For simplicity reasons, the transport device overlying the elevator belts, has been omitted from the drawing, said device being any desired one.
The numeral 5 designates an interlocking or consent switch actuated by the presence of signatures, a contact reed whereof is indicated at 5a. The numeral 6 designates an additional switch, a contact reed whereof, 6a, lies in the path of the travel of the signatures 3 during their upward movement, said switches 5, 6 being operative, in the absence of signatures 3 moving past it, to operate the motor driving the belts 1 to produce a forward movement of, or rather apply a forward push to, the pack of signatures 3, thus ensuring positive engagement of the foremost signature, should the latter arrive in an excessively inclined attitude and fail to strike the contact reed 5a of the switch 5. By providing the circuit with the switches 5 and 6, which are preferably connected in series to each other, ensure a satisfactory operation of the conveyor.
According to a variation of this invention, the entraining rings 4 may be replaced with a plurality of through holes 7, which may be arranged for instance in two circumferential rows located at the same position as the rings 4, which holes are connected to suction means, known per se and not shown. An inner diaphragm 8 enables the suction or vacuum to be only applied at the signatures 3 pick up area of the belts 2. In the exemplary embodiment shown, the deflecting roller 2a for the belts 2 is still employed. Even when the suction arrangement is utilized, the conveyor operation is as described hereinabove and allows the signatures 3 to be moved upwards in a similarly overlapped relationship. The suction or vacuum generating unit, and its related control circuitry, are not illustrated herein, because they are known per se and well within the capabilties of an expert.
Furthermore, with the arrangement of the belts 2 according to this invention, it is also possible to utilize belts 2 provided with outer pick up lugs 9 on the outer surfaces of the belts 2 spaced apart from one another, said lugs projections being for example in the form of projecting strips, laid side-by-side similarly to studs, etc., as shown in projections FIG. 7.
In practicing the invention, the rings 4 may be formed from any suitable material, e.g. rubber, and their outer surfaces may be roughened to any desired pattern; alternatively, annular or ring-like ridges may be provided integrally with the belt deflecting roller (see FIG. 5), whereto a high frictional coefficient coating is then applied, depending on individual applicational requirements.
It will also be possible to replace any individual parts with other technically and functionwise elements: for example, the substantially vertical run of the belts 2a at the belts 1 may be caused to extend along a sloping direction, or a supporting cylinder may be provided for the rings 4 other than the deflecting roller 2a, mounted in the proximity of the latter, or even form the supporting cylinder for the rings 4, for example, from a synthetic material; as a further alternative, one switch 5 may be provided, or a higher number of rings 4 may be provided, or a cylinder pre-assembled with the rings 4 may be introduced in a conventional type of conveyor proximate to the crossing point of the feeder belts with the elevator belts, and so forth, without departing from the purview of this invention.
It will be appreciated from the foregoing that the solution proposed effectively achieves the objects and advantages mentioned in the preamble, and in particular that of a positive engagement with the signatures to be picked up, a high speed of upward transport of the same in overlapping relationship, very simple construction, applicability to existing conveyors, as well as a reliable operation, as ensured by the provision of an interlock switch sensing the presence of paper in the same plane as the feeder belts, and preferably of a further interlock switch downstream of said entraining rings or the like. Such advantages are also to be secured by the embodiment providing a pneumatic type of pick up, although the latter will involve the provision of additional equipment.
Advantageously, the protruding thickness of the entraining rings is selected to relate to the thickness of the thickest signatures being handled.
The dimensions and materials may be selected as desired without departing from the purview of the instant inventive concept.
All of the features which can be inferred from the foregoing description, from the drawing and appended claims, are substantial to the invention, either individually or in any desired combination thereof.
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An improved conveyor for signatures, loose sheets, gathered sheets, and the like, with a device for picking them up. The improved conveyor achieves fast signature transport capabilities in overlapped relationship. A mechanism is also provided for entraining the signatures which are operative on each signature prior to a preceding signature moving fully away from the following one. Advantageously, the entrainment members have an outer surface with a high friction coefficient. The initial section of the elevator conveyor belts follows a path which deviates from the oblique plane of lay thereof, preferably a substantially vertical path.
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BACKGROUND—FIELD OF INVENTION
This invention relates to cleaning, to materials used in cleaning, and particularly to the employment of electric energy to do the work of cleaning by a method and device which operates to apply electrical energy directly to washing fluid at a site of cleaning, thus affecting the physical properties or characteristics of a cleaning substance, resulting in a reduced dependence on traditional chemical forms of energy to do the work of cleaning, and a reduced discharge of chemical waste, resulting in reduction of environmental pollution due to chemical waste discharge to a greater extent than heretofore possible.
BACKGROUND—DESCRIPTION OF PRIOR ART
Ideally, there should be no detectable difference in water before and after it is used for cleaning (other than the presence of the soil transferred from the laundry to the water). All forms of energy used to do the work of cleaning should have no lasting effect on the water used and should not be detected in the effluent. In the conventional chemical energy dominated laundry processes of the prior art, chemical energy is the only one of the three form of energy that violates this criteria.
The thermal energy of hot water has a temporary effect occurring in the water which is very effective in the cleaning process. There is no detectable difference in water that has been heated to aid in the cleaning process, once the cleaning is done and the water again cooled. Environmentally, this is the ideal situation.
The kinetic energy present in agitated water during the laundering process is not detectable once the cleaning is done and the water allowed to come to rest. Water that has induced turbulence during the cleaning process is no different after as compared to before it is used for cleaning.
The only source of energy used in the conventional cleaning process that causes a detectable difference is the energy of chemicals added to the water. Chemical energy from the addition of chemical substance to the water remains in the water after the cleaning process, and is the source of pollution caused by the cleaning process.
Thus is the long recognized and unfilled need to reduce the amount of polluting detergent chemicals being discharged into the environment.
The cleaning process of the prior art as used in the home laundry is a major contributor to pollution of the environment due to the discarding of spent chemicals into the environment.
Much of the resources used for producing laundry cleaning chemicals is non renewable.
It has not been practical to recycle spent laundry detergent chemicals from home laundry use.
Allergic reactions are caused by chemical residue in the fabric of clothes.
The health and growth of plants and animals are affected by chemical waste from home laundering.
The purity of drinking water is decreased by chemical waste from home laundering.
Water treatment requirements of public waste water is increased by chemical waste from home laundering.
Traditionally the cleaning process involved three different forms of energy used to dislodge soil from the items that were cleaned. Those forms of energy were kinetic energy, thermal energy, and chemical energy. Kinetic energy was from rubbing, scrubbing, or agitating. Thermal energy was from hot water. Chemical energy was principally from detergents. These forms of energy did the work of cleaning. To some extent, tradeoffs of one form of energy for another were employed. The amount of one form of energy was reduced at the cost of increasing the amount of another form. Chemical energy requirement was reduced by increasing the use of mechanical energy by rubbing, scrubbing, or agitating harder or longer. Thermal energy use was reduced by increasing the dependency on chemical energy.
Two significant developments increased the dependency on chemical energy in recent times.
First was the development of the automatic washing machine. The old fashioned ringer washer was used to clean several loads of wash before the water with it's laundry chemicals was discarded. The newer modern automatic washing machines, to eliminate the manual labor of removing the clothes from the wash tub to the rinse tub moved the washing and rinsing process to the same tub by changing the water rather than the clothes. Wash water was discarded after washing only one load of laundry. This resulted in a many fold increase in the number of loads of waste water, with it's polluting chemicals, being released into the environment each day.
The second development was the advent of the philosophy of saving energy by washing in cold water. In reality, the energy required to do the work of cleaning was not reduced. Only the source of energy was changed. More dependence on chemical energy was the change. More dependence on chemical energy resulted in a greater quantity of chemical pollutants released into the environment.
Ever since modern automatic washing machines reduced to one the number of loads of laundry to be cleaned by a single charge of cleaning solution, there has been a long recognized and unfilled need to reduce the amount of polluting detergent chemicals being discharged into the environment.
At the same time there has been a demand for improvements in the appearance, odor, and other characteristics of clean laundry.
Accordingly, in order to improve the cleaning efficiency, many clothes washing machine makers have utilized various methods including such methods as improving the agitators ability to scrub the laundry, extending the operating time of the motor during agitation, and improving the quality and/or increasing the quantity of detergent used in the washing machine. However, there were limits to improvements in the cleaning efficiency by the aforementioned methods for the following reasons:
(a) The methods utilizing increased mechanical force to improve the washing efficiency caused damage to the laundry or reduced efficiency of the washing machine.
(b) In methods utilizing increased amounts of detergent, a relatively large amount of the detergent did not react with the laundry and was discharged where it caused environmental pollution.
(c) Some detergent residue stuck to the laundry and thus the laundry was not effectively cleaned. Many people were allergic to detergent residue in the clothes they wore.
(d) Also, it was well known that if more than the recommended amount of detergent was used in the clothes washing machine, the washing efficiency of the washing machine was reduced.
Accordingly, inventors attempted to create several types of ionic water treatment devices to generate water containing non polluting chemical energy in the form of surface tension reducing ions for the purpose of reducing the amount of detergent required. In the absence of chemical detergent, all of these devices had the same shortcoming of the short life of oppositely polarized ions in the absence of energy to hold the mutually attracted ions apart.
U.S. Pat. No. 5,309,739 to Lee (1994) disclosed a device which claimed the generation of surface-tension-reducing hydroxyl ions for the purpose of reducing the amount of detergent required using tourmaline and ultrasonic energy. This device was integral to the washing machine and was required to be added on to the standard automatic washing machine at time of manufacture. The process was slow and at a point in the machine that was spatially removed from the point of the cleaning work. Any separation of the water into ions was quickly neutralized before reaching the locality where soil was being removed from the clothes, because the opposite nature of the charge on the ions caused them to attract each other and to be immediately neutralized. It has not become a commercial success because it was not significant in its effect.
U.S. Pat. No. 4,066,393 to Morey and Dooley (1978) disclosed a device which utilized a cation exchange resin device to remove calcium and/or magnesium ions from the water for the purpose of reducing the amount of detergent required. However, this device required a manual step in the washing process and it too was an add on to the standard automatic washing machine requiring mechanical assembly. It only softened the water by adding more chemicals to the water so the chemical detergent could work better. It did not replace the use of chemical detergent. It removed some metal ions from the water by adding others in substitution. It did not reduce pollution of the environment, it only moved the pollution from one waste product to another. And it did nothing to improve water that was already soft.
U.S. Pat. No. 5,358,617 to Ibbott (1994) disclosed a water treatment devise for use in a standard automatic washing machine which utilized electrically isolated electrodes of different electrochemical potential to ionize the wash water inside the washing machine for the purpose of reducing the amount of detergent required. However, the effectiveness of this device was quite limited by the slow rate of the process, and in this device the separation of the locality of ion generation and ion use was so great that the ions were neutralized by the time they got to the locality of the cleaning work.
U.S. Pat. No. 2,997,870 to Serra (1961) disclosed a washing machine claiming ionic generation due to friction of the motion of air, water, and an India rubber vessel for the purpose of reducing the amount of detergent required. However, ions thus produced were not effectively transported to the active site of the cleaning before being neutralized by their very nature of being oppositely polarized. And thus the machine was impractical to solve the unfilled need.
Devices utilizing the weak ionization developed by the mineral tourmaline have been proposed, and even marketed, to generate ions which reduce the surface tension of water. However, the process, if it did work, was so weak, and so slow, that it did not prove to be practical.
Many attempts have been made to utilize energy in the form of non chemical ionic phenomena to do the work of cleaning, but the products have not been as effective as the claims made. For example, devices such as plastic balls or ceramic discs that had been offered on the market had such a weak effect that courts of law in many states declared them to be fraud. None of them supplied enough energy, in the right place to do sufficient work to take the place of the work done by chemical detergent.
Electrostatic precipitators have been used for years to clean air of soil particles rather than let that form of pollution go up the smokestack. Currently there is no equivalent for particles in home laundry waste water. Instead, detergent molecules attach themselves to soil particles and are released with the soil particles into the environment.
Less harmful chemicals have been proposed to be substituted for more harmful chemicals. That is, chemicals that have not been declared to be so harmful but with less track record of being safe have been substituted, However, in doing so, the composition of the waste chemical has only been changed, the quantity has not been reduced, and the flow of spent chemicals polluting the environment continues.
None of these substitutions or devices have satisfied the unfilled need for reduction of the polluting chemical discharge from household laundry, nor have they contributed significantly to reduce the problem. To the contrary, more polluting chemicals have been developed to overcome the reduced effectiveness of the cleaning process to give the appearance of better cleaning. Among these are chemical brighteners, chemical whiteners, chemical perfumes, and chemical fabric softeners. The current use of the prior art method of cleaning continues to contribute significantly to environmental pollution. The long recognized and unfilled needs for increased cleaning effectiveness, and reduction of pollution produced by household laundry operations has not been met by the prior art.
OBJECTS AND ADVANTAGES
All three forms of energy of the prior art that are used to do the work of cleaning are related and it is possible by careful adjustment of one component to overcome limitations of either one or both of the other components. As an object of the invention, a fourth form, electric energy, is added, substituting, at least in part, for chemical energy. With the addition of this fourth form of energy, in sufficient quantity, and at the right place, the goal of reducing or even eliminating detergent chemical pollution from household laundering can be accomplished by careful adjustment of the other forms of energy. Electric or electrostatic energy, when properly applied by the inventive method, is used to accomplish, at least in part and to some extent, the work in it's various forms that has been done in the prior art by chemical detergents. Like thermal and kinetic energy, electrostatic energy added during the cleaning process is not detectable once the cleaning process is complete. Surprisingly, the rubbing between the water, laundry articles, and electrically polarized dielectric surfaces of the invention causes a surprising increase in the washing efficiency due to the generation of ionic action in the water at the right time and place to be useful during it's short life. By virtue of a simple looking device, and the unobvious benefits it enables, an entire, normal capacity washing machine is increased in cleaning efficiency. With no need to rinse a chemical residue from the laundry, this invention eliminates an energy wasting need for a separate non cleaning cycle for rinsing, making all cycles of the currently popular automatic washing machine into cleaning cycles.
Accordingly, several objects and advantages of the present invention are:
(a) to provide a cleaning method which does some of the work of cleaning using electrical energy in sufficient quantity and effectiveness to reduce the requirements for the other forms of energy which are thermal, kinetic, and chemical, in particular chemical, reducing or eliminating the need to discard chemical waste, filling that long recognized and unfilled need for reducing laundry chemical waste polluting the environment;
(b) to provide a cleaning method which protects our environment from pollution by making effective use of a minimal amount of detergent by substituting a non polluting source of energy to do the work of cleaning;
(c) to provide a form of detergent which is recycled rather than discarded;
(d) to provide a cleaning method which fills that long recognized and unfilled need for reducing detergent residue in the clean laundry by substituting a non polluting source of energy to do the work of cleaning;
(e) to provide a cleaning method which reduces the effect of chemical effluent on the health and growth of plants and animals by substituting a non polluting source of energy to do the work of cleaning;
(f) to provide a cleaning method which reduces the effect of chemical effluent on human drinking water by substituting a non polluting source of energy to do the work of cleaning;
(g) to provide a cleaning method which reduces the water treatment requirements of public waste water treatment plants to process laundry chemicals by substituting a non polluting source of energy to do the work of cleaning, thereby reducing the quantity of spent laundry chemicals needing treatment;
(h) to provide a cleaning method which reduces the dependency on chemical energy by substituting a non polluting source of energy to do the work of cleaning;
(i) to provide a cleaning method which improves the appearance, odor, and other characteristics of clean laundry by substituting a non polluting source of energy to do the work of cleaning;
(j) to provide a cleaning device or devices which embodies the methods of this invention; and
(k) to provide a cleaning device suitable to be marketed as a commercial product to be used in place of or in addition to laundry detergent.
Unlike many other attempts to fill the need reduce chemical pollution of the environment, this invention operates in the manner to which the homemaker is already accustomed, and little, if any, instruction is needed.
For the preferred embodiment of the invention the operation is as simple as putting the device in the washing machine with the load of laundry, operating the machine normally, and, when the load is finished, removing the device from the machine, and taking the laundry out.
Or the device may be held in a hand and used for scrubbing as with a standard wash cloth or sponge.
For other embodiments, such as the one where the washing machine agitator itself is the implementation of the invention, the operation is even simpler. Load the machine with clothes, operate the machine normally, and take the clothes out when the washing is done.
In conjunction with the inventive device, other substances may be desired to be used, such as fabric softener. For such cases, just follow the directions that come with the other substances.
The water from the home laundry, being free of chemical detergent pollution can optionally be recycled to water the garden or yard.
An object of this invention is to exploit a heretofor unexploited form of energy to do the work of cleaning.
A further object of the present invention is to provide a means of exploiting the new technology of surface chemistry and utilizing electric energy to reduce the need for other forms of cleaning energy of the prior art. The combination provides a superior process of cleaning without increased damage to the items being cleaned nor to the environment.
A further object of the present invention is to provide a means of attracting and holding soil particles, removing them from the wash water, rather than flushing them down the drain. In similar fashion to the electrostatic precipitator removing soil particles from smoke so they do not pollute the air, a device made from the surface chemistry detergent of this invention can attract and hold soil particles removing them from the drained wash water. Again in similar fashion to the electrostatic precipitator, the device made from the inventive surface chemistry detergent can be renewed by reversing the attraction.
In an embodiment of the present invention no external power source is needed other than the agitation that is already present in the normal washing machine.
With the present invention no renewal parts such as batteries are needed.
With the present invention no renewal source of anything is needed such as chemical refills.
The present invention is simple and easy to use.
The present invention does not require a large bulky attachment; or external machine or process.
The present invention is not used up in the washing process.
The present invention is not discarded after the cleaning process.
Other laundry products which produce pleasant sensations to the human senses are compatible with the present invention. Appearance, feel, or odor enhancement products and process may be used and not interfere with the operation of the current invention. Whiteners, brighteners, softeners, or perfumes are completely compatible and may be used in conjunction if so desired.
Accordingly, the above objects and advantages are to provide a non polluting washing method and aid to be used many, many times rather than be discarded with each load of wash, resulting in improving our lives in many ways, including, having cleaner laundry, having less chemical residue to irritate sensitive skin, improving cleaning efficiency without increasing the damage due to abrasion, heat, and chemicals, newly exploiting a form of energy which is non-polluting, eliminating many disruptions in our lives such as running out of laundry detergent at inopportune times, conserving rather than waste and pollute our natural resources to a greater extent than heretofore possible.
The aforementioned objects and advantages of the invention, will, in part, become obvious from the following more detailed description of the invention, taken in conjunction with the accompanying drawings, which form an integral part thereof.
DRAWING FIGURES
The present invention will be more fully understood by reference to the following detailed description thereof when read in conjunction with the attached drawings, and wherein:
FIGS. 1A and 1B are perspective views of a first embodiment of a laundry cleaning device according to the invention, directly coupled to an agitator;
FIGS. 2A and 2B are perspective views of a second embodiment of a laundry cleaning device according to the invention, indirectly coupled to an agitator;
FIGS. 3A through 3F are edge views of piezoelectric charge generation according to the invention; FIGS. 3A through 3C are perspective views; FIGS. 3D and 3E are enlarged edge views; FIG. 3F is a cutaway edge view;
FIGS. 4A through 4E are perspective views of a third embodiment of a free floating laundry cleaning device according to the invention;
FIG. 5 is a schematic view illustrating the mechanism of frictional electric charge generation, distribution, and application powered by washing action;
FIG. 6 is a perspective view of a vital part of a preferred embodiment according to the invention;
FIG. 7 is a perspective view of a special design agitator of an alternate embodiment according to the invention;
FIG. 8 is a perspective view of a flexible agitator made of piezoelectric polymer or composite of another alternate embodiment according to the invention;
FIG. 9 is a perspective view of a single anode capacitative agitator according to the invention;
FIG. 10 is a perspective view of a spray on coating of a simple, yet practical embodiment according to the invention; and.
FIG. 11 is a magnified schematic view illustrating the separation of ions in water due to electric charge.
DRAWING REFERENCE NUMERALS
10 tine, nub, point, fin, flange, vane, filament, or elastomer (electric charge generating, distributing, and/or applying means)
12 surface
14 attached end or edge
16 attachment means
18 agitator of wash machine, (washing action imparting means)
20 fin of agitator
22 attachment ring
30 side
32 edge
34 left flex
36 right flex
38 tension
40 compression
42 internal electron movement
44 negative charge (electron concentration)
46 positive charge
48 direction of washing action movement generating friction
50 unattached device
52 bundle of elastomers
54 binder ring or wire
56 knot or tie
58 loose end of elastomer
60 tub of a washing machine
62 water, or washing fluid
64 item to be washed, article of clothing or fabric
66 fiber of cloth
68 surface chemistry detergent coating
70 agitator made out of special material
72 flexible agitator
74 capacitative agitator
76 plastic coated metal
78 spray on coating
80 electric charge generator
82 wire
84 soil, oil, dirt, micro organism, foreign matter
86 Hydrogen ions (H + )
88 Hydronium ions (H 3 O + )
90 water molecules (H 2 O)
92 Hydroxide ions (OH − ),
94 Hydroxyl ions (H 3 O 2 − ),
96 detergive attraction
SUMMARY OF INVENTION
According to this invention, there is provided a method of producing a cleaning effect comprising steps of converting mechanical energy into electrical energy, distributing electric energy in the vicinity of the location of the desired cleaning effect, and applying electric energy so as to provide the effect of cleaning, and there is provided inventive apparatus for implementing the inventive method. In accordance with the invention, mechanical energy, thermal energy, and chemical energy is supplemented by the energy of electric charge applied to effect the work of cleaning. Embodiments optionally comprise one or more of the features described in the following “Features of Invention.”
FEATURES OF INVENTION
It may be helpful to the understanding of the invention to list many of the features.
A feature of the invention is the generation of electric energy to do the work of cleaning.
A feature of the invention is the distribution of electric energy to do the work of cleaning.
A feature of the invention is the application of electric energy to do the work of cleaning.
A feature of the invention is a surface chemistry detergent.
A feature of the invention is the modulation of the physical properties of a surface chemistry detergent by electric charge.
A feature of the invention is a method of cleaning laundry utilizing surface chemistry effects modified by electric charge.
A feature of the invention is a method of cleaning the environment utilizing surface chemistry effects modified by electric charge.
A feature of the invention is an anchored device for use inside an automatic laundry washing machine.
A feature of the invention is the application of electric energy in such a way as to effect cleaning by such phenomena as temporary chemistry changes or temporary physical changes in water.
A feature of the invention is a method of cleaning laundry utilizing the direct effects of electric charge (static and differential)
A feature of the invention is an unanchored device for use inside an automatic laundry washing machine.
A feature of the invention is a flexible surface, vane, or filament made of a frictioning material.
An example of such a material is extruded natural rubber.
A feature of the invention is a water treating processing means for the generating of hydroxide ions in wash and rinse water
A feature of the invention is a water treating processing means for the generating of hydroxyl ions in wash and rinse water
A feature of the invention is a water treating processing means for the generating of Hydronium ions in wash and rinse water
A feature of the invention is increased cleaning time by being effective in cleaning during rinse cycles as well as the normal wash cycle of a standard automatic washing machine.
A feature of the invention is less injury to garments by elimination of the requirement for increased mechanical agitation time.
A feature of the invention is increased cleaning efficiency due to combined action of micro turbulence and non uniform ionic distribution.
The aforementioned examples of features of the invention, will, in part, become obvious from the following more detailed description of the invention, taken in conjunction with the accompanying drawings, which form an integral part thereof. Although the list above contains many features, these should not be construed as limiting the scope of the invention but merely as providing illustrations of some of the presently preferred embodiments of the invention. This list is not to be taken as a complete list, but as examples of many other features obvious to one versed in the art.
Therory of Operation
The Inventive Concept
It has long been known that water can be prepared for washing which has improved cleaning characteristics. Water can be heated then clothes washed in the heated water. The heat treated water remains effective for a duration of time on the order of minutes because it takes that much time for heat to dissipate. Water can be treated with chemical detergent then used for wash water. The time duration of the effectiveness of detergent treated water is days, or even weeks. Therefore, we have become accustomed to the idea of preparing wash water ahead of time, then washing clothes in the prepared water. That has been the failing of all prior art attempts to prepare ion enhanced wash water without chemical presence. Ionic treatment of water retains it's effectiveness (except for some very weak residual due to secondary effects) for a period of time of only a fraction of a second. It is not practical to enhance the ionic disassociation of wash water and expect it to stay that way in the absence of some force to keep the ions from recombining.
Applying ionic treatment to a batch of wash water, then washing clothes in it makes no more sense than applying kinetic energy (in the form of turbulence) to a batch of wash water then putting clothes in the settled water expecting the spent kinetic energy to clean the clothes. Even so, this is exactly the process that has been attempted many times over in the prior art attempts to ionically treat wash water. However, applying kinetic energy to wash water at the right time and right place is very effective in cleaning. In other words, turbulence really does clean clothes.
The practical effectiveness of kinetic energy in wash water lasts only a few seconds after application. The practical effectiveness of electric energy in wash water lasts only a fraction of a second after application.
The inventive concept is to apply this same philosophy to the application of electric energy that we apply to kinetic energy. The inventive concept is to apply the electric energy at the time and place where the cleaning is expected to occur.
Practical useful static electric fields do exist under water, even in highly conductive salty sea water. An example of this is the electric eel. These static fields do, however, have a short life because the conductivity of the water rapidly drains off the charge. One might argue that the water shorts out the field. However, that is exactly the desired result. As the electric charge of the invention is dissipated in the water in the vicinity of the soiled clothes, it does the work of cleaning. This inventive concept is a revolution in the theory of cleaning.
The friction of rubbing two dislike solid substances gives rise to the transfer and dislocation of electrons from the surface of one substance to the surface of the other. The movement of the rubbing further dislocates the excess electrons on the surface of one material from the depletion of electrons on the surface of the other. In the presence of low conductivity, electric charge builds up. In the presence of high conductivity, the electrons flow back to regions of the opposite charge. In the case of washing as in the invention, conductivity is low enough that some charge builds up, balanced by some flow of electrons to equalize the charge. While in the presence of the built up charge, the ions of the water are also displaced as they take place in the flow of electrons to neutralize the charges. This displacement of ions in the water give rise to an increase in the natural ionic dissociation of the water and an increase in the concentration of those naturally occurring ions having detergency.
The effect of electric energy on water to do the work of cleaning is powerful, but short lived. Where previous attempts of the prior art lacked sufficiency of effect was the failure to apply the energy in sufficient quantity at the location and time the work of cleaning was to be done. In the batch process of preparing the water then washing with prepared water, the effect was so diminished by the time the cleaning was attempted that it was like heating water to do the washing, then waiting for it to cool down before using it. This problem is overcome in the method of the present invention by the application of the electric energy at the same time and location where the kinetic energy of the scrubbing action is taking place
The Cleaning Process
A practical working prior art description of the cleaning process is found in Publication No. 348 published by The New Zealand Department of Agriculture, Ruakura Agricultural Research Centre, Hamilton, New Zealand.
“The aim of the cleaning process is to provide sufficient energy to a system to change soil adhered to a surface into a suspended or dissolved state. Soil is held to surfaces by occlusion in surface interstices, by electrostatic forces between surface and soil and by the attraction of soil fractions for each other, . . . The sum total of all these forces may be expressed as the energy of soil adhesion. The energy in a cleaning solution is made up of the kinetic energy of the solution provided by turbulence, the thermal energy provided by solution temperature and the chemical energy provided by the constituents of a detergent. All three factors are related and it is possible by careful adjustment of one component to overcome limitations of either one or both of the other components.”
Cleaning is work. In prior art discussions of cleaning this is work that is done on soil by a combination of kinetic energy, thermal energy, and chemical energy. Kinetic energy is in the form of turbulence. Thermal energy is in the form of elevated temperature. Chemical energy comes in two forms, chemical energy inherent in the chemical composition of water, and chemical energy in the form of detergent composition. Any form of energy that works to overcome the energy of soil adhesion to change soil adhered to a surface into a suspended or dissolved state does the work of cleaning. By careful manipulation of any one or more of these forms of energy, the work required to be done by any or all of the others can be reduced if not eliminated. For example, with more scrubbing, the requirement for hot water and detergent can be reduced. For another example, with the proper detergent, the need for higher temperature of the water can be reduced or eliminated. If another form of energy were found which contributed to the work of cleaning, that form of energy too could be manipulated to reduce or replace any or all of the other forms of energy to some extent.
An object of this invention is to effectively exploit another form of energy to do the work of cleaning.
The other effects of the work done in cleaning are to dissolve substances that are soluble such as sugar, or to melt substances such as grease, or sterilize by killing germs. Typically, the work done to dissolve substances is not the intention of chemical detergents. Dissolving is left to the natural chemical energy of water enhanced by thermal energy of hot water. Typically the melting of substances is not enhanced by chemical detergents, but again as in dissolving, melting is done by the natural thermal energy of hot water. Historically, the work done to sterilize laundry was accomplished by the thermal energy of hot water. Recently, without hot water, sterilization is left to be done by the heat of the dryer, or done by the addition of a chemical poison which remains in the waste water as a pollutant. Sterilization is not done by the chemical detergents, some of which are actually fertilizers, enhancing the growth of fungus or bacteria.
Other Laundry Related Processes
Processes other than cleaning are related to the laundering of clothes. Sterilization, fabric softening, static elimination, odor control, appearance related non-cleaning such as whitening and brightening and other processes obvious to one versed in the art of laundering are all processes that apply energy to do the work involved. In the past, various forms of energy were utilized. For example, radiant energy from the sun or ultra violet lamps, or thermal energy from hot water were used for sterilization. In recent times, chemical energy is the dominant form of energy used in such processes.
The chemical detergent companies would like us to believe that shifting the work of cleaning and other related processes toward the chemical form of energy is desirable. We have been taught that we do not need hot water to clean clothes. We have been taught that this saves energy and is good. This is because chemical energy can replace the thermal energy of hot water to lower the surface tension and thereby clean the clothes without the need for hot water.
However, when we changed the standard method of cleaning clothes to eliminate the hot water, the sterilization work of the heat energy was eliminated. The work of chemical energy again came to the rescue. The work of chemical energy replaced the work of thermal energy by the addition of chemical poisons to sanitize the laundry. In the saving of energy in the thermal form, energy in the chemical form was substituted. The main effect of this substitution of the chemical form of energy for other forms of energy is not the saving of energy, but is the pollution of the environment.
Evaluation of Effect
The major objection to the electrical treatment of water is not in the observations of the users not seeing cleaning being done, but in the lack of scientific explanation or lack of understanding of any underlying mechanism commonly accepted in the scientific community. Some scientists would assume that because no chemical detergent was added to the water that no detergency action resulted. This is an erroneous assumption. Therefore a dogmatic scientist, in not understanding how or why it worked, would say it did not work and was a fraud. That is like a blind person turning on a light switch and not detecting a light going on would say that electric lighting was a fraud. Since practically no scientist can completely explain why electricity would produce light, a blind scientist would conclude that electricity does not produce light. Those who actually benefit from the light have no problem with the lack of a complete explanation of why. In the same way, those who actually benefit from the clean clothes without the use of chemical detergent do not have a problem with the lack of scientific explanation for how it works. That is, they don't have a problem until some dogmatic scientist who does not understand it tells them it is a fraud. Then, not wanting to appear to be a fool, suddenly have a problem telling someone that their clothes actually got clean.
In other words do clothes in a batch of general household laundry get clean without chemical detergent? Be careful here how you define clean. By clean we mean the removal of soil or contaminants. In judging the results of any tests be careful not be fooled by the addition of chemical contaminants that fool the eye into thinking laundry is cleaner. Chemical agent whitener is added by some detergent manufactures, and the chemical detergent may even be weakened to prevent the detergent from removing the whitener. Clothes washed in this product appear to be whiter but do not remove very much (if any) more contaminants than washing in plain water. The whiteness of the laundry washed in this product can be removed by immediate repeated multiple washings in plain water after washing in this product.
It is suggested that the user of a detergent run an experiment by washing some white towels with stains in their favorite detergent. Save one of the clean towels out and wash the others over again a couple of times in water alone. When you compare the results of the multiple washes, see for yourself that the whitener of the detergent is washed out. The towels washed extra times in plain water will have the whitener chemical removed leaving a cleaner, yet less white towel.
If this whitener is desired, it can be added without the use of a chemical detergent, but should not be confused with cleanness. The same is the case with the addition of chemical brighteners. The results of chemical brighteners should not be confused with cleanness. Chemical brighteners too can be added to the cleaning process if desired, without sacrificing the environment by the addition of chemical detergent. In addition to whiteners and brighteners, there are fabric softeners and perfumes to give the clothes the feel and odor we associate with cleanness. There are also germicides and fungicides, which are actually chemical poisons to sterilize the laundry. Whiteners, brighteners, fabric softeners, perfumes, germicides and fungicides are actually the addition of foreign substances to the laundry, rather than the removal of foreign substances from the laundry. If these additives are desired to give the laundry the appearance, feel and odor of cleanness, they can be added without adding the chemical detergent.
With the scientific explanation for the present invention being so straight forward and documented, that problem with the blind dogmatic scientist has gone away. Now there is a scientific explanation of how electric fields are generated in substances like plastic or rubber and how electric fields from such substances produce reactions in the water, and how the reactions in the water are related to cleaning of laundry, and why there is no detectable difference in the water before and after the treatment of the water which is effective only during the cleaning process, leaving no residual effect. This lack of residual difference in the water which is a stumbling block to the doubting scientist, is not a weakness, but is the most desired effect sought after in the quest to keep the environment pollution free.
Many tests and demonstrations have been performed demonstrating the effectiveness of the invention.
Theoretical Basis
It may be helpful to understand the theory behind some features of this invention. While we believe this theory to be valid, we do not wish to be limited thereto as other considerations may be pertinent. The validity of the invention has been empirically established. Several effects will be explained.
Electrically Induced Detergency
The Matsuoka Experiment
Takahisa Matsuoka and Mutsuo Iwamoto describe the effect on surface tension and permeability due to the electrical treatment of water in an experiment described in the Japanese Journal of Food Science and Technology, Nippon Shokuhin Kaogyao Gakkaishi, Volume 38, No. 5, 1991, pages 422-424. The article is entitled “Surface Tension and Permeability of Water Treated by Polar Crystal Tourmaline.” In the experiment, water was electrically treated using the electrically polar crystalline substance tourmaline. The treated water, which started out with a normal surface tension of approximately 65 dynes per centimeter, had a surface tension of approximately 50 dynes per centimeter immediately after treatment. The surface tension reduction was a temporary effect and returned to normal after a few minutes. After returning to normal, the water had no detectable difference in any properties from before the treatment. The electrical treatment did not result in any permanent change in the water any more than water which has been heated and then cooled back down is any different than water that has never been heated. The results of the experiment can be summarized by saying that just like water that has been heated has lower surface tension, water that has been electrically treated has lower surface tension, neither has any permanent detectable effect.
However, in the Matsuoka experiment, there is a discrepancy between the effect on distilled water and city tap water. The water containing impurities had a greater measured effect and retained the effect longer in time. This discrepancy gives a clue to the reason the ionic separation lasted even long enough to be measured. It appears that the effect was much greater immediately upon treatment in the immediate vicinity of the electric charge, and was preserved by the detergency attachment to impurities in the water. More impurities in the water resulted in greater accumulation of effect, and longer duration of effect. This effect of impurities causing electrically treated water to retain detergency longer is explained by the chemical formulas in the next section. Even so, the effect measured immediately after accumulating a batch of treated water was only on the order of half the effect of chemical laundry detergent. The water treatment process used in the Matsuoka experiment is very slow. The treatment of water by the electrically polar crystalline substance tourmaline requires much longer time to fill up one washing machine tub than the effect lasts. This yields this process of batch treatment before use as impractical as a laundry solution. In the current inventive method the treatment is done simultaneously with the work of cleaning and in the same location as the work of cleaning is being done.
This temporary reduction in surface tension in this experiment is significant, because water that has had it's surface tension lowered by the addition of chemical detergent does have a permanent change that can be measured in the waste water. It has chemical pollutant which in many cases would not be allowed to be discharged if it were from an industrial plant.
Hypothetical Explanations
Several hypotheses have been proposed to explain the increase in the effectiveness of the physical property of detergency when water is treated electrically. One hypothesis uses dissolved oxygen, another the liberation of hydrogen, another the disassociation of water only with no gain or loss of hydrogen or oxygen. Which hypothetical mechanism is in operation may depend on the voltage and current conditions of the electric charge or some other factor, but the net results are the same: Temporary detergency is induced into the water, and impurities prevent the induced detergency from immediate dissipation. Two of the hypothesis have been herein expanded in detail sufficient for one versed in the art to develop others.
Hypothesis 1: Dissolved Oxygen In Water
In the washing machine are water (H 2 O), oil, cloth, and an embodiment of the current invention.
In the washing machine the agitator causes kinetic energy to do the work of whipping air, containing Oxygen (O 2 ), and oil into the water (H 2 O).
H 2 O+O 2 +Oil
The water is naturally, weakly disassociated into Hydrogen ions (H + ) and Hydroxide ions (OH − ), and Oxygen (O 2 ) is naturally dissolved.
6(H 2 O)+O 2 +Oil⇄8(H + )+4(OH − )+4(O = )+Oil
With the introduction of an electric charge into the water by an embodiment of the current invention, the Hydroxide ions (OH − ) are repelled by the negative charge and the Hydrogen ions (H + ) are attracted to the negative charge, and vise versa for the positive charge. Thus the energy of the electric charge does the work of spatially separating the Hydrogen ions (H + ) from the Hydroxide ions (OH − ) where the Hydrogen ions (H + ) combine with dissolved oxygen (O = ) and the Hydroxide ions (OH − ) having the physical property of detergency attach themselves to the oil, resulting in an oil water emulsion.
8(H + )+4(OH − )+4(O = )+Oil.→4(H 2 O)+(4(OH − )+Oil)
The total reaction in the presence of electrical charge driving the arrows to the right being:
6(H 2 O)+O 2 +Oil→8(H + )+4(OH − )+4(O = )+Oil.→4(H 2 O)+(4(OH − )+Oil).
The first arrow is by natural dissociation. The second arrow is by the work of electrical charge energy.
With the removal of the electrical charge, the source of energy driving the second arrow to the right, the wash water slowly returns to the natural state, being slowed by the attachment of the Hydroxide ions (OH − ) to the oil.
6(H 2 O)+O 2 +Oil←8(H + )+4(OH − )+4(O = )+Oil.←4(H 2 O)+(4(OH − )+Oil
After the removal of the source of electrical energy the duration of time for the return reaction being on the order of approximately an hour to approximately three hours is sufficient for the water and soil emulsion to be rinsed out of the wash machine. This is of the same order of magnitude time as the cooling time for hot water to return to ambient temperature once the source of thermal energy is removed.
As the emulsion separates the water returns to it's normal composition and the water looses it's detergency, the soil held in suspension separates from the water and settles out, aiding the natural process of purifying the water as it is returned to the environment.
Hypothesis 2: Disassociation Of Water Only
In the washing machine are water (H 2 O), oil, cloth, and an embodiment of the current invention.
H 2 O+Oil
Naturally, water is weakly disassociated into Hydrogen ions (H + ) and Hydroxide ions (OH − ).
(H 2 O)+Oil⇄(H + )+(OH − )+Oil
With the introduction of an electric charge into the water by an embodiment of the current invention, the Hydroxide ions (OH − ) are repelled by the negative charge and the Hydrogen ions (H + ) are attracted to the negative charge, and vise versa for the positive charge. Thus the energy of the electric charge does the work of spatially separating the Hydrogen ions (H + ) from the Hydroxide ions (OH − ). The Hydrogen ions (H + ), being spatially separated from the Hydroxide ions (OH − ) due to the work done by the electric charge of an embodiment of the current invention, combine with other water molecules (H 2 O) forming Hydronium ions (H 3 O + ).
(H 2 O)+(H + )→(H 3 O + )
Meanwhile, the Hydroxide ions (OH − ), being spatially separated from the Hydrogen ions (H + ) due to the work done by the electric charge of an embodiment of the current invention, combine with other water molecules (H 2 O) forming Hydroxyl ions (H 3 O 2 − ).
(H 2 O)+(OH − )→(H 3 O 2 − )
Hydronium ions (H 3 O + ), and Hydroxyl ions (H 3 O 2 − ), being spatially separated from each other due to the work done by the electric charge of an embodiment of the current invention, and each having the physical property of detergency attach themselves to the oil, resulting in an oil water emulsion.
(H 3 O + )+Oil→(H 3 O + +Oil)
(H 3 O 2− )+Oil→(H 3 O 2 − +Oil)
The total reaction in the presence of electrical charge driving the arrows to the right being:
3(H 2 O)+Oil→2(H 2 O)+(H + )+(OH − )+Oil→(H 3 O + )+Oil+(H 3 O 2 − )→(H 3 O + +Oil)+(H 3 O 2 − +Oil)
The first arrow is by natural dissociation in the abundance of water (H 2 O ) driven right by the removal of Hydrogen ions (H + ) and Hydroxide ions (OH − ) from the right side of that equation by the second arrow. The second arrow is by the work of electrical charge energy. The third arrow is driven right by the detergency physical property of Hydronium ions (H 3 O + ), and Hydroxyl ions (H 3 O 2 − ) and the abundance of Hydronium ions (H 3 O + ), and Hydroxyl ions (H 3 O 2 − ) due to the work of electrical charge driving the second arrow to the right.
With the removal of electrical charge, the source of energy driving the second arrow to the right, the wash water slowly returns to the natural state, being slowed by the attachment of Hydronium ions (H 3 O + ), and Hydroxyl ions (H 3 O 2 − ) to the oil.
3(H 2 O)+Oil←2(H 2 O)+(H + )+(OH − )+Oil←(H 3 O + )+Oil+(H 3 O 2 − )←(H 3 O + +Oil)+(H 3 O 2 − +Oil)
After the removal of the source of electrical energy the duration of time for the return reaction being on the order of approximately an hour to approximately three hours is sufficient for the water and oil emulsion to be rinsed out of the wash machine. This is of the same order of magnitude time as the cooling time for hot water to return to ambient temperature once the source of thermal energy is removed.
As the emulsion separates the water returns to it's normal composition and the water looses it's detergency, the soil held in suspension separates from the water and settles out, aiding the natural process of purifying the water as it is returned to the environment.
Micro-Turbulence
Surface tension prevents water from penetrating the micro interstices of cloth to remove the soil particles entrapped therein. Turbulence reduces this effect of surface tension by forcing water into and out of smaller spaces. Micro-turbulence is induced in water by static electric charges. Water is attracted to a charge opposite that contained in the water, and repelled by a like charge. An experiment was done with a comb run through hair to gain a static electric charge. The charged comb was then brought near a cup of water filled to the point of overflowing prevented only by surface tension. A camcorder was positioned like a microscope to record the effect. As the charged comb was brought near the water, a small droplet of water, in less than one fifteenth of a second, overcoming the surface tension, jumped toward the comb, but never touched the comb. As the droplet approached the comb, charge was transferred to the water so that the charge on the water droplet became the same polarity as the comb and the droplet was immediately repelled by the charge remaining on the comb. It is believed that this process is present in the froth of air and water in the immediate vicinity of the electric charge distributing means of the current invention. This rapid moving back and forth of the water on a scale smaller than that of the droplets formed by surface tension, is called micro-turbulence. This effect is especially probable where the oscillating action of the agitator causes one polarity charge to be produced by movement in one direction and then the opposite polarity charge to be produced in the other direction, resulting in the article of clothing in the immediate vicinity of the electric charge distributing means of the current invention to have the opposite polarity charge as the electric charge generating means of the current invention.
Of the two types of turbulence, micro turbulence is more on the size scale of the interstices of the cloth in which the soil is entrapped. Another example of micro turbulence is the turbulence induced by ultrasonic sound energy in ultrasonic cleaning. Both are the result of an outside source of energy doing the work of overcoming the energy of surface tension.
Direct Electrostatic Effect
The forces that hold soil to surfaces includes electrostatic forces. Soil is held to surfaces by occlusion in surface interstices, by electrostatic forces between surface and soil and by the attraction of soil fractions for each other. The sum total of all these forces may be expressed as the energy of soil adhesion. Since electrostatic forces are included in the forces of attraction, and since opposite forces attract and like forces repel, electrostatic forces have a direct effect in overcoming those electrostatic forces of soil adhesion. It is hypothesized that in the immediate vicinity of the electric charge distributing means of the current invention this energy of soil adhesion is overcome by work expended by the electric charge energy of the current invention.
Surface Tension
Surface tension is the force which causes water to have self attraction. Surface tension is the force which prevents water from entering small interstices of cloth that has not been prewetted. Surface tension causes water when slowly exiting a capillary tube to form up into a ball until the forces of attraction of water for itself are overcome by the force of gravity causing the ball of water to drop. A commonly accepted method of measuring the force of surface tension is called the drop weight method, or drop volume method. I have constructed a relative surface tension meter based on a variation of that method. I call it the drop count or drop frequency method. The device forces one ml of fluid through a steel capillary tube in four minutes. (It is driven by a clock mechanism which turns once in sixty seconds.) The reciprocal of the time between drops gives the number of drops in one ml. The number of drops per ml. is inversely proportional to the surface tension. With the relative surface tension meter, normal tap water at room temperature drops approximately every four seconds, yielding 58 drops per ml. When water is mixed with a popular brand of laundry detergent in a wash machine according to the proportions directed on the container, the relative surface tension meter yields 132 drops per ml., indicating less than half the surface tension of normal tap water. However, in measuring normal tap water at room temperature, while dropping approximately every four seconds, connecting a high voltage static electric charge to the steel capillary tube causes the drop size to so drastically decrease as to raise the drop rate to between 1200 and 1400 drops per ml. That is a approximately one twentieth the size of drop formed by the same water the instant before the electric charge is connected and the instant after the electric charge is disconnected. Stated another way, the electric charge affects the surface tension ten times as much as the laundry detergent. The experiment was repeated using the electric charge of a plastic comb run through my hair and brought near the forming drop. The effect was of a similar order of magnitude.
Permeability
Permeability is a measure of the ability of water to pass through material which is prewetted to remove surface tension effects. The Matsuoka experiment demonstrated that related to the reduction of surface tension due to electrical treatment is also an increase of permeability, a reduction of the resistance of water to flow through the interstices of prewetted cloth.
Surface Chemistry Detergency Modulated by Electric Charge
An inventive feature of this invention is the use of a surface chemistry detergent. Surface chemistry detergent is a solid having detergent molecules attached to the surface of the solid, possibly by chemical bonding. Alternately the detergent molecules are an integral fraction of the solid with the detergent molecules at the surface extending out and attached at only one end. Examples of surface chemistry molecules having detergency are long polymer string molecules terminated at the free end with a terminal benzoic acid group conjugated to a piezoelectric polymer. This gives the surface the physical characteristic of attracting and holding soil particles by molecular bonding.
Another inventive feature of this invention is the use of electric charge to modulate the attraction of a surface chemistry detergent. This modulation is performed by reversing the electric charge at the terminal end of the detergent molecule by exploiting the electrical properties of the main bulk of the solid. As shown in FIG. 3D, FIG. 3E, and FIG. 3F, in the case of a main bulk containing a piezoelectric polymer, flexing the main bulk of the solid in one direction makes the whole bulk negatively charged, and flexing the main bulk of the solid in the other direction makes the whole bulk positively charged. Alternatively, stretching the main bulk makes one side positive and the other side negative. In either case, the surface with the detergent molecule has a reversing polarity electric charge which modulates the detergency properties. When stretched or flexed in one direction, the molecule attracts and holds soil by virtue of the molecular characteristic of hydrophobic attraction. When relaxed or flexed in the other direction the molecule releases the soil into the charged water where it is held in suspension or emulsion by the temporary detergency properties of water having been charged by the charge draining off the same surface. Think of it as a rubber band which when stretched by being dragged past a particle of soil on an article of clothing, attracts and holds that particle until the agitator reverses and the rubber band snaps back ejecting the soil particle into the water along with electric charge which gives the water the physical property of detergency to hold that particle until the water is drained from the washing machine. As explained elsewhere herein, the detergency physical property induced into the water by the electric charge is temporary and after a short period of time the soil will automatically separate from the discarded wash water leaving clear non polluting water to return to the environment, thus filling that long recognized and unfilled need for reducing laundry chemical waste which is polluting the environment.
A material having piezoelectric properties produces an electric charge when flexed, then produces an electric charge of the opposite polarity when flexed the other direction. Piezoelectric polyvinylidene fluoride (PVDF) is an example of such a substance. Other examples are composite materials too numerous to list.
Piezoelectric polyvinylidene fluoride (PVDF) is an example of a plastic substance having piezoelectric properties:
Such a substance or a copolymer is synthesized with the added physical property of surface molecular attraction detergency due to hydrophobic attraction. The object of the synthesis is to attach a detergent type molecule to a piezoelectric polymer such as PVDF or to make a copolymer that acts to break up surface tension of water and attract grease or soil particles in a way similar to existing chemical additive detergents.
General Scheme: (Protected Amine is One Example of Possible Chemical Synthesis)
The resulting copolymer with a terminal benzoic acid group conjugated to the piezoelectric polymer results in alternating negative (deprotonated) and neutral (protonated) charges upon mechanical agitation. This alternating charge breaks the surface tension while the long conjugated greasy part of the molecule attracts soil by hydrophobic attraction, then alternatingly, by the opposite charge overcoming the molecular hydrophobic attraction, releases the soil as fine particles into the wash water to be held in suspension or emulsion until rinsed away.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
As will become obvious, there are multiple preferred embodiments of the present invention. In general, each embodiment has a body such as a central core, or an agitator, and external parts more resembling fins which sometimes flex, or sometimes a flange which rubs without flexing. The body is usually a mass with inertia, and the fins are points or areas of application of the electric energy to the process of cleaning.
First Embodiment—FIGS. 1A and 1B Direct Attachment to Agitator
FIGS. 1A and 1B illustrate a first embodiment of the present invention. In this embodiment there is direct attachment to a source of kinetic energy, and electric energy is generated using the principle of piezoelectricity.
Generally at 10 is an external part 10 , which is a tine, nub, point, fin, vane, filament, or elastomer. Throughout the descriptions of the figures, this part, fin 10 , takes on various forms and is made of various materials having various characteristics. This part, fin 10 , functions as a means for generating, distributing, and/or applying of electric charge. As long as the function and general appearance remain the same, this item 10 will be referred to with the number 10 . Fin 10 of this first embodiment is made of material having a physical property of piezoelectric electric charge generation. An example of such a material is piezoelectric polyvinylidene fluoride (PVDF). The molecular structure of PVDF is described above in the section on theoretical basis. Fin 10 of a first embodiment of the invention has a width dimension which is much greater than a thickness dimension such that fin 10 will flex more readily in the width plane than in the thickness plane. An attached end or edge 14 has an attachment means 16 such as a conventional adhesive, weld, or clamp. Attachment means 16 secures fin 10 to an agitator 18 of a conventional clothes washing machine (not shown.) FIG. 1B shows a plurality of fins 10 of various shapes attached to agitator 18 in various locations on agitator 18 . A plurality of fins 10 are attached to agitator 18 . When a conventional washing machine (not shown) applies a washing action by agitation action of agitator 18 , such washing action moves the fins against water (not shown) and against clothes (not shown.) This causes fins 10 to flex, generating electric charge and distributing electric charge in the vicinity of the clothes (shown.elsewhere herein)
Second Embodiment—FIGS. 2A and 2B Indirect Attachment to Agitator
FIGS. 2A and 2B illustrate a second embodiment of the present invention. In this embodiment there is indirect attachment to a source of kinetic energy, and electric energy is generated using the principle of piezoelectricity. In this embodiment fins 10 are attached to an intermediate device 22 which in turn secures fins 10 to agitator 18 . Intermediate device 22 is removable from agitator 18 . Filaments or fins 10 made of material having a physical property of piezoelectric electric charge generation, as in the first embodiment described above, are attached by conventional attachment means 16 to a donut shaped ring 22 which fits around agitator 18 of a conventional washing machine (not shown.). An attaching device 22 can be made of various designs as would be obvious to one versed in the art. In the case illustrated in FIGS. 2A and 2B, ring 22 is made from a flexible material of shape and form similar to a donut with a large hole through which agitator 18 snugly fits. An example of such a material is conventional clear polyvinyl chloride (PVC) tubing formed into a ring of a size appropriate to fit on agitator 18 . The back and forth washing action of agitator 18 flexes fins 10 back and forth as fins 10 move against the water and clothes in the washing machine.
Piezoelectric Charge Generation—FIGS. 3A Through 3F
FIGS. 3A through 3F illustrate piezoelectric electric charge generation. Each figure is an edge view of fin 10 made of material having a physical property of piezoelectric electric charge generation. FIG. 3A shows fin 10 having a broad side 30 and a narrow edge 32 and having one end attached 14 . FIG. 3B shows fin 10 having a left flex 34 . FIG. 3C shows fin 10 having a right flex 36 . In use the flex alternates between right and left. FIGS. 3D and 3E are edge views of a fin 10 type part illustrating a conventional prior art use of a similar piezoelectric material used to convert kinetic energy to electric energy as in, for example, the generation of electric power from the action of ocean waves. In FIG. 3D, depending on the alignment of the piezoelectric properties, an applied tension 38 results in an internal electron movement 42 to the left resulting in a negative electric charge 44 on the left side and a positive electric charge 46 on the right side. In conventional electric generation use, a conventional conductor (not shown) on each side of fin 10 leads the charge away as a current to do useful work elsewhere. In FIG. 3E, the same fin 10 is shown under compression 40 . This compression 40 reverses the direction of internal electron movement 42 to the right, resulting in a negative electric charge 44 on the right side and a negative electric charge 46 on the left side, the opposite sides as in FIG. 3 D. FIG. 3F illustrates this inventive use of material having a physical property of piezoelectric electric charge generation. An edge view of fin 10 is shown in the same orientation as in FIGS. 3D and 3E. However, the fin 10 of FIG. 3F is flexed such that compression 40 occurs on the left side, and tension 30 simultaneously occurring on the right side. This causes the internal electron movement 42 direction to be left near the left surface, and right near the right surface, resulting in a concentration of electrons near both outer sides of fin 10 when flexed left. The opposite positive charge is concentrated in the middle of the thickness of fin 10 , the dielectric properties of the material of fin 10 preventing the flow of electrons to neutralize the charge. This negative charge on the outer surface of fin 10 , being closer to the water (not shown) and clothes (not shown) surrounding fin 10 appears to this surrounding water and clothes to be the only charge, and thus has the desired effect as described in the preceding section entitled theoretical basis. When that same fin 10 is flexed in the opposite direction (not shown) the mechanism is similar, with reversal of the polarity to positive near the outer surface of fin 10 . In either case, electric charge does the work of cleaning in the water as described in the preceding section entitled theoretical basis.
Third Embodiment—FIGS. 4A through 4E Inertial Coupling to Agitator
FIGS. 4A through 4E illustrate a third embodiment of the present invention. In this embodiment, an electric charge generating means, an electric charge distributing means, and an electric charge applying means are all integrated into one device. In this embodiment this device is an external part more resembling a filament 10 . In this embodiment electric energy is generated using the principle of frictional electric charge generation. In this embodiment a great plurality of fins, vanes, filaments, or elastomers 10 are attached to a free floating unattached device 50 . Filaments or fins 10 are made of material having a physical property of frictional electric charge generation. An example of such a material is extruded natural rubber. Free floating unattached device 50 is put into a tub 60 of a conventional washing machine (not shown) along with water or a washing fluid 62 and items of laundry 64 . Kinetic energy is transmitted to unattached device 50 by the interaction of agitator 18 , water 62 , items of laundry 64 , and device 50 , in the presence of conventional agitation washing action, device 50 generates electric charge and transmits it directly to the immediate vicinity of the cleaning work being done by the kinetic energy, where the electric energy does work of modifying the physical properties of water to increase the naturally occurring detergency properties of water, as described in the above theoretical basis section. Alternatively, device 50 may be hand held as shown in FIG. 4E to be used as a scrubbing device for such diverse cleaning tasks as spot removal, bathing and shampooless hair cleaning.
FIG. 4A illustrates the general appearance of a third embodiment of a device constructed to be used in accordance with the invention. Device 50 is formed with a large plurality of elongate, floppy, elastomeric filaments 10 , each of which, as is clearly evident in FIG. 4B, has cross-sectional dimensions of the loose ends 58 of filaments 10 which are extremely small in relation to the length of the filament. As will be more fully explained shortly, these filaments are joined in a central core region in such a manner that they radiate outwardly in a fairly uniform dense and bushy fashion, in multiple angularly offset planes to form a substantially spherical or ragged pompom like configuration. In this embodiment the central core region is the body as defined above. While the outside diameter of device 50 may be of any desired size, a very satisfactory diameter lies in the range of about 3 to about 10 inches.
While, to be sure, various techniques and devices may be used for joining these filaments to produce the desired resultant object, device 50 has been formed, as is illustrated in FIG. 4 C. A large plurality of extruded rubber filaments are bundled and stretched to about three times their relaxed length. Next a conventional cinching device 54 is wound as illustrated around the mid point of the bundle and secured by a knot or twist tie 56 . The stretched rubber filaments are then released, with the result that the stretched filaments spring back toward their gathered centers, with a natural tendency to fan out radially in all planes to have the substantially spherical form which is illustrated.
Clearly, device 50 is extremely simple and inexpensive in construction.
The specific nature of device 50 can be altered, of course by changing cross-sectional dimensions, cross sectional aspect ratios and specific materials employed for the filaments 10 and cinching device 54 .
The material selected can have a piezoelectric characteristic in place of or in addition to a frictioning characteristic.
The device 50 can optionally have a conventional floatation device (not shown) attached or be made from material having a floatation characteristic for the purpose of achieving floatation just above neutral buoyancy such that device 50 floats with approximately 3 to 15 percent of its volume above the surface of water 62 .
This device 50 can be used in a washing machine for washing clothes, or as a hand held scrubbing device as in, for example, shampooless hair cleaning.
When used in a washing machine, the floatation at nearly neutral buoyancy will allow the device to occasionally be drawn under the surface of water 62 as agitator 18 turns the clothes over with it's scrubbing action. The action of agitator 18 causes differential movement between the device 50 and clothes 64 , giving rise to friction causing the conversion of kinetic energy to electric energy. As the device is moved the resulting positive and negative electric charges are displaced causing the charge to effect water 62 in the immediate vicinity.
This embodiment of this invention is made with surfaces, vanes, or filaments of a material having frictioning properties, and is caused to pass through the water among the clothes in a standard washing machine of the prior art by the flexing action induced by the agitator of that washing machine, thus rubbing against fabric, giving rise to electric charge. Simultaneously those same surfaces, vanes, or filaments distribute that charge in the vicinity of the fabric being cleaned.
Frictional Electric Charge Generation—FIG. 5
FIG. 5 illustrates the mechanism of frictional electric charge generation, distribution, and application means. Differential movement 48 between a fiber of cloth 66 and filament 10 as filament 10 is dragged along by attached end 14 causes rubbing to occur between fiber 66 and filament 10 . This washing action rubbing along with the frictional and electrical properties of the material with which filament 10 is made, cause electrons 44 to be rubbed off fiber 66 and stick to filament 10 . As filament 10 is dragged along, the distance between the source of electrons 44 and their current location gives rise to a negative static electric charge 44 on the surface of filament 44 and an unbalanced positive electric charge on the fiber. In the presence of a substance having low conductivity, such as water, surface electric charges 44 and 46 do persist, but for only a short time. There is empirical evidence that electric charge also builds up inside the material of which fin 10 is made, and, being much more effectively insulated from the water by the dielectric characteristic of that material remains active, functioning as an electret. The function of electric charge in doing the work of cleaning is adequately described in the section on theoretical basis. Independent of the source of the differential electric charge 44 and 46 , be it from friction, a conventional electronic device, piezoelectric properties of materials of construction, or any other source, the mechanism of hydrolization within water 62 remains the same. There are theories that different parts of the mechanism are more dominant dependent on voltage and current, but the results are always changes in the physical properties of water 62 if only momentarily, but long enough to do the work of cleaning.
Preferred Embodiment
FIG. 6 shows a fin, vane, filament, or elastomer 10 of a preferred embodiment having the same function and general appearance as in other embodiments. Each of the plurality of fins 10 of this preferred embodiment are made of or coated with a substance 68 which has detergent acting surface molecules as described elsewhere herein in the section on theoretical basis. An example of such a material is a copolymer with a terminal benzoic acid group. These surface detergent molecules alternately attract and repel, (cling to and release) dirt as the polarity of the electric charge alternates due to the back and forth flexing of fin 10 caused by the agitator or by other means. The net result can be visualized as similar to the result obtained by rubbing something with a wash rag to transfer the dirt to the rag, then rinsing the rag in wash water. However, in this case, the electric energy rather than kinetic energy does the work more efficiently.
Alternate Embodiments
The inventive method of utilizing electric energy to do the work of cleaning by producing a charge, distributing that charge to the location of cleaning, and applying the charge to the water in the immediate vicinity of the work to be done, may be embodied by many various designs.
One design shown in FIG. 7 is a special agitator 70 of a conventional washing machine (not shown) made out of special electric charge producing material. Such special material is at least one of those described elsewhere herein, or an alternate material functioning to produce charge.
Another design shown in FIG. 8 is a piezoelectric agitator 72 in a conventional washing machine (not shown.) Piezoelectric agitator 72 is made out of durable, flexible, piezoelectric polymer or composite such that the edges of agitator 72 flex, providing generation, distribution, application of electric charge in similar fashion as the agitator fin extenders described in embodiment one above.
Another design shown in FIG. 9 is a special capacitative agitator 74 and/or other parts (not shown) of a conventional washing machine (not shown). Agitator 74 is designed as be a one electrode capacitor to be means to distribute and apply the electric charge generated elsewhere. One design for agitator 74 is plastic coated metal 76 (one electrode capacitor with environment as second electrode) then optionally coated with surface detergent 68 . The energy of electric charge is supplied by a conventional electric charge generator 80 connected to agitator 74 by electric wiring 82 The charge supply is either constant or alternating.
FIG. 10 shows still another simple, yet practical embodiment. An agitator 18 of an existing conventional washing machine (not shown) is sprayed with the proper composition material in the form of a spray on coating 78 .
Each of the alternate embodiments produces the electric charge by some means, distributes the energy of the charge by virtue of being at the right place at the time, and applies that charge by virtue of continuing to produce charge by the input of kinetic or some other form of energy as the distribution takes place.
FIG. 11 shows the hypothetical separation of ions in water due to electric charge, and the resulting concentration of ions having detergency in a highly magnified schematic view. This description of FIG. 11 should be read with the above theoretical basis description of Hypothesis 2 in mind. Hydrogen ions (H + ) 86 and Hydronium ions (H 3 O + ) 88 being positively charged are attracted to the negative charge 44 which is a build up of electron concentration 44 in the vicinity of fin 10 , where Hydrogen ions (H + ) 86 and Hydronium ions (H 3 O + ) 88 are concentrated due to attraction of opposite charges. Hydroxide ions (OH − ) 92 and Hydroxyl ions (H 3 O 2 − ) 94 being negatively charged are repelled from the negative charge 44 , away from fin 10 , to the vicinity of a fiber of cloth 66 with particles of soil, oil, dirt, micro organism, or foreign matter 84 being held to fiber of cloth 66 by forces of soil adhesion which must be overcome in the cleaning process, where Hydroxide ions (OH − ) 92 and Hydroxyl ions (H 3 O 2 − ) 94 are concentrated due to repulsion of like charges. Having detergency characteristics, Hydroxyl ions (H 3 O 2 − ) 94 are attracted to soil particle 84 by detergive attraction 96 where Hydroxyl ions (H 3 O 2 − ) 94 surround soil particle 84 and separate soil particle 84 from fiber of cloth 66 , thus cleaning fiber of cloth 66 . Water molecules (H 2 O) 90 , being neutral in charge, are more concentrated in the area between the concentrations of charged ions where the charged ions are separated from water molecules (H 2 O). Being separated from the charged ions, the natural disassociation of water into ions results in more charged ions, which are further separated from each other, thus driving even greater concentration of detergive ions into the area immediate to the fiber of cloth where cleaning takes place.
Operation of Invention
How the Invention Works
An object of this invention is to exploit another form of energy, the energy of electric charge, in an application which fills those long recognized and unfilled needs for increased effectiveness of cleaning, and reduction of pollution produced by household laundry operations.
The general embodiment of this invention is made with surfaces, vanes, or filaments of a material having frictioning properties, and sufficient surface area, and is caused to pass through the water among the clothes in a standard washing machine of the prior art by the flexing action induced by the agitator of that washing machine, thus rubbing against fabric, giving rise to electric charge. Simultaneously those same surfaces, vanes, or filaments distribute and apply that charge in the vicinity of the fabric being cleaned.
As an embodiment 50 (FIG. 4D) according to the invention passes through the water 62 among the clothes 64 it drags electrons 44 (FIG. 5) along by friction with the fiber 66 of clothes or by flexing of vanes or filaments 10 (FIG. 3F) causing the rise of electric charge 44 . The electric charge 44 causes several immediate effects in the water. As the electric charge immediately drains off, (described in section on theoretical basis) the electric charge causes micro turbulence and hydrolyzes the water in the immediate vicinity of the micro turbulence. This hydrolization of the water reduces the surface tension momentarily in the vicinity of the micro turbulence. This sets up the conditions which causes removal of soil particles from the interstices of the cloth. These conditions include turbulence, reduced surface tension, and the physical property of detergency. No lasting effect is caused in the properties of the water. The only lasting effect is the soil particles have been removed from the clothes and are held in suspension in the water until the water is removed from the clothes by draining away. That lasting effect too, is short lived. After a few minutes the residual detergive qualities of the discarded waste water which hold the soil in suspension fade away, and the water naturally separates itself from the soil particles held in suspension.
Of the four forms of energy added to water to effect the work of cleaning, the electrostatic energy is the safest. Hot water can scald your hand. Hot water sets stains. An agitator used to induce turbulence can injure your hand. Turbulence wears out fabric. Chemical detergents can irritate your skin. Chemical detergents pollute the environment. Electrostatic energy does not set stains, does not wear and tear the fabric and does not pollute the environment. Electrostatic energy simply overcomes the forces holding the soil to the fabric thus separating the soil from the fabric. Electrostatic energy simply promotes temporary physical property changes in the water which work to separate the soil and hold it separate in the water until the water is separated from the laundry. The electrostatic energy is the same as is built up on the comb when combing your hair when it is very dry. When combing your hair, long before you can experience a slight shock, electrostatic energy can be detected by picking up bits of paper with an electrified comb. Electrostatic build-up only occurs in air when the air is very dry. In wet laundry there is no dangerous static build-up, the conditions are very wet and the electrostatic energy is quickly dissipated into the water as it does it's work of cleaning.
Surface Detergent Modulated by Electric Charge
Another object of this invention is to exploit surface chemistry properties of detergency, and using the energy of electric charge to modulate these properties in an application which fills that long recognized and unfilled need for reducing laundry chemical waste which is polluting the environment.
Surface chemistry refers to chemical reactions that occur on the surface of a solid reacting in and with a fluid rather than reactions between and among chemicals dissolved in a fluid. In the past, detergents were chemicals in solution rather than on and part of a surface. Being in solution, the chemical detergent was discarded with the wash water.
This new inventive method uses a chemical detergent which is detergent attached to the surface of a solid substance rather than dispersed throughout the wash water. The chemical detergent is therefore completely recycled and never thrown away with the wash water. The function of a surface detergent is to separate the soil from the laundry. In conjunction, the function of alternating electric charge is to modulate the function of the surface detergent to periodically cause the surface detergent molecules to separate themselves from the soil and to stimulate temporary detergency properties of plain water. Only the removed waste soil is left in the water. Since most of the soil in laundry is from the environment, returning the soil to the environment is non-polluting. In addition, since there is no chemical detergent in the waste water to hold the soil in suspension, the soil rapidly settles out after being discarded, leaving a much cleaner water to be recycled to the environment.
A material having piezoelectric properties will produce an electric charge when flexed, then produce an electric charge of the opposite polarity when flexed the opposite direction. Piezoelectric polyvinylidene fluoride (PVDF) is an example of a plastic substance having piezoelectric properties. Other examples are composite materials too numerous to list. An embodiment of this invention made with vanes or filaments of a flexible material having piezoelectric properties, and having a surface chemistry physical property of detergency is modulated as described above by the flexing action induced by the agitator of a washing machine.
Conclusions, Ramifications, and Scope
Accordingly the reader will see that according to the invention, electric energy is added to the traditional three forms of energy to do the work of cleaning. Providing any means to supply electric energy, any means to distribute electric energy, and any means to apply electric energy, according to this invention, reduces or eliminates the need for chemical detergent pollution from home laundry operation to a greater extent than possible with heretofore available technology.
While the above description contains many specificities, these should not be construed as limitations on the scope of the invention, but as exemplifications of the presently preferred embodiments thereof. Many other ramifications and variations are possible within the teachings of the invention. No particular apparatus description is to limit the scope of the means to provide electric energy. No particular apparatus description is to limit the scope of the means to provide distribution and application of that energy.
For example, a piezoelectric, or frictional electric device, when flexed or rubbed under water induces electric charge into the water, distributing that energy in the water and applying that energy at the site of the work of cleaning. The device is flexed back and forth by the action of agitation. The device can be attached to the agitator in the washing machine as an add on device, it can be integrated into the agitator itself, it could be a spray on substance having particular frictional electric properties, or it could be a device not connected to anything, yet receive kinetic energy through the agitation action of the water itself. It could be positioned away from the agitator and receive kinetic energy to do the flexing from some other source. It could be assisted by or wholly dependent upon electric charge from a charge producing electronic device wired to distribute the electric energy to the vicinity of the cleaning work being done. Very simply implemented, the electric energy could be generated at the same point in space and time that the turbulence is working, thus the means for distributing and application are incorporated in the generation means.
A further example is a laundry cleaning ball shaped device coated with a polymer having surface detergent properties and having these properties modulated by an electric charge from energy transmitted to the ball from a conventional transmitter via ultra sonic or microwave energy. Such a ball could be a passive energy receiver having conventional electronic receiving circuitry and conventional electronic power conversion circuitry to convert received energy into an electric charge which changes with time or with a change in characteristics of signal transmitted to such a ball. Such a ball could have segments of it's surface of opposite polarity by use of metal segments underlying the surface detergent polymer coating. Such a ball could be of any size from micro circuit to a large proportion of a washing machine such balls could be used in multiple quantities and automatically separated from the items being washed after washing by another property of the ball such as magnetism. The balls could even be automatically removed from items of laundry after being put inside a dryer by such a mechanism as a special trap to capture and hold the balls. Such a device need not be round in the shape of a ball. Almost any shape could be used as long as it did not interfere with the circulation of the object within a cleaning container.
Surface detergent of this invention could be used without electrical modulation during the laundry process. It could be made into tiny laundry granules just large enough to be caught and trapped by a screen such as a lint screen. These granules could be added to the laundry just as conventional detergent powder, then toward the end of the washing cycles the water could be circulated through such a trap where the granules could be caught to be externally renewed and recycled.
The invention has uses beyond normal home laundry. Dry cleaning, car parts washing, farm produce washing, separation of clay from gold in a mining operation are but a few of the obvious uses.
Many obvious modifications come to mind that have not been included above. Examples of such things that anyone versed in the art would assume to be obvious are:
The size is not limited to that of the standard household washing machine. A much larger or smaller version is obviously within the scope of the invention.
Substitution of various assemblies for individual components, or the addition or deletion of various assemblies in place of individual components are but a few among many of the various options.
Where various mechanisms of charge generation have been described others such as direct thermal energy conversion could be substituted.
Cleaning fluid or other washing solution could be used instead of water.
Other water treatment device or devices may be used in conjunction with the invention. Water treatment device may be an option depending on water condition in users area.
The washing container does not have to be a conventional laundry washing machine. It may be oval or some other shape. It may be a dish washing machine with electric charge distribution among the dishes and electric charge from a conventional electronic high voltage circuit. It may even be a scrub board and bucket of water.
The shape does not have to be round. It could be curved. It could be in the shape of a conveyor belt. Many parts that have been shown one shape could be another.
The invention may be implemented as a single-unit or as multiple units.
The invention may be free to move randomly or it may be anchored.
Some embodiments could even be operated in case of a lack of power. The embodiment could be used to massage the item of clothing in the presence of water, by hand or by foot, then the clothing removed and hand wrung.
In an alternate design for an anchored embodiment, the items to be cleaned could be moved rather than the device itself.
Alternate uses could by made such as washing one's hair with the inventive device rather than with or in addition to using shampoo.
While plastic or rubber has been described, a more rugged embodiment could have many parts made of metal.
Many items detailed above are optional, and can be omitted. Many can be changed in size, made of different material, made of a different shape, connected or associated in a different manner, made integrally or in sections, or varied in other ways without departing from the invention in its broader aspects. These items are offered by way of illustration only and not as a limitation.
Several alternate scrubbing actions and means of generating those actions have been described. Others too numerous to include are obvious to one versed in the art. A set of multiple agitating methods could be used simultaneously, or alternatingly.
While specific theory and hypothesis have been described, actual detail may vary. For example it is not clear whether electron build up in under water charge is exterior to surface or interior to surface of diaelectric material. We do not wish to be limited thereto as the validity of the invention has been empirically established.
While particular embodiments of the present invention have been shown and described, it will be obvious to those skilled in the art that changes and modifications may be made without departing from the invention in its broader aspects. For example, where water is mentioned throughout the descriptions, it is obvious that other cleaning solution may be substituted. (Other fluids, for example, petroleum based fluids, have demonstrated a similar physical properties change when under the influence of an electric charge.) Where plastic or rubber are mentioned throughout the descriptions, it is obvious that other non conductive or piezoelectric materials may be substituted, where piezoelectric electric charge is mentioned in the descriptions, it is obvious that electric charge from another source may be substituted, where textiles or clothes are mentioned throughout the descriptions, other objects could be washed including such diverse items as farm produce or the removal of clay from placer gold. Therefore, the aim in the appended claims is to cover all such changes and modifications as fall within the true spirit and scope of the invention. The matter set forth in the foregoing description and accompanying drawings is offered by way of illustration only and not as a limitation. The actual scope of the invention is intended to be defined in the following claims when viewed in their proper perspective based on the prior art.
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A washing method and apparatus characterized by employment of the electric form of energy in addition to the traditional three forms of energy (kinetic energy, thermal energy, and chemical energy) to do the work of cleaning, thereby reducing the requirement for and dependency on the traditional three forms of energy. Electric charge is employed to do work of cleaning by various physical phenomena. The phenomena include, but are not limited to effecting the physical characteristics of surface chemistry, the physical characteristics of water, and the chemical characteristics of water, Such characteristics include but are not limited to surface tension, agitation, hydrolization, and adhesion. Such effects of the physical or chemical characteristics are temporary, and are not detectable after the washing water is discarded so as to have minimal polluting effect on the environment. After the cleaning work is done, this temporary energy effect of the physical or chemical characteristics is just as transient, undetectable and non-polluting as is the thermal energy of hot water that has been cooled or the kinetic energy of moving water that has been stopped. Previous to this invention, the work of cleaning was done by three forms of energy: Thermal energy, kinetic energy, and chemical energy. This invention adds electric energy to the forms of energy that do the work of cleaning. Of the four forms of energy, the only one that remains in the waste water is chemical energy. Adding this additional form of energy allows the reduction of requirement for work to be done by any or all of the other forms of energy. The net result is the transfer of the work load from chemical energy, thus resulting in less dependence on the one form of energy that pollutes the environment.
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RELATED APPLICATION
[0001] This application is a division of Ser. No. 09/977,838, filed Oct. 15, 2001.
FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] This invention was made with government support under Grant No. NAG8-1687 awarded by NASA. The government has certain rights in the invention.
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] The present invention is concerned with methods of forming large quantities of ligated nanoparticles which can be deposited in two- and three-dimensional superlattices. Broadly speaking, the method involves initially forming a first colloidal dispersion made up of nanoparticles solvated in a molar excess of a first solvent, a second solvent different from the first solvent, and a quantity of ligand moieties. Thereupon, a substantial part of the first solvent is removed and the ligand moieties are caused to ligate to the nanoparticles to give a second colloidal dispersion. Preferably, the second dispersion is subjected to a heat and reflux digestive ripening process to give substantially monodispersed colloidal particles. The invention also pertains to the ligated nanoparticle colloidal dispersions and to the final products.
[0005] 2. Description of the Prior Art
[0006] It is known that high surface area nanoparticles can be formed by a vaporization-co-condensation process sometimes referred to as the solvated metal atom dispersion (SMAD) method. The latter involves vaporization of a metal under vacuum and codeposition of the metal atoms with the vapors of a solvent on the walls of a reactor cooled to 77 K (liquid nitrogen temperature). After warm-up, nanoparticles are stabilized both sterically (by solvation) and electrostatically (by incorporation of negative charge). The SMAD technique was first disclosed in 1986 by Klabunde and co-workers, and is also described in U.S. Pat. No. 4,877,647. A major advantage of the SMAD process is that no biproducts of metal salt reduction are present, and pure metal colloids are formed. Additionally, the SMAD process lends itself to industrial-scale operations, as opposed to other competing processes such as the inverse micelle and reductive procedures for metal colloid preparation.
[0007] Organization of nanoparticles into two and three-dimensional structures (nanocrystalline superlattices, NCSs) leads to the formation of materials characterized by very different properties compared to those of the discrete species. The manifestation of novel and technologically attractive properties is due to the collective interactions of the particles, as well as to the finite number of atoms in each crystalline core. Synthesis and characterization of such materials are interesting from both fundamental and industrial points of view. Regularly arranged nanosized particles find applications in the development of optical and electronic devices, and magnetic recording media, for example. Nanoparticles of gold and other noble metals have attracted significant attention not only because of ease of preparation, but also due to their potential application in nano and microelectronics. Heretofore the challenge has been to form a structure of a planar array of small metal islands separated by tunnel barriers for use in electronics. Gold nanoparticles are excellent candidates in this respect.
[0008] Numerous methods for synthesis of particles arranged in 2D- and 3D-NCSs have been reported in the literature. The most common procedures include reduction of a suitable metal salt in the presence of different stabilizing agents. In all methods, the most important requirement is the ability to produce monodispersed particles that can order over a long-range. Crystalline arrays of particles covered by organic molecules have become of great interest, especially since the improved synthesis of thiol-stabilized gold nanoparticles has been developed (Brust, et al., J. Chem. Soc., Chem. Commun., 1994, 801-802). Their advantage is that they behave as simple chemical compounds in respect that they can be dissolved, precipitated, and redispersed without change in properties, much as molecular crystals can.
SUMMARY OF THE INVENTION
[0009] The present invention is broadly concerned with methods of forming ligated nanoparticle colloidal dispersions and recovered ligated nanoparticles which may be in superlattice form. In general, the method involves initially forming a first colloidal dispersion comprising nanoparticles solvated in a molar excess of a first solvent, a second solvent different than the first solvent, and a quantity of ligand moieties. Next, a substantial part of the first solvent is removed and the ligand moieties are caused to ligate to the nanoparticles to give a second colloidal dispersion comprising the ligated nanoparticles solvated in the second solvent. If desired, the ligated nanoparticles may then be recovered as a dry product which, depending upon the nature of the nanoparticles and ligands selected, may assume a superlattice configuration.
[0010] Preparation of the first colloidal dispersion is preferably accomplished by vaporizing the solid substance (e.g., metal or metal salt) and first solvent in a reactor to give vaporized atoms or molecules and depositing the vaporized atoms or molecules and first solvent onto a cold surface. Upon subsequent warming of this mixture, nanoparticles are formed by aggregation of the atoms or molecules, and these nanoparticles and first solvent are allowed to mix with a second solvent and ligand moieties. Thereupon, the first solvent is removed by vacuum, which substantially completely eliminates the first solvent and also, to a limited degree, some of the second solvent.
[0011] In a particularly preferred technique, the second colloidal dispersion is subjected to a digestive ripening process so that the variation in particle size of the ligated nanoparticles is reduced; this ripening process is advantageously carried out until the second colloid is essentially monodispersed. This ripening process is also important if a superlattice dry product is desired.
[0012] The nanoparticles useful in the invention are generally selected from the group consisting of the elemental metals having atomic numbers ranging from 21-34, 39-52, 57-83 and 89-102, all inclusive, the halides, oxides and sulfides of such metals, and the alkali metal and alkaline earth metal halides. Elemental gold and silver are particularly preferred, with elemental gold being the single most preferred nanoparticle material. The nanoparticles should have an average diameter of from about 2-50 nm, and more preferably from about 3-15 nm. Similarly, the nanoparticles should have a BET surface area of from about 15-500 m 2 /g, and more preferably from about 50-300 m 2 /g.
[0013] The first and second solvents should be selected so that the first solvent may be readily removed by vacuum distillation or other techniques from the initial colloid. In practice, the first solvent should have a boiling point at least about 25° C. (more preferably at least about 40° C.) below the boiling point of the second solvent. Of course, the first and second solvents must also have the ability to solvate the nanoparticles and ligated nanoparticles, respectively.
[0014] Although a wide variety of solvents may be employed, preferably the first solvent is a ketone, and especially a ketone selected from the group consisting of ketones of the formula
[0015] where R 1 and R 2 are independently and respectively selected from the group consisting of straight and branched chain C1-C5 alkyl and alkenyl groups, and the C1-C5 straight and branched chain alcohols. The single most preferred first solvent is acetone. The first solvent should be used at a level so that it is in molar excess relative to the nanoparticles, and preferably a molar excess of from about 50-1000 should be established.
[0016] The second solvent is preferably an aryl organic solvent such a toluene or xylene. More broadly, the solvent is advantageously selected from the group consisting of solvents of the formula
[0017] where X 1 and each X 2 are each independently and respectively selected from the group consisting of H and C1-C5 straight and branched chain alkyl and alkenyl groups, n is from 0 to 3, each X 2 may be independently located at any unoccupied ortho, meta or para position relative to X 1 .
[0018] A variety of ligands may be used in the invention, and can be atoms, ions, or compounds. As used herein “ligand moieties” refers to all such ligand species. The preferred class of ligands are thiol compounds selected from the group consisting of compounds
R 3 SH
[0019] where R 3 is a C5-C20 straight or branched chain alkyl or alkenyl group. More preferably, R 3 is a C10-C15 straight or branched alkyl or alkenyl group; an especially preferred ligand is dodecanethiol.
[0020] The digestive ripening process comprises the step of heating and refluxing the second colloidal dispersion, preferably at a temperature of from about 60-180° C. under an inert gas such as argon for a period of from about 10-400 minutes. The goal of digestive ripening is to reduce the particle size variation in the ligated nanoparticles; preferably, this process is carried out to achieve a ligated nanoparticle surface area of up to about 20% above and below the mean surface area of the ligated nanoparticles.
[0021] The final ligated nanoparticles in general have the formula Y(Z) x where Y is the nanoparticle and Z is the ligand; x is variable depending upon the nanoparticle and ligand selected. In the case of the preferred Au(dodecanethiol) ligated nanoparticles, x would typically range from about 300-10,000, with a ligand density on the gold nanoparticle surface ranging from about 1-10 ligand moieties per square nanometer of nanoparticle surface area.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] [0022]FIG. 1 is a flow diagram illustrating the synthetic steps in a preferred method for the preparation of nanocrystal superlattice products;
[0023] [0023]FIG. 2 is an TEM micrograph of gold particles in an Au-acetone-toluene-thiol colloid (colloid 1) described in the Example;
[0024] [0024]FIG. 3A is a TEM micrograph of gold particles in an Au-toluene-thiol colloid (colloid 2) described in the Example;
[0025] [0025]FIG. 3B is another TEM similar to that of FIG. 3A, but viewing another area of the TEM grid;
[0026] [0026]FIG. 4 is a graph depicting the UV/VIS absorption spectra of as-prepared colloid 2 (solid line) and the digestively ripened colloid (dotted line);
[0027] [0027]FIG. 5A is a TEM micrograph of gold particles after the digestive ripening step in the Example, where sampling was done from the hot colloidal dispersion;
[0028] [0028]FIG. 5B is another TEM photograph similar to that of FIG. 5A;
[0029] [0029]FIG. 6A is TEM micrograph of gold particles after the digestive ripening step of the Example (sampled from hot dispersion);
[0030] [0030]FIG. 6B is a histogram derived from the measurement of 400 particles which corresponds to the gold particle TEM micrograph of FIG. 6A;
[0031] [0031]FIG. 7A is a TEM micrograph of gold particles 15 minutes after the completion of the digestive ripening process of the Example;
[0032] [0032]FIG. 7B is a TEM micrograph similar to that of 7A, but depicting the gold particles one day after the completion of the digestive ripening process of the Example;
[0033] [0033]FIG. 7C is another TEM micrograph similar to that of 7B, and depicting the gold particles one day after the completion of the digestive ripening process of the Example; and
[0034] [0034]FIG. 7D is a TEM micrograph similar to that of 7A, but depicting the gold particles approximately two months after the completion of the digestive ripening process of the Example.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0035] The following example sets forth presently preferred methods for the preparation of ligated nanoparticle superlattices in accordance with the invention. It is to be understood, however, that this Example is provided by way of illustration and nothing therein should be taken as a limitation upon the overall scope of the invention.
[0036] [0036]FIG. 1 is a flow diagram of the most preferred preparation of gold-containing nanocrystalline superlattice products. This method is also explained in detail below.
EXAMPLE
[0037] A) Preparation of Au-acetone-toluene-thiol colloid (colloid 1).
[0038] A stationary reactor described in Klabunde, et al., Inorg. Syn ., Shriver, D., ed., 19, (1979), 59-86 was used for the synthesis of Au-acetone-toluene-thiol colloid. Acetone and toluene solvents were purchased from Fisher. Acetone was dried over molecular sieve. Both acetone and toluene were degassed five times by the standard freeze-thaw procedure prior to the reaction. Dodecanthiol was purchased from Aldrich and used as received. All glassware was rigorously cleaned before use.
[0039] A W-Al 2 O 3 crucible was assembled in the SMAD reactor and the whole system was pumped down. This was followed by a step-wise heating of the crucible and the pressure was allowed to reach 4×10 −3 Torr at each heating step. The crucible was heated to red in about half an hour, then the heating was decreased and the whole reactor was left under vacuum overnight while the crucible was gently heated. This process ensured no contamination of the crucible. After the overnight treatment, the reactor was filled with air and the crucible was charged with ˜0.3 g Au metal. At the same time 8 ml (6.8 g, 3.4×10 2 mol) of dodecanethiol was placed in the bottom of the reactor chamber together with a stirring bar. Degassed acetone and toluene solvents were placed in Schlenk tubes and attached to the SMAD reactor. The whole system was evacuated and a liquid nitrogen filled Dewar placed around the vessel. Dodecanethiol was frozen in this way in the bottom of the reactor. When the vacuum reached 4×10 −3 Torr, 40 ml of toluene was evaporated in ˜15 min and frozen on the walls of the reactor. The liquid nitrogen Dewar was removed and toluene allowed to melt undisturbed and fall to the bottom of the reactor. The liquid nitrogen Dewar was again put in place, and Au vapor (0.27 g, 1.4×10 −3 mol) and acetone (100 ml) were codeposited over a period of 3 hours. During this time, the pressure was maintained at about 4×10 −3 Torr. The frozen matrix had a deep red color at the end of the deposition. After the process was complete the liquid nitrogen Dewar was removed and the matrix allowed to warm slowly over a period of ˜1 hour. During the warmup process argon gas was allowed to fill the reactor system. Upon melting the Au-acetone matrix mixed with the toluene and the color became deep brown. When the dodecanethiol started to melt, stirring was started and the whole solution was agitated for another 45 min. The as-prepared dark brown Au-acetone-toluene-thiol colloid (colloid 1) was syphoned under argon into a Schlenk tube.
[0040] B) Preparation of Au-toluene-thiol colloid (colloid 2).
[0041] The Schlenk tube containing the as-prepared Au-acetone-toluene-thiol colloid (colloid 1) was connected to a vacuum line and the acetone was evaporated until a constant 1×10 −2 Torr pressure was reached (the more volatile acetone was removed along with some of the toluene). At this time the Au-toluene-thiol colloid was diluted to 80 ml by addition of degassed toluene. Thus the total volume of the final dark brown Au-toluene-thiol colloid was 80 ml containing about 0.20 g of gold.
[0042] C) Digestive Ripening.
[0043] The digestive ripening process is an important step for formation of a monodispersed colloid from the polydisperse Au-toluene-thiol colloid (colloid 2). The procedure involved heating under reflux of a certain amount of Au-toluene-thiol colloid for 1.5 hours. The heating temperature is the boiling point of the colloidal solution (˜120° C.). The digestive ripening was carried out under an argon atmosphere.
[0044] D) Isolation of a Dry Product.
[0045] Isolation of a dry product was done after the gold-toluene-thiol colloid (colloid 2) was subjected to digestive ripening for 1.5 h. After cooling down to room temperature, 10 ml of the digested colloid (containing 0.025 g Au) was precipitated with 50 ml of absolute ethanol. After overnight treatment, the precipitation was complete and the supernatant was carefully removed by sucking out with a Pasteur pipette. The remaining precipitate together with a small amount of leftover toluene, thiol and ethanol was dried under vacuum until constant pressure (5×10 −3 Torr). After drying, the color of the product was brown-red and it had the appearance of a wet paste. An additional 3 ml of ethanol was added and the system was left undisturbed overnight. The supernatant was then removed and the sediment again was dried under vacuum at constant pressure. After drying the precipitate (0.0214 g) was a powder with small shiny-dark crystals. It was washed again with 3 ml of ethanol, left overnight, the supernatant removed and dried under vacuum. After drying, the precipitate was 0.0207 g and no change of the mass was recorded after additional washing with ethanol and drying under vacuum. The yield was 84% based on gold. If the adsorbed thiol is taken into account, the yield was ˜73%.
[0046] The final dry product was in the form of soft, shiny dark crystals, which are readily soluble in toluene or hexane. After addition of the solvent, the crystals immediately dissolved giving wine-red colored colloidal solution. However, the crystals are not soluble in ethanol or acetone.
[0047] E) UV-VIS Spectroscopy.
[0048] UV/VIS absorption spectra were obtained using a Fiber Optic CCD Array UV-VIS Spectrophotometer of Spectral Instruments, Inc.
[0049] F) Transmission Electron Microscopy (TEM).
[0050] TEM studies were performed on a PHILIPS CM100 operating at 100 kV. The TEM samples were prepared by placing a 3 μl drop from the colloidal solution onto a carbon coated formvar copper grid. The grids were allowed to dry in air for 1 hour and left undisturbed at ambient conditions.
[0051] Results and Discussion
[0052] Since the first report in 1986 (Lin, et al., Langmuir, 2, (1986), 259-260) of the synthesis of nonaqueous colloidal gold solutions by the SMAD method, considerable work has been carried out on the preparation and characterization of several non-aqueous metal nanoscale particles (Franklin, et al., High - Energy Processes in Organometallic Chemistry ; Suslick, K. S., ed., ACS Symposium series, (1987), 246-259; Trivino, et al., Langmuir, 3, 6, (1987), 986-992). Colloidal solutions of gold in acetone have been one of the most intensively studied and well-understood systems. Acetone, as a polar solvent, solvates the metal atoms and clusters during the warmup stage. In this way steric stabilization is achieved and gold colloids are stable for months.
[0053] These earlier results were the motivation for choosing acetone as an initial solvent in the present example. Preliminary attempts to improve size-distribution of particles from pure acetone solutions using the digestive ripening procedure turned out unsuccessful, and it was discovered that an additional stabilizing agent like dodecanethiol was needed. However, when only acetone was used as the solvent, addition of dodecanethiol did not allow the formation of a stable colloid. For example, the precipitate formed after addition of dodecanethiol to Au-acetone colloids, when separated and dried under vacuum, was only partially redispersable in toluene. Digestive ripening of the partially redispersed Au-colloids led to the size improvement of only those particles that were redispersed. The particles that remained in the sediment did not change their shape and size during this procedure. Therefore, it was found that a combination of solvents such as acetone and toluene was needed during the SMAD reaction and subsequent cluster growth and ligation by the thiol. The role of acetone was found to be stabilization of the gold nanoparticles in a preliminary way.
[0054] The size and shape changes of nanoparticles in the different samples were investigated by TEM. Representative transmission electron micrographs of the gold colloids at each step of the preparative procedure of the monodispersed colloid are shown in the Figures. A flow diagram of the major synthetic steps is given in FIG. 1. The results from the separate preparative stages are discussed below.
[0055] Formation of Monodispersed thiol-protected Au-colloid
[0056] A) Au-acetone-toluene-thiol colloid (colloid 1).
[0057] The initial Au-acetone-toluene-thiol colloid has a dark brown color. TEM studies of this colloid (FIG. 2) illustrate particles ranging from 5 to 40 nm with no definite geometrical shapes. These particles are very similar to the ones obtained in pure acetone solvent. As reported in the prior art, two types of stabilization are characteristic for these systems:
[0058] 1) steric stabilization (by solvation with the acetone molecules) and 2) electrostatic stabilization (by acquiring electrons from the reaction vessel walls, electrodes, solvent medium). Another indication that the gold particles are negatively charged is the occasionally observed ‘blinking’ in the electron microscope due to the interaction of the particles with the negatively charged electron beam. However, it should be pointed out that in no case was change in the shape or morphology of the particles observed under the influence of the electron beam. Both stabilization processes take place during the warmup step, should to be carried out slowly in order to ensure good stabilization.
[0059] B) Au-toluene-thiol colloid (colloid 2).
[0060] The Au-toluene-thiol colloid (colloid 2) was obtained by vacuum evaporation of all the acetone from colloid 1. TEM micrographs of two representative types of particles found in the colloid are shown in FIGS. 3A and 3B. Drastic change of the size and shape of the particles is characteristic at this stage. Nearly spherical particles with sizes in the range of 1 to 5 nm are dominant. There are also a small number of larger particles (10-40 nm) like those in the initial acetone-containing colloid.
[0061] UV/VIS absorption spectrum (FIG. 4) of colloid 2 is in agreement with the sizes of the particles observed in TEM. It is characterized by a broad plasmon absorption band with no definite maximum.
[0062] One possible explanation for the change of size and shape of the gold particles induced by the removal of acetone is the following. In colloid 1 the amount of acetone is in great excess. It strongly solvates the gold particles and the attachment of dodecanethiol molecules on the particles' surface is suppressed. As acetone is removed from the system, the ability for thiol adsorption is increased. Thus acetone acts as a preliminary stabilizing agent, which is substituted by dodecanethiol molecules when acetone is evaporated. This ensures good dispersity of the thiol-ligated gold particles in the toluene medium. The fact that most of the particles in the Au-colloid after evaporation of acetone have size in the region of 1 to 5 nm suggests that some ripening has already taken place, presumably due to the strong adsorption of dodecanethiol molecules on their surface. At this stage the colloid is ready for digestive ripening.
[0063] C) Digestive Ripening of colloid 2 and Organization of the Gold Particles.
[0064] Heating of colloid 2 under reflux results in a dramatic narrowing of the particle size-distribution. TEM studies (FIGS. 5A and 5B) of a hot colloidal solution show formation of spherically shaped particles with sizes of about 4 nm. They have a tendency to organize into 2D-layers. Some of the particles from the hot colloid organize in nice 3D-structures. The remarkable effect of the digestive ripening procedure is the great improvement of the size-distribution. Practically polydisperse colloid containing particles with sizes ranging from 1 to 40 nm are transformed into an almost monodispersed colloid with particles' sizes of about 4-4.5 nm. A photograph taken at higher magnification (FIG. 6) reveals that the shape of the particles is more polyhedral rather than spherical. The average size diameter is 4.5 nm and the size-distribution is log-normal as typical for colloidal systems. The UV/VIS absorption spectrum of the colloid after cooling to room temperature (FIG. 4) shows an appearance of a definite plasmon absorption maximum at 513 nm, which is in agreement with the size and monodispersity of the obtained particles.
[0065] The TEM micrographs of colloids cooled down for a different amount of time are shown in FIGS. 7 A- 7 D. The amazing result is that the particles predominantly organize on the TEM grid in large 3D-structures in only about 15 min after the digestive ripening process is finished (FIG. 7A). A small number of areas of 2D-arrangement is also observed.
[0066] Even larger 3D-structures (>3 μm) are observed after 1 day (FIGS. 7B and 7C) and after ˜2 months (FIG. 7D). The results suggest that the activation energy for 2D-organization is lower compared to this of 3D-organization.
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A method of forming ligated nanoparticles of the formula Y(Z) x where Y is a nanoparticle selected from the group consisting of elemental metals having atomic numbers ranging from 21-34, 39-52, 57-83 and 89-102, all inclusive, the halides, oxides and sulfides of such metals, and the alkali metal and alkaline earth metal halides, and Z represents ligand moieties such as the alkyl thiols. In the method, a first colloidal dispersion is formed made up of nanoparticles solvated in a molar excess of a first solvent (preferably a ketone such as acetone), a second solvent different than the first solvent (preferably an organic aryl solvent such as toluene) and a quantity of ligand moieties; the first solvent is then removed under vacuum and the ligand moieties ligate to the nanoparticles to give a second colloidal dispersion of the ligated nanoparticles solvated in the second solvent. If substantially monodispersed nanoparticles are desired, the second dispersion is subjected to a digestive ripening process. Upon drying, the ligated nanoparticles may form a three-dimensional superlattice structure.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims priority to Korean Patent Application Number 10-2010-0121516 filed Dec. 1, 2010, the entire contents of which application is incorporated herein for all purposes by this reference.
BACKGROUND OF INVENTION
[0002] 1. Field of Invention
[0003] The present invention relates to a fuel injection control method of a GDI engine, and more particularly, to a technology of injecting fuel, with good start performance and operability of an engine even if a high-pressure fuel pump fails.
[0004] 2. Description of Related Art
[0005] Gasoline direct injection (GDI) engines are gasoline engines that directly inject fuel into a combustion chamber, in which fuel supplied from a low-pressure fuel pump in a fuel tank is increased in pressure by a high-pressure fuel pump and then supplied to an injector, in order for the fuel to be directly injected in to the combustion chamber.
[0006] The fuel injection method of the GDI engine is basically divided into two injection methods, compression injection and intake injection, and division injection combining them is also used.
[0007] The compressing injection is generally used to start the engine and reduces the amount of fuel for starting the engine by injecting the fuel in the compression stroke such that the gas mixture is dense around the ignition plug.
[0008] The intake injection is used for common injection, reduces the intake temperature by injecting the fuel in the intake stroke, and is advantageous in making uniform gas mixture by preparing the compression injection, using intake flow.
[0009] In the related art, when fuel injection under high pressure is impossible in a combustion chamber due to a breakdown of a high-pressure fuel pump in the GDI engine, fuel is supplied to the injector under lower temperature than a normal state, such that the intake injection control is performed, instead of the compression injection control, even in starting the engine.
[0010] In this case, a larger amount of fuel is required for starting the engine, as compared with the compression injection control, such that fuel is additionally further injected, in addition to the basic amount of fuel for starting the engine in order to start the engine.
[0011] Further, common normal control is performed, similar to when the high-pressure pump has been in the normal state, after the engine is started.
[0012] However, there is a problem in that when the high-pressure fuel pump breaks and the engine is started at low temperature, for example, 20 degrees below zero, it is impossible to start the engine only by further injecting the fuel other than the basic amount of fuel for starting the engine, and even if the engine is started, combustion stability in the worm-up section of the engine is deteriorated.
[0013] The information disclosed in this Background section is only for enhancement of understanding of the general background of the invention and should not be taken as an acknowledgement or any form of suggestion that this information forms the prior art already known to a person skilled in the art.
SUMMARY OF INVENTION
[0014] Various aspects of the present invention provide for a fuel injection control method for a GDI engine that can ensure good starting performance and operability of an engine, regardless of whether the engine is started at low temperature, when a high-pressure fuel pump in the GDI engine breaks, and can improve NVH performance and reduce starting time, with improved combustion stability.
[0015] Various aspects of the present invention provide for a fuel injection control method for a GDI engine, which comprises determining whether fuel pressure is at a low level where normal fuel pressure is difficult to be made by a high-pressure fuel pump, setting a fuel injection end time that restricts the fuel injection end time within a range where the fuel pressure is larger than combustion chamber pressure, when the fuel pressure is at a low level, calculating the amount of fuel right after starting engine that determines the fuel injection amount in a function of engine cooling water temperature and fuel pressure, independently from the normal fuel pressure right after the engine is started, when the fuel pressure is at a low level, and calculating an advance amount of a fuel injection starting time that determines the advance amount of a fuel injection starting time in consideration of fuel injection time at low pressure taken to inject all the required fuel, when the fuel pressure is at a low level.
[0016] According to various aspects of the present invention, it is possible to ensure good starting performance and operability of an engine, reduced starting time with improved combustion stability, and improve noise vibration harshness (NVH), regardless of whether the engine is started at low temperature even if a high-pressure fuel pump in a GDI engine breaks, without using an additional device.
[0017] The methods and apparatuses of the present invention have other features and advantages which will be apparent from or are set forth in more detail in the accompanying drawings, which are incorporated herein, and the following Detailed Description, which together serve to explain certain principles of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 is a flowchart illustrating an exemplary fuel injection control method for a GDI engine according to the present invention.
[0019] It should be understood that the appended drawings are not necessarily to scale, presenting a somewhat simplified representation of various features illustrative of the basic principles of the invention. The specific design features of the present invention as disclosed herein, including, for example, specific dimensions, orientations, locations, and shapes will be determined in part by the particular intended application and use environment.
[0020] In the figures, reference numbers refer to the same or equivalent parts of the present invention throughout the several figures of the drawing.
DETAILED DESCRIPTION
[0021] Reference will now be made in detail to various embodiments of the present invention(s), examples of which are illustrated in the accompanying drawings and described below. While the invention(s) will be described in conjunction with exemplary embodiments, it will be understood that present description is not intended to limit the invention(s) to those exemplary embodiments. On the contrary, the invention(s) is/are intended to cover not only the exemplary embodiments, but also various alternatives, modifications, equivalents and other embodiments, which may be included within the spirit and scope of the invention as defined by the appended claims.
[0022] Referring to FIG. 1 , various embodiments of the present invention includes determining whether fuel pressure is at a low level where normal fuel pressure is difficult to be made by a high-pressure fuel pump (S 101 ), setting a fuel injection end time that restricts the fuel injection end time within a range where the fuel pressure is larger than combustion chamber pressure, when the fuel pressure is at a low level (S 102 ), calculating the amount of fuel right after starting that determines the fuel injection amount in a function of engine cooling water temperature and fuel pressure, independently from the normal fuel pressure right after the engine is started, when the fuel pressure is at a low level (S 103 ), and calculating an advance amount of a fuel injection starting time that determines the advance amount of the fuel injection starting time in consideration of fuel injection time at low pressure taken to inject all the required fuel, when the fuel pressure is at a low level (S 104 ).
[0023] After it is determined whether the fuel pressure is at a low level, all of the setting a fuel injection end time (S 102 ), the calculating the amount of fuel right after starting (S 103 ), and the calculating the advance amount of the fuel injection starting time (S 104 ) is not performed together, and each or combination of them may be selectively controlled, if necessary.
[0024] Since it is difficult to make the normal fuel pressure due to breakdown of the high-pressure fuel pump, when the fuel pressure is at a low level, the compression pressure of the combustion chamber may become larger than the fuel injection pressure of the injector when the fuel is injected, in which the gas mixture in the combustion chamber may flow backward to the injector and the fuel rail and the fire may be extinguished and the engine may not be started until this phenomenon is removed.
[0025] Therefore, the setting a fuel injection end time (S 102 ) is performed to prevent the state described above in this embodiment.
[0026] The setting a fuel injection end time (S 102 ) sets the fuel injection end time before a time where a difference between the fuel pressure measured by a fuel pressure sensor and the combustion pressure calculated by modeling is 0 or more such that fuel is injected only to the time where the fuel injection pressure is larger than the pressure of the combustion chamber when the fuel is injected from the injector, thereby preventing the gas mixture from flowing backward to the injector, as described above.
[0027] In this configuration, the combustion chamber pressure is acquired by multiplying all of the intake manifold pressure, the cylinder volume efficiency, a compression ratio according to a crank angle measured by a test, and a compensation value according to a change in phase angle of an intake cam which is set by a test.
[0028] That is, it is calculated by the following formula.
[0029] Combustion chamber pressure=(intake manifold pressure×cylinder volume efficiency)×compression ratio according to crank angle (set by a test)×compensation value according to a change in phase angle of intake cam (set by a test).
[0030] Meanwhile, the calculating the amount of fuel right after starting (S 103 ) determines the amount of fuel injection from a map that is a function of engine cooling water temperature and fuel pressure, independent from the normal fuel pressure, right after the engine is started when the fuel pressure is at a low level.
[0031] That is, since fuel is injected under fuel pressure very smaller than the fuel pressure of the normal intake injection when the fuel pressure is at a low level, when normal control of fuel amount is performed right after the engine is started, the fuel substantially injected into the combustion chamber is insufficient and unstable combustion occurs, such that the engine may stop. Therefore, the amount of fuel injection is made denser than the normal control of the amount of fuel.
[0032] Therefore, when amount of fuel is controlled right after the engine is started at the amount of fuel injection determined denser than the normal state, combustion stability of the engine is improved and the engine can be prevented from stopping.
[0033] Meanwhile, the end time of fuel injection is later than the normal state even if the same amount of fuel is injected when the fuel pressure is at a low level, such that the fuel injection is started at the same time as the normal state, the time taken to make a gas mixture after fuel injection becomes short, and accordingly, the combustion stability of the engine is deteriorated, and particularly, this phenomenon becomes worse in worming-up of the engine.
[0034] Therefore, the fuel injection time is advanced more than the normal state in accordance with the advance amount of the fuel injection starting time which is calculated by the calculating the advance amount of the fuel injection starting time (S 104 ), thereby improving combustion stability.
[0035] The calculating the advance amount of the fuel injection starting time (S 104 ) calculates a required advance time of the fuel injection starting time, by subtracting the normal fuel injection time, which is determined as a function of desired pressure and the required amount of fuel from the fuel injection time at low pressure which is determined as a function of the current fuel pressure and required amount of fuel, and changes the required advance time of the fuel injection starting time into the advance amount of the fuel injection starting time, in the crank angle unit.
[0036] That is, the required advance time of the fuel injection starting time (ms)=fuel injection time at low pressure−normal fuel injection time.
[0037] The required advance time of the fuel injection starting time (ms) is changed into the advance amount of the fuel injection starting time, by the following formula.
[0038] Advance amount of a fuel injection starting time (crank angle)=required advance time of fuel injection starting time (ms)/time for one rotation (ms)×360(crank angle)=required advance time of fuel injection starting time (ms)/(1/[revolution number of engine (rpm)/60]×1000)×360(crank angle)=required advance time of fuel injection starting time (ms)×revolution number of engine (rpm)×0.006.
[0039] Further, the exemplary embodiment further includes acquiring fuel injection starting time at low pressure in the crank angle unit, by subtracting the advance amount of fuel injection starting time from the normal fuel injection starting time (S 105 ).
[0040] Therefore, an engine controller performs control such that fuel is directly injected at the fuel injection starting time at low pressure acquired in the crank angle unit, such that the actual fuel injection starting time is advanced and a sufficient gas mixture is generated after the fuel is injected, thereby improving combustion stability.
[0041] Obviously, the fuel injection starting time at low pressure should be limited in a range after the intake top dead center (TDC) where the intake process starts.
[0042] The foregoing descriptions of specific exemplary embodiments of the present invention have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the invention to the precise forms disclosed, and obviously many modifications and variations are possible in light of the above teachings. The exemplary embodiments were chosen and described in order to explain certain principles of the invention and their practical application, to thereby enable others skilled in the art to make and utilize various exemplary embodiments of the present invention, as well as various alternatives and modifications thereof. It is intended that the scope of the invention be defined by the Claims appended hereto and their equivalents.
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It is possible to ensure good starting performance and operability of an engine, reduce starting time with improved combustion stability, and improve noise vibration harshness (NVH), regardless of whether the engine is started at low temperature even if a high-pressure fuel pump in a gasoline direct injection (GDI) engine breaks, without using an additional dedicated device.
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BACKGROUND OF THE INVENTION
The present invention relates to a dust-boot for a booster used in a vehicle, more particularly, to an improved dust-boot provided with a noise preventing (when air is sucked) wall of plate type.
It is widely practiced to employ a vacuum booster (hereinafter simply called booster), as a sort of servomechanism, for getting a strong braking force under a light braking operation. When this booster, partly projecting into the cabin, i.e., projecting from the dash-panel into the driver's room, is actuated, rapidly sucked air through the air-sucking hole (or holes), which is formed in the dust-boot covering the above-mentioned projected portion of the booster, produces a kind of intermittent sucking noise. This noise caused by an eddy turbulence of air is directly delivered to the driver, without being damped, to his great disagreeableness, because the noise source is exposed, without any cover, to the driver's ears.
As a countermeasure against this noise problem, provision of silencers made of a layer of various fibers, and of air cleaners made of filter paper, filter cloth, etc., inside the air-sucking hole(s), has been tried with no satisfactory results.
The reason for this problem having been closed up resides in that the size of the booster has gradually been enlarged for enhancing the performance of the brake system and for decreasing the brake pedal depressing force. It can be well understood that the volume of air sucked rapidly increased in consequence, bringing about the increase of the noise, and on the other hand the driver's assessment for the noise prevention effects has become sensitive.
SUMMARY OF THE INVENTION
It is therefore a primary object of this invention to provide a dust-boot, having a noise preventing wall, for a vacuum booster.
It is another object of this invention to provide a dust-boot having a noise preventing wall, for a vacuum booster of a vehicle, wherein the noise preventing wall is attached to the main body of the dust-boot to mitigate the air-sucking noise when the same is in operation.
It is still another object of this invention to enhance the air-sucking-noise-preventing effect, which noise is produced at the air-sucking hole(s) in the dust-boot main body, and thereby to eliminate the disagreeable feeling, to the driver, due to such air-sucking noise.
Other objects and advantages of this invention will be apparent from the later stated detailed description of the embodiments with reference to the appended drawings.
This noise preventing purpose of this invention can be realized, to say in a word, by providing a wall member in such a mode that it covers the air-sucking hole(s) and forming an air flowing passage different in the direction of the air flow from that at the air-sucking hole(s), by means of being bent or wound at least once on the way.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a vertical cross-section, in elevation, of a conventional vacuum booster, partly broken away (prior art);
FIG. 2 is a projection of a part of the vacuum booster (in FIG. 1), seen from the position indicated by the line II--II (prior art);
FIG. 3 is a vertical cross-section, in elevation, of an essential part of a first embodiment of the dust-boot in accordance with this invention;
FIG. 4 is a vertical cross-section, in elevation, of an essential part of a second embodiment of the dust-boot in accordance with this invention; and
FIG. 5 is a vertical cross-section, in elevation, of an essential part of a third embodiment of the dust-boot in accordance with this invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
For better understanding, construction and operation of a booster will be described on a conventional one illustrated in FIG. 1, before entering the explanation of the preferred embodiments.
A booster 1 is located in the engine room side of a vehicle and attached on a dash-panel 2, with a part thereof around an operating rod 3 being projected into the cabin (on the side of the driver's room). A main body 1 of the booster is enveloped in a shell 4, which body being divided into two parts, i.e., a negative-pressure chamber 5 and a variable-pressure chamber 6, by a diaphragm 7.
A power piston 8, which supports the diaphragm 7, is partly extended beyond the dash-panel 2 into the cabin as a cylindrical sliding portion 8a, which is capped and protected by a dust-boot 9, made of an elastic material such as rubber, of cylindrical form with a bottom. On the end surface (bottom portion) of the dust-boot 9, on the side of a brake pedal 12, a plurality of air-sucking holes 9a, 9a . . . are concentrically formed, with an equal circumferential angular distance to each other, with the operating rod 3 as shown in FIG. 2. Inside the sliding portion 8a of the piston 8, that is, inside the dust-boot bottom, is disposed just in contact therewith a silencer 10 made of various fibers and a plurality of air cleaners 11 made of filter paper, filter cloth, etc. closely placed in layers in the axial direction of the operating rod 3.
Both the negative-pressure chamber 5 and the variable-pressure chamber 6 are usually under the influence of vacuum pressure, so the piston 8 is constantly urged rightwards by a return spring 18, in the status shown in FIG. 1. When the brake pedal 12 is depressed, the operating rod 3 is shifted leftwards to urge an air valve 13 in a direction of separating the same from a control valve 14, which causes a flow-in of atmospheric air into the variable-pressure chamber 6 through a passage which is not shown. The pressure difference between the atmospheric pressure in the variable-pressure chamber 6 and the vacuum pressure in the negative-pressure chamber 5 urges the power piston 8 leftwards to impart a strong thrust on a push rod 15. This leftward shifting of the push rod 15 thus actuated is transferred to the well-known master cylinder 20 for delivering the brake fluid to each braking mechanism. The problem questioned lies in the noise produced by the air introduced to the variable-pressure chamber 6 at the air-sucking hole(s) 9a. Although the silencer 10 and the air cleaner 11 are effective in the noise prevention for the sound within the booster, the noise at the air-sucking portion is left utterly unsolved.
This invention is to solve the very question, which is in essence to cover the noise source with a noise preventing wall of a circular plate member 9b in FIG. 3, having the same axis of symmetry with the dust-boot main body 9'. The wall (plate member) 9b is disposed, with a distance B spaced from the air-sucking hole(s) 9a, on the brake pedal side of the dust-boot main body 9', being integrally formed with the main body 9' surrounding a through bore 17 for the operating rod 3. This wall 9b for covering the air-sucking hole(s) 9a is so designed as to properly select the distance B and the radius R for not giving an acute variation of the cross-sectional area of the passage for the sucked air, i.e., to render the same gradually and smoothly decreased. For the same reason the cross-sectional area of the air-sucking hole(s) is preferable to be of an elongated sector form or a crescent-like form, instead of a circular form.
The inside surface 9'b of the wall 9b and the outer surface 9e of the dust-boot main body 9' confronted therewith are preferable to be as coarse as possible. For making these surfaces coarse a few suitable methods are practiced. One is, for example, to make the inside surface of the molding dies coarse or rugged in advance, when molding is utilized for preparing these members. Another is to coarsen or make rugged the molded members afterwards, by means of conventionally well-known surface coarsening processes. The wall 9b may be however separately manufactured to be attached afterwards to the dust-boot main body 9', wherein the working of the coarse surface is advantageously easy.
In this first embodiment of such a construction, air-sucking noise runs against the wall 9b to be changed its direction approximately 90°, a part of which energy being transformed into heat energy. It results in muffling the sound zone of high frequency, and damping of sound pressure, due to reflection and diffusion of sound waves between the coarse surfaces on opposite sides. Besides, the air-sucking noise is damped by the detour of the transit course, instead of direct arriving thereof to the driver's ears. Making the air-sucking hole(s) round at the mouth by removing the edge, that is rounding off the angles of the hole entrance is effective in reducing the eddy turbulence of air and muffling the noise.
In a second embodiment shown in FIG. 4, the noise preventing wall is provided with, in addition to the circular plate wall 9b, a slantwise extension 9c along with a slope portion of the end surface of the dust-boot main body 9' for forming a truncated conical shape in the extension alone. It is effective in muffling the noise, because the additional extension makes the passage of the noise bent and longer to enhance the noise preventing capability, and furthermore it changes the position and direction of the sound outgoing to more remote and indirect to the driver's ears.
FIG. 5 illustrates a third embodiment, in which the noise preventing wall is further extended, in addition to the extension 9c in the second embodiment, in the axial direction parallel to the operation rod 3, that is to say, an extension of cylindrical shape 9d attached to the end of the slope portion (slantwise extension 9c). The extension of cylindrical shape 9d is a cylindrical wall member extending concentrically with the main body 9' of the dust-boot 9. This wall is therefore composed of three portions, 9b, 9c, and 9d. The third embodiment thus makes the passage of the air-sucking noise more complicated and bent for leading the direction of the sound outgoing to a turnabout by 180° from the sound source. Besides, a silencer 16 made of a fiber layer of a predetermined thickness is disposed, in addition to the silencer within the dust-boot 9 main body 9', between the outer surface of the main body 9' and the inner surface of the cylindrical wall portion 9d. Disposition of a silencer 16 exclusively for the air-sucking hole(s) 9a enhances the sound muffling effect, in cooperation with the above-mentioned reversing of the direction of the opening for the sound outgoing. An air inlet 9f disposed at the end of the cylindrical wall 9d is made much larger in the cross-sectional area than the air-sucking hole(s) 9a.
In summarizing the invention, it can be said to have solved the noise preventing problem only by disposing a wall of a simple circular plate, or with one extension, or further with double extensions. Extending, bending, and reversing direction of the sound outgoing passage have been proved to be highly effective, with the aid of reflection and diffusion of sound waves by the coarse surface of the wall, and the disposition of the silencer and the air cleaner, in noise preventing. It takes only a small space, and an integral formation of the wall with the dust-boot main body itself makes the manufacturing process easy and the cost therefor inexpensive. Further increase of bending portions of the sound passage, increase of coarse surface, or increase of silencers are all quite easy to be executed at will for enhancing the effect more.
The above embodiments are all described only for examples, so the invention should not be construed to be limited to the description and the drawings attached. Variations and modifications are practicable without departing from the spirit and the scope of the invention to those skilled in the art.
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A dust-boot for a vacuum booster, which is partly protruded into the driver's room, characterized in being provided with a noise preventing wall firmly formed in such a mode, that it covers the air-sucking hole(s) to prevent the air-sucking noise from directly reaching the driver's ears, through the formation of an air flowing passage between the wall and the outer surface of the dust-boot main body, which air flowing passage is different in the direction of the air flow from that at the air-sucking hole(s) and bent or wound at least once on the way.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims the priority of U.S. provisional Application Ser. No. 61/297,374 entitled “A NOVEL COMPACT RESPIRATORY PROTECTIVE DEVICE” filed on 22 Jan. 2010, the entire contents and substance of which are hereby incorporated in total by reference.
GOVERNMENT LICENSE RIGHTS
[0002] The U.S. Government has a paid-up license in this invention and the right in limited circumstances to require the patent owner to license others on reasonable terms as provided for by the terms of Contract No. W91 CRB-07-C-0081 awarded by US Army RDECOM Acquisition Center.
FIELD OF THE INVENTION
[0003] The present invention relates generally to personal protective equipment and in particular to respiratory protective devices fitted with a mouthpiece which forms an effectively airtight connection between the mouth of the wearer of the device and the filter box assembly or connection to the source of contaminant-free breathing gas.
BACKGROUND OF THE INVENTION
[0004] A number of respiratory protective devices are fitted with mouthpieces which provide an effectively airtight connection between the mouth of the wearer of the device and the filter box assembly in filter devices or the connection to the source of contaminant-free breathing gas.
[0005] For many respiratory protective devices it is important that the stored bulk of the device is as low as possible to ensure that such devices can be carried on the person, in a handbag or briefcase or stored in large numbers close to the likely point of usage so that the devices are available when required. Devices, which are too bulky to be so carried or stored, may not be available when required, and will therefore provide no protection.
[0006] Low bulk is therefore an essential prerequisite of effective respiratory protective devices, such as for self-rescue or in industrial, commercial or mining environments.
[0007] Although mouthpiece devices are generally less bulky than equivalent devices fitted with conventional facepieces, the mouthpieces incorporated in conventional devices impact adversely on the volume of the packed device.
[0008] Therefore, it is an object of the present invention to obviate, or at least mitigate, at least some of the drawbacks associated with the prior art.
[0009] Further aims and objects of the invention will become apparent from a reading of the following description.
SUMMARY OF THE INVENTION
[0010] Briefly described, in one aspect the invention comprises a method of reducing the packed dimensions of a respiratory protective device fitted with a mouthpiece in order to enable it (for example) to be carried unobtrusively on the person, in a briefcase, in a handbag, or stored in large numbers close to the point of likely usage. There is also described, in one aspect, a respiratory protective device fitted with a mouthpiece and having reduced packed dimensions.
[0011] According to a first aspect of the invention there is provided a respiratory protective device comprising a filter box assembly and a mouthpiece assembly, said mouthpiece assembly configured for fluid connection to said filter box assembly, wherein the mouthpiece assembly is moveable, relative to the filter box assembly, between a packed and an unpacked position, such that in the packed position the mouthpiece assembly is located at least partly within the profile of the filter box assembly, thereby reducing the size of the device.
[0012] The mouthpiece assembly may comprise a mouthpiece and other components, or may consist only of (or essentially of) a mouthpiece.
[0013] In the context of the present invention, the mouthpiece assembly is located at least partly within the profile of the filter box assembly in the packed position insofar as the mouthpiece assembly may be partly or wholly contained within the filter box assembly, or insofar as the mouthpiece assembly is located externally to the filter box assembly and is orientated to provide a partial or complete overlap with at least some of the dimensions (length, depth or width/height) of a side of the filter box assembly.
[0014] The device may comprise an air channel and a filter. As the device is very compact, the depth of the air channel can be increased or optimised without making the device unnecessarily large. Optimising or increasing the depth of the air channel improves utilisation of the filter, thus enhancing filter efficiency, and reducing breathing resistance, which maximises wearer acceptability. Furthermore, this can be achieved in a device which is small and compact enough to be conveniently carried or stored, which maximises the appeal of the device to individuals and corporations alike.
[0015] The packed position is the “not in use” or “non-use” position, and the unpacked position is the “in use” or “use” position.
[0016] The mouthpiece assembly may comprise a mouthpiece.
[0017] Typically, at least part of the mouthpiece is elastically deformable to minimise the size thereof. At least part of the mouthpiece may be foldable.
[0018] The mouthpiece is typically made from resilient elastomeric materials such as neoprene, butyl rubber or suitable silicone which can be easily folded, and which will return to their original shape.
[0019] Typically, in the packed position, a majority of the mouthpiece assembly is located within the profile of the filter box assembly. Typically, in the unpacked position, a minority of the mouthpiece assembly is located within the profile of the filter box assembly.
[0020] In one embodiment, in the packed position the mouthpiece assembly is at least partially contained within the filter box assembly.
[0021] In one embodiment, in the packed position the mouthpiece assembly is at least partially recessed into the filter box assembly.
[0022] The mouthpiece assembly may be retractably connected to the filter box assembly. The mouthpiece assembly is typically retracted in the packed position.
[0023] The mouthpiece assembly may be extendibly connected to the filter box assembly. The mouthpiece assembly is typically extended in the unpacked position.
[0024] The mouthpiece assembly may be rotatably connected to the filter box assembly.
[0025] Alternatively, the mouthpiece assembly may be pivotally connected to the filter box assembly.
[0026] The device may further comprise a flexible diaphragm located between the mouthpiece assembly and the filter box assembly, said diaphragm providing a hermetic seal.
[0027] The flexible diaphragm provides a hermetic (airtight) seal between the filter box assembly and the mouthpiece or mouthpiece assembly, thus ensuring that in use air can only be breathed through the filter box assembly, and not directly from the atmosphere. As it is flexible, it allows the mouthpiece or mouthpiece assembly to move relative to the filter box assembly, whilst retaining a hermetic seal, and thus enables the mouthpiece or mouthpiece assembly to be moved from a packed to an unpacked position.
[0028] The device may further comprise a biasing means configured to move the mouthpiece assembly into the unpacked position.
[0029] The biasing means may be, for example, a spring.
[0030] Optionally, the device further comprises a first backplate attached to the mouthpiece, and a second backplate attached to the filter box assembly.
[0031] Typically, in the unpacked position, the first backplate abuts the second backplate. This fixes the mouthpiece or mouthpiece assembly in place so that the device is stable in use. The backplates move relative to each other, which enables the mouthpiece or mouthpiece assembly to extend out of the filter box assembly.
[0032] In one embodiment, the mouthpiece assembly is located externally to the filter box assembly and, in the packed position, is positioned such that at least part of the mouthpiece assembly overlaps with a side of the filter box assembly.
[0033] The mouthpiece assembly may overlap a side of the filter box assembly that is defined by the height and depth thereof.
[0034] Typically, in the packed position, the mouthpiece or mouthpiece assembly lies juxtaposed the smallest (by area) side of the filter box assembly, along the depth axis, thereby creating a substantially flat device, which is compact and easily stored or carried.
[0035] The mouthpiece assembly may be rotatable relative to the filter box assembly. Typically, the mouthpiece assembly is rotatably connected to the filter box assembly.
[0036] The device may further comprise a gasket located between the mouthpiece assembly and the filter box assembly, said gasket configured to provide a hermetic seal therebetween when the mouthpiece assembly is rotated to the unpacked position.
[0037] It is useful for the gasket to remain uncompressed until it is to be used. This is because if the gasket is stored under compression for extended periods of time it can become adhered to the mouthpiece/mouthpiece assembly or the filter box assembly. This can act to prevent rotation of the mouthpiece assembly relative to the filter box assembly, or can cause the gasket to become ruptured or otherwise structurally compromised over the passage of time, or by attempted rotation of the mouthpiece assembly relative to the filter box assembly. This can then enable leakage of unfiltered contaminants into the filter box assembly.
[0038] Alternatively, the mouthpiece assembly is pivotable relative to the filter box assembly. Typically, the mouthpiece assembly is pivotally connected to the filter box assembly.
[0039] The device may further comprise bellows located between the mouthpiece assembly and the filter box assembly, said bellows providing a hermetic seal therebetween. The bellows may form part of the mouthpiece assembly.
[0040] The filter box assembly may further comprise a filter in fluid connection with the mouthpiece assembly and configured to permit ingress of air from the atmosphere.
[0041] Typically, the filter is a longitudinal filter extending along the longest axis of the filter box assembly.
[0042] The filter box assembly may further comprise an air channel located between the filter and the mouthpiece assembly and in fluid connection therewith. Typically the air channel is a longitudinal air channel extending along the longest axis of the filter box assembly, substantially in parallel with the filter.
[0043] The air channel acts as a downstream air channel. As the device is very compact, the depth of the air channel can be increased or optimised. This improves utilisation of the filter elements, thus enhancing filter efficiency, and reducing breathing resistance, thus maximising wearer acceptability.
[0044] The filter may be configured to selectively inhibit the passage of one or more toxic substances. The filter may be configured to selectively inhibit the fluid passage of one or more toxic substances.
[0045] A toxic substance may be, for example, a gas, aerosol or particulate substance which is harmful to humans, or any substance that emits breathable toxins.
[0046] Typically, the filter is configured to selectively inhibit the passage of smoke.
[0047] Optionally the filter box assembly further comprises at least one exhalation valve configured to allow the expulsion of air from the filter box assembly, and to inhibit the ingress of air into the filter box assembly. Of course, the ingress of air is still permitted through the filter.
[0048] The exhalation valve may be a non-return valve orientated to allow air out of the filter box assembly, and to prevent air from entering the filter box assembly. Thus, the exhalation valve enables the user to exhale air directly into the atmosphere, but prevents the user from inhaling air directly from the atmosphere.
[0049] Typically, the exhalation valve is at least partially recessed into the filter box assembly.
[0050] Optionally, the device further comprises a hood. Typically, the hood is connected to the filter box around the mouthpiece assembly. Alternatively, the device can be used with a conventional noseclip as is known in the art.
[0051] According to a second aspect of the invention there is provided a respiratory protective device in which the mouthpiece can be fully or partly recessed into the downstream air channel and/or filter assembly and/or other components of the device or rotated or retracted into the depth of the device to reduce or minimize the packed volume of the device.
[0052] A device as stated in the second aspect in which the mouthpiece is rotated or extended either manually or by a suitable means when the device is unpacked for use.
[0053] A device as stated in the second aspect, and as stated in the paragraphs relating thereto, in which the downstream air channel is so configured as to maximize the utilization of the efficiency and capacity of the filter media.
[0054] A device as stated in the second aspect, and as stated in the paragraphs relating thereto, in which relative rotation of the relevant component(s) causes the means of providing an airtight seal between the fixed and rotating components to be compressed to enhance the air tightness of the seal.
[0055] A device as stated in the second aspect, and as stated in the paragraphs relating thereto, in which the exhalation valve(s) is/are recessed into the downstream air channel and/or other component of the device to reduce or minimize the packed volume of the device.
[0056] The present invention reduces the overall volume of the packed respiratory protective device by retracting, folding, or rotating the mouthpiece into the depth of the filter box assembly. The mouthpiece is then extended when required for use.
[0057] The reduced bulk of the device permits the depth of the downstream air channel to be increased without adverse impact within a compact device. This increased depth of the downstream air channel improves utilisation of the filter elements, thus enhancing filter efficiency, and reducing breathing resistance, thus maximizing wearer acceptability.
BRIEF DESCRIPTION OF THE DRAWINGS
[0058] There will now be described, by way of example only, embodiments of the invention with reference to the following Figures, of which:
[0059] FIG. 1 shows an end elevation of a filter device in which the retractable mouthpiece is in the in-use position;
[0060] FIG. 2 shows a side elevation of a filter device in which the retractable mouthpiece is in the in-use position;
[0061] FIG. 3 shows an end elevation of a filter device in which the retractable mouthpiece is in the packed position;
[0062] FIG. 4 shows a plan view of a filter device in which the rotatable mouthpiece is in the packed position;
[0063] FIG. 5 shows a side elevation of a filter device in which the rotatable mouthpiece is in the in-use position;
[0064] FIG. 6 shows an end elevation of a filter device in which the rotatable mouthpiece is in the in-use position;
[0065] FIG. 7 shows an end elevation of a filter device in which the rotatable mouthpiece is in the packed position;
[0066] FIG. 8 shows a plan view of a filter device in which the mouthpiece is connected to the filter box assembly using an airtight flexible bellows and with the mouthpiece in the packed position;
[0067] FIG. 9 shows an end elevation of a filter device in which the mouthpiece is connected to the filter box assembly using an airtight flexible bellows and with the mouthpiece in the packed position;
[0068] FIG. 10 shows an end elevation of a filter device in which the mouthpiece is connected to the filter box assembly using an airtight flexible bellows and with the mouthpiece in the in-use position;
[0069] FIG. 11 shows a plan view of a filter device in which the mouthpiece is connected to the filter box assembly using a hollow airtight axle and with the mouthpiece in the packed position;
[0070] FIG. 12 shows a side elevation of a filter device in which the mouthpiece is connected to the filter box assembly using a hollow airtight axle and with the mouthpiece in the packed position;
[0071] FIG. 13 shows a side elevation of a filter device in which the mouthpiece is connected to the filter box assembly using a hollow airtight axle and with the mouthpiece in the in-use position;
[0072] FIG. 14 shows a plan view of a filter device in which the mouthpiece is connected to the filter box assembly using an airtight bellows and with the mouthpiece in the packed position;
[0073] FIG. 15 shows a side elevation of a filter device in which the mouthpiece is connected to the filter box assembly using an airtight bellows and with the mouthpiece in the packed position; and
[0074] FIG. 16 shows a side elevation of a filter device in which the mouthpiece is connected to the filter box assembly using an airtight bellows and with the mouthpiece in the in-use position.
[0075] In summary: FIGS. 1 to 3 illustrate a retracting mouthpiece embodiment; FIGS. 4 to 7 illustrate a rotating mouthpiece embodiment; FIGS. 8 to 10 illustrate an embodiment incorporating airtight bellows; FIGS. 11 to 13 illustrate an embodiment incorporating an airtight hollow axle; and FIGS. 14 to 16 illustrate an embodiment incorporating airtight bellows.
DETAILED DESCRIPTION
[0076] In FIG. 1 , device 10 consists of filter box assembly 11 , which incorporates filter 13 and downstream air channel 14 . Mouthpiece 12 is fitted in an airtight manner to moveable backplate 15 . Airtight flexible diaphragm 16 provides an airtight seal between moveable backplate 15 and fixed backplate 17 , part of the filter box assembly 11 , which forms the rear of downstream air channel 14 . Flexible diaphragm 16 can be in the form of a sheet of flexible gas-tight material which can be either elastic or non-elastic or can be in the form of flexible bellows, not shown. Spring(s) 18 is/are located between the downstream surface of filter 13 and moveable backplate 15 . In the device illustrated a hood 19 is fitted to fixed backplate 17 . Hood 19 is worn over the wearer's head to provide protection to the wearer's eyes.
[0077] A benefit of the device described above is that downstream air channel 14 can be deeper than the more usual 3-7 mm used in many devices. This greater airflow channel depth ensures a more uniform airflow through the full area of the filter media than in devices with shallower downstream air channels and thus maximizes filter efficiency and capacity and reduces inhalation resistance.
[0078] Exhalation valve(s) 21 , if fitted, can also be located in the depth of downstream air channel 14 as illustrated in FIG. 2 . Exhalation valve(s) 21 so located within the increased depth of downstream air channel 14 can provide a lower exhalation resistance than such valves in conventional devices with shallower downstream air channels.
[0079] A further benefit of the invention embodiment described above is that, if used with a hood or visor, such components can be folded against or wrapped around smooth and/or flat surfaces. This can permit the use of a semi-rigid or rigid visor with enhanced optical quality as compared with a fully flexible hood which, in a device with a fixed mouthpiece, would usually be packed around or against uneven surfaces.
[0080] FIG. 3 shows that by compressing spring(s) 18 mouthpiece 12 can be retracted into filter box assembly 11 for packaging.
[0081] In the packed position, FIG. 3 , mouthpiece 12 has been retracted into downstream air channel 14 by compressing spring(s) 18 . In addition, parts 20 of mouthpiece 12 , which fit inside the wearer's mouth, have been “folded back” inside the depth of downstream air channel 14 . Hood 19 can then be folded and packed against the back of fixed backplate 17 or can be wrapped around filter box assembly 11 and can hold mouthpiece 12 in the packed position. The parts 20 may be foldable parts.
[0082] Once hood 19 has been unpacked, spring(s) 18 are free to force moveable backplate 15 and mouthpiece 12 out of downstream air channel 14 into the in-use position and parts 20 of mouthpiece 12 spring into their normal use position, as shown in FIGS. 1 and 2 .
[0083] The embodiments illustrated in FIGS. 1 to 3 comprise a mouthpiece, which is part of a mouthpiece assembly. In some embodiments, a mouthpiece assembly consists only of (or essentially of) a mouthpiece.
[0084] As an alternative embodiment of the invention FIGS. 4-7 illustrate a device in which mouthpiece 12 can be rotated around a fixed point to lie within the depth of filter box assembly 11 in the packed condition and rotated into the in-use position.
[0085] FIGS. 5 and 6 illustrate this embodiment with mouthpiece 12 in the in-use position. FIGS. 4 and 7 illustrate the device with mouthpiece 12 in the packed position.
[0086] In FIGS. 4-7 mouthpiece 12 is fitted to assembly 22 which is located on one of the shorter sides of filter box assembly 11 . Assembly 22 incorporates hollow male threaded section 23 and air channel 26 such that air can flow through male threaded section 23 into mouthpiece 12 . Male threaded section 23 screws into matching female threaded section 24 which is incorporated into filter box assembly 11 . In this embodiment of the invention filter box assembly 11 also incorporates extended air channel 25 such that air can flow from downstream air channel 14 through air channel 25 , through male threaded section 23 , through air channel 26 and into mouthpiece 12 . To ensure an airtight seal between filter box assembly 11 and assembly 22 a suitable airtight gasket 27 is located between filter box assembly 11 and assembly 22 . Assembly 22 may be a mouthpiece assembly, and air channel 25 may be a mouthpiece air channel.
[0087] In the packed position, as shown in FIGS. 4 and 7 , assembly 22 and mouthpiece 12 lie within the depth of filter box assembly 11 , allowing parts 20 of mouthpiece 12 , which fit inside the wearer's mouth, to be folded to fit within the depth of filter box assembly 11 .
[0088] When rotated to the in-use position, FIGS. 5 and 6 , assembly 22 and filter box assembly 11 are drawn together by the action of the screw thread, having the effect of compressing airtight gasket 27 : thus ensuring a more positive seal. The axis of rotation being about the line X-X in FIG. 4 .
[0089] An exhalation valve, if fitted, can be incorporated in assembly 22 , not shown.
[0090] FIGS. 8-16 illustrate further embodiments of the invention.
[0091] FIGS. 8-10 illustrate a device in which the airtight connection between mouthpiece 12 and downstream air channel 14 is ensured by airtight bellows 28 .
[0092] FIGS. 8 and 9 illustrate this embodiment with mouthpiece 12 in the packed position. Connector 29 is fixed to filter box assembly 11 and is connected to hinged mouthpiece assembly 30 and mouthpiece 12 by airtight bellows 28 . Mouthpiece 12 lies on the short axis of filter box assembly 11 and, if necessary to minimized bulk, parts 20 of mouthpiece 12 , which fit inside the wearer's mouth, can be folded to fit within the depth of filter box assembly 11 . Assembly 30 may be a mouthpiece assembly.
[0093] To bring mouthpiece 12 into the in-use position, FIG. 10 , mouthpiece assembly 30 is rotated around pivot point 30 . To hold mouthpiece assembly 30 and mouthpiece 12 in the in-use position, a stop, not shown, may be provided.
[0094] The material(s) from which bellows 28 is constructed should be suitable for agents against which the device is intended to be used.
[0095] FIGS. 11-13 illustrate an embodiment in which assembly 32 and mouthpiece 12 can be rotated through about 90° so that in the packed position these assemblies lie on the long axis of filter box assembly 11 and in the in-use position rotate to stand proud of filter box assembly 11 . Assembly 32 may be a mouthpiece assembly.
[0096] FIG. 11 illustrates this embodiment of the invention in plan view with mouthpiece 12 in the packaged position. FIGS. 12 and 13 show section A-A in side elevation. FIG. 12 showing the mouthpiece assembly 32 in the packed position and FIG. 10 showing the mouthpiece assembly 32 in the in-use position. Assembly 32 is fitted to hollow axle 33 , which is located and suitably connected in an airtight manner to hollow extensions 34 , which form an air passage between mouthpiece 12 and downstream air channel 14 . Parts 20 of mouthpiece 12 , which fit inside the wearer's mouth, can be folded to minimize bulk.
[0097] To bring mouthpiece 12 into the in-use position, shown in FIG. 13 , mouthpiece 12 and assembly 32 are rotated through about 90°. The axis of rotation being about the line Y-Y in FIG. 11 .
[0098] FIGS. 14-16 illustrate an alternative arrangement of the embodiment shown in FIGS. 11-13 in which hollow axle 33 and extensions 34 are replaced by suitable airtight bellows 35 .
[0099] FIGS. 14 and 15 illustrate this embodiment of the invention in plan and side elevation respectively with mouthpiece 12 in the storage position, and parts 20 , which fit inside the wearer's mouth, being folded back to reduce overall stored dimensions. Mouthpiece 12 is connected in an airtight manner to downstream air channel 14 by bellows 35 .
[0100] To bring mouthpiece 12 into the in-use position, shown in FIG. 16 , mouthpiece 12 and assembly 36 are rotated through about 90° around pivot point 37 . To hold mouthpiece 12 in the in-use position, a stop, not shown, may be provided. Assembly 36 may be a mouthpiece assembly.
[0101] The material(s) from which bellows 35 are constructed should be suitable for agents against which the device is intended to be used.
[0102] While this invention has been described with reference to the sample embodiments thereof, it will be appreciated by those of ordinary skill in the art that modifications can be made to the structure and elements of the invention without departing from the spirit and scope of the invention as a whole.
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A compact respiratory protective device fitted with a mouthpiece or mouthpiece assembly that retracts, pivots or rotates into the depth of the device to reduce size when packed. This reduction in size also permits the depth of the downstream air channel to be increased while still producing a compact device. This increase in the depth of the downstream air channel maximizes the efficiency and capacity of the filter assembly and reduces the inhalation resistance of the device. The reduced breathing resistance enhances usability.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. application Ser. No. 14/147,183, filed Jan. 3, 2014, which is a continuation of U.S. application Ser. No. 13/330,120 filed Dec. 19, 2011, now issued as U.S. Pat. No. 8,636,613, the disclosures of which are incorporated in their entirety by reference herein.
TECHNICAL FIELD
[0002] The present disclosure relates to a system and method to control speed-ratio upshifts in an automatic vehicle transmission for achieving reduced transmission output shaft torque transients during an upshift.
BACKGROUND
[0003] Known automatic transmissions for automotive vehicles include step ratio controls for effecting speed ratio changes in response to changing driving conditions. The term “speed ratio”, for purposes of this description, is defined as transmission input shaft speed divided by transmission output shaft speed.
[0004] A so-called speed ratio upshift occurs when the driving conditions require a ratio change from a lower ratio (high speed ratio) to a higher ratio (low speed ratio) in the transmission gearing. The gearing may include, for example, either a planetary type gear system or a lay shaft type gear system. An automatic gear ratio shift is achieved by friction torque establishing devices, such as multiple disk clutches and multiple disk brakes. The friction torque establishing devices include friction elements, such as multiple plate clutches and band brakes, which may be actuated hydraulically or mechanically.
[0005] A step-ratio automatic transmission uses multiple friction elements for automatic gear ratio shifting. A ratio change from a low gear ratio to a high gear ratio occurs in a synchronous clutch-to-clutch upshift as one friction element is engaged and a second friction element is disengaged. One friction element may be referred to as an off-going clutch (OGC). It is released while a second friction element, which may be referred to as an oncoming clutch (OCC), engages to create the upshift. The upshift event is divided into a preparatory phase, a torque phase and an inertia phase.
[0006] During the preparatory phase, a transmission controller reduces the OGC torque capacity to prepare for its release and simultaneously, adjusts the position of an OCC actuator to prepare for its engagement. During the torque phase, the controller increases the OCC torque capacity in a controlled manner while the OGC is still engaged or allowed to slip at a controlled slip rate. This causes torque that is transmitted through the OGC to drop significantly in accordance with an increase in torque capacity of the OCC. The controller may maintain enough OGC torque capacity to keep the OGC securely engaged or locked during the torque phase, which immediately follows the preparatory phase. Alternatively, the controller may allow the OGC to slip at a controlled rate.
[0007] During the torque phase of a conventional control system, torque transmitted through the OGC decreases when the transmission output shaft torque drops. This creates a so-called torque hole. A large torque hole can be perceived by the vehicle occupants as an unpleasant shift shock. The inertia phase begins when the OGC is released or has no significant torque capacity.
SUMMARY
[0008] Various embodiments of the present disclosure provide associated advantages. For example, various embodiments eliminate or reduce transient torque disturbances, such as the torque hole effect, during an upshift event. A transmission controller may provide estimated friction element torque targets using friction element actuator pressures in the case of a transmission control system with pressure operated actuators. In one embodiment, the controller executes control algorithms in a software control strategy without knowing actual torque profiles for the oncoming and off-going friction elements.
[0009] In a control system in one embodiment of the present disclosure, powertrain sensors may provide direct reading of operating variables, such as output torque. Torque sensors may be used, together with physical properties and functions of the transmission and driveline components, algorithms governing those functions and appropriate transfer functions, to provide accurate torque values for the oncoming and off-going clutches. The sensors provide torque feedback signals for correcting estimates of friction element torque in a closed loop fashion during calculations of actuator pressures.
[0010] The present disclosure includes a control strategy for coordinating the actuators to achieve minimal torque disturbance at the output shaft. The control strategy and associated algorithms may determine the desired clutch torque and assume, based on a clutch model, that this torque will be delivered using a calibrated transfer function between clutch pressure command and clutch torque. However, the clutch actuators are non-linear and their response to control pressures is affected by variables such as transmission oil temperature and other environmental factors. This can result in OCC torque transients or disturbances. Torque sensors may provide real time feedback of the actual clutch torques during an upshift.
[0011] The present disclosure describes a feedback control that uses one or more sensors (e.g., torque sensors) to develop an actual, real time sensor feedback (e.g., torque feedback) to calculate an oncoming friction element torque to ensure that the oncoming friction element torque tracks a target torque and to obtain a desired off-going friction element torque to ensure the off-going friction element remains locked as desired depending on the particular phase or progress of the shift. A torque sensor signal is used to calculate corrected oncoming and off-going friction element torque values as a direct torque measurement. For example, a torque sensor can be located at a transmission torque input shaft or at a transmission torque output shaft, or at both locations. Torque at other locations can be calculated using the direct readings for the sensors.
[0012] When the transmission input and output torques are known, the friction element torques can be calculated during the shift using a technique such as that disclosed in U.S. application Ser. No. 12/861,387, filed Aug. 23, 2010, which is assigned to the assignee of the present disclosure. Reference also may be made to U.S. Patent Publication 2010/0262344, filed Apr. 9, 2009, which also is assigned to the assignee of the present disclosure. Those references explain, for example, how to estimate the input shaft torque if only the output shaft torque is measured, and vice versa.
[0013] By knowing the friction element torques, performance and predictability of the algorithms can be improved because it is possible to determine if a friction element torque is actually achieved and to provide accurate modulation of the OCC actuator pressures so that torque transients at the OCC are minimized as the OGC remains locked. The target level of the OCC torque capacity is determined using governing equations to achieve a seamless output shaft torque transition from the torque phase of an upshift to an inertia phase.
[0014] A companion co-pending continuation-in-part patent application, which is assigned to the assignee of the present disclosure, discloses a control strategy for achieving a smooth upshift in a multiple ratio transmission without sensor feedback. The co-pending patent application is application Ser. No. 12/871,485, filed Aug. 30, 2010. The present application has some features that are common to that co-pending application.
[0015] A companion co-pending application, which is assigned to the assignee of the present disclosure, discloses a control strategy for achieving a smooth upshift in a multiple ratio transmission with sensor feedback in a lay shaft transmission, in particular where the OGC has a controlled slip during the torque phase. The co-pending application is application Ser. No. 13/155,867 filed Jun. 8, 2011.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 is an example of a stepped ratio planetary automatic transmission according to an embodiment of the present disclosure;
[0017] FIG. 1 a is a schematic drawing of elements of the control system for controlling ratio shifts according to an embodiment of the present disclosure;
[0018] FIG. 2 is an example of a step-ratio planetary automatic transmission, as shown in FIG. 1 , wherein the gearing is conditioned for first gear operation;
[0019] FIG. 3 is an example of a step-ratio planetary automatic transmission, as shown in FIG. 1 , with the gearing conditioned for second gear operation;
[0020] FIG. 4 is an example of a step-ratio planetary automatic transmission, as shown in FIG. 1 , in which the gearing is configured for third gear ratio operation;
[0021] FIG. 5 is an example of a time plot showing the shift characteristics of a synchronous, clutch-to-clutch upshift control for a planetary transmission characterized by a so-called torque hole at the output shaft;
[0022] FIG. 6 is an example of a time plot corresponding to FIG. 5 of the shift characteristics for a synchronous upshift control for a planetary transmission, according to an embodiment of the present disclosure;
[0023] FIG. 7 is a functional flowchart of an upshift control with a locked off-going clutch according to an embodiment of the present disclosure;
[0024] FIG. 8 is a functional flowchart of an upshift control with a locked off-going clutch according to another embodiment of the present disclosure; and
[0025] FIG. 9 is a functional flowchart of an upshift control with a locked off-going clutch according to another embodiment of the present disclosure.
DETAILED DESCRIPTION
[0026] As required, detailed embodiments of the present disclosure are disclosed herein; however, it is to be understood that the disclosed embodiments are merely examples of the invention that may be embodied in various and alternative forms. The figures are not necessarily to scale; some features may be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present invention.
[0027] FIG. 1 shows an example of a conventional planetary step-ratio automatic transmission. It comprises an engine driven torque input shaft 10 and a transmission input shaft 12 . A transmission output shaft 14 delivers torque to transmission torque output gearing 16 . A torque converter may be disposed between engine driven torque input shaft 10 and transmission input shaft 12 , as shown at 18 . A torque converter impeller 21 is in fluid flow relationship with respect to turbine 23 . A stator 25 is disposed between the flow inlet section of impeller 21 and the flow exit section of turbine 23 .
[0028] In the particular planetary transmission shown in FIG. 1 , there are three simple planetary gear units 20 , 22 and 24 . Output torque is delivered from the carrier 26 to the torque output gearing. Carrier 26 is connected to the ring gear for gear unit 24 and to output shaft 14 . An overrunning coupling 28 anchors the carrier 30 of planetary gear unit 24 against rotation in one direction, but freewheeling motion is provided in the opposite direction. During reverse drive and during low ratio operation, carrier 30 is braked by coupling 32 against the transmission housing 34 . During forward drive operation, the sun gear for gear unit 20 is anchored to the housing through forward driving coupling 36 .
[0029] During intermediate ratio operation, the sun gear for gear unit 24 is anchored to the housing 34 by intermediate coupling 38 .
[0030] During direct drive, input shaft 12 is clutched by direct coupling 40 to input shaft 12 , thus establishing a one-to-one driving ratio through the planetary gearing. Overdrive coupling 42 , when engaged, directly connects the carrier for gear unit 24 and the ring gear for gear unit 22 to the input shaft 12 . FIG. 1 a shows an engine 11 which acts as a source of torque for the transmission. If the transmission has a torque converter, engine speed will equal speed of converter impeller 21 and transmission input speed will equal converter turbine speed.
[0031] Engine 11 is controlled by an electronic engine control (EEC) 13 , which receives control signals from controller 15 based on multiple variables or driving condition data, such as engine throttle position, engine speed, desired engine torque, input and output speeds and a driver selected ratio range. A transmission control module 17 is also controlled by controller 15 . A pump (P) 19 , driven by the engine, supplies clutch and brake servo pressure to the transmission under the control of controller 15 .
[0032] As previously mentioned, torque sensor embodiments of the present disclosure are used to obtain direct-reading oncoming and off-going clutch torques. In the case of the planetary transmission of FIG. 1 , a torque sensor 33 may be located on torque input shaft 12 . Likewise a torque sensor 35 may be located on torque output shaft 14 . A measurement from the torque sensor 33 represents a sum of oncoming (OCC) and off-going clutch (OGC) torques when no significant inertia torque is present during a torque phase of an upshift. The clutch torques can be decomposed into oncoming and off-going clutch torque levels based on clutch actuator positions or apply forces whose measurements are readably available by pre-calibration.
[0033] FIG. 2 shows the transmission in the first gear configuration. Input torque is delivered to the sun gear of gear unit 22 and the ring gear of gear unit 22 acts as a reaction element as reaction torque is delivered to the housing 34 through overrunning coupling 28 . Forward coupling 36 is engaged so that the sun gear of gear unit 20 acts as a reaction element. The carrier 26 is the output element, which delivers torque to the output gearing 16 through a cross drive chain, not shown, or torque transfer gearing.
[0034] Second gear configuration is shown in FIG. 3 where the sun gear for gear unit 24 is anchored by the intermediate coupling 38 , and the sun gear for gear unit 20 is anchored by the forward coupling brake 36 . Input torque from shaft 12 is delivered to the sun gear of gear unit 22 . Driving torque then is divided and delivered to the carrier 30 and to the ring gear for gear unit 20 , thus driving carrier 26 . A torque flow path through gear unit 22 is established as the carrier for gear unit 22 drives a ring gear for gear unit 20 . The carrier 26 of the gear unit 20 acts as a torque output member.
[0035] Third gear configuration is shown in FIG. 4 where input torque from the shaft 12 is delivered through clutch 40 to the sun gear of gear unit 24 . The carrier for gear unit 24 drives the ring gear for gear unit 22 . The ring gear for gear unit 24 drives the carrier for gear unit 20 , which is drivably connected to the torque output gearing 16 . Torque input shaft 12 also delivers torque to the sun gear of gear unit 22 . The divided torque flow path through gear unit 22 extends to the ring gear for gear unit 20 .
[0036] An automatic transmission according to an embodiment of the disclosure may be a planetary type as shown in FIGS. 1-3 , or a lay shaft type transmission. A speed ratio change occurs in accordance with driving conditions. This is achieved by the friction elements as described above. The friction elements can be plate clutches or band brakes and may be actuated hydraulically, mechanically or through other means.
[0037] During a typical automatic transmission upshift event, a friction element or coupling, referred to as an off-going clutch (OGC), disengages while a different friction element or coupling, referred to as an on-coming clutch (OCC) engages in order to lower a speed ratio.
[0038] A shift event can be divided into a preparatory phase, a torque phase and an inertia phase. During the preparatory phase, an automatic transmission controller reduces off-going clutch torque capacity to prepare for its release while adjusting the position of an on-coming clutch actuator to prepare for its engagement, as described above.
[0039] In the first gear configuration, shown in FIG. 2 , the overrunning coupling 28 grounds the carrier for reaction gearing 24 and forward clutch 36 grounds the sun gear for planetary gear set 20 . All the other clutches are disengaged. The speed ratio for the input shaft to the output shaft is at its highest value for the transmission. During an upshift event, one or more of the clutches are in the process of being engaged or disengaged as the speed ratio of the input shaft 12 to the output shaft 14 varies between two steady-state ratio values.
[0040] In the example shown in FIG. 3 , there is a change in the torque flow path through the planetary gear sets. Each component of the gear sets has a different level of torque, causing the various components to accelerate or decelerate. The overrunning coupling 28 will begin to overrun, and when the intermediate clutch 38 , after it is fully engaged, will cause a speed ratio of the input shaft 12 to the output shaft 14 to be lower than it was in first gear. This shift requires management of the torque of only a single clutch.
[0041] FIG. 4 shows an example of a conventional planetary step ratio transmission in third gear configuration. To change from the second gear ratio (high speed ratio) to the third gear ratio (low speed ratio), the intermediate clutch 38 is disengaged and the direct clutch 40 is engaged. Clutch 38 will be referred to as the off-going clutch and direct clutch 40 will be referred to as the on-coming clutch (OCC). Both clutches must be managed carefully so that the torque being carried by the off-going clutch 38 is transferred to the on-coming clutch 40 in a smooth manner. The swapping of these two clutches causes the sun gear of the reaction planetary gear unit 24 to be connected to the input shaft 12 instead of being grounded against the housing. Ultimately, the intermediate clutch 38 is fully disengaged and the direct clutch 40 is fully engaged. The speed ratio of the input shaft to the output shaft will be lower than it was in second gear. This shift sequence requires careful management of both clutches 38 and 40 .
[0042] FIG. 5 shows a conventional “power-on” upshift from a low gear configuration to a high gear configuration. The upshift event, diagrammatically illustrated in FIG. 5 , is an upshift with an accelerator pedal position greater than zero degrees. The upshift event occurs under a constant engine throttle. This conventional upshift control method is a characteristic of a known planetary type transmission system, as illustrated in FIGS. 1-4 , but it could apply also to a lay-shaft type transmission.
[0043] The conventional upshift event, illustrated in FIG. 5 , is divided into a preparatory phase, a torque phase and an inertia phase. It will be assumed, in a description of the upshift control of FIG. 5 , that the upshift is accomplished with two clutches that are controlled synchronously, one clutch releasing from a holding state, which is called the off-going clutch, and one clutch engaging from an open state, called the on-coming clutch. Other transmissions can use other types of friction elements besides clutches, but the principles would be the same.
[0044] During the preparatory phase, the torque capacity of the off-going clutch (OGC), is reduced, as shown at 50 , to prepare release of the OGC. However, enough OGC torque capacity is maintained to keep the OGC from slipping. A transmission controller adjusts an actuator piston for the clutch pressure operated servo for the on-coming clutch (OCC) to prepare for engagement of the OCC. At the end of the preparatory phase, the on-coming clutch (OCC) is yet to carry significant torque capacity, as shown at 54 .
[0045] During the torque phase, OGC torque capacity is further reduced, as shown at 56 , while the controller increases OCC torque capacity, as shown at 58 . The OGC is still securely locked without slipping, which maintains a torque flow path in the low gear configuration. Accordingly, the input shaft speed, as shown at 60 , remains the same as that of the output shaft speed multiplied by the gear ratio of the low gear.
[0046] The engine speed and the input shaft speed are not necessarily interchangeable because the engine may be connected to the input shaft through a torque converter, thus the term “input shaft speed” may be used in this description rather than engine speed.
[0047] If the OGC torque capacity were to be controlled to induce a small slip, the input shaft speed would be higher than that of the output shaft speed multiplied by the gear ratio of the low gear configuration. When OGC slips, it is OGC slip torque capacity for the OGC plot at 56 that drives the downstream gear elements all the way to the output shaft.
[0048] During the torque phase, increasing on-coming clutch (OCC) torque capacity reduces the net torque flow through the off-going clutch (OGC) when the off-going clutch remains engaged or locked. Thus, the output shaft torque drops significantly, as shown at 62 , creating a so-called torque hole representing a significant, immediate reduction in output shaft torque. A large torque hole can be perceived by a vehicle occupant as sluggish powertrain performance or an unpleasant shift shock.
[0049] The inertia phase begins when the off-going clutch (OGC) torque capacity is reduced to a non-significant level, as shown at 64 . The on-coming clutch (OCC) carries enough torque capacity, shown at 70 , to pull down input speed, as shown at 68 , closer to the speed of the output shaft, as shown at 66 , multiplied by the ratio of the high gear configuration. The input speed is higher during the torque phase than during the inertia phase, as shown at 60 . During the inertia phase, the output shaft torque is primarily affected by the on-coming clutch (OCC) torque capacity at 70 .
[0050] Also shown in FIG. 5 is a reduced input torque at 72 during the inertia phase. This reduction is achieved by controlling engine spark timing, which is a common practice in conventional shift control strategies. It enables the on-coming clutch (OCC) to engage within a calibration target shift duration without requiring excessive torque capacity.
[0051] The shift event is completed when the on-coming clutch (OCC) is fully engaged. The input shaft then is securely coupled to the output shaft through the high gear ratio configuration. Further, the input speed is matched to the output shaft speed multiplied by the gear ratio of the high gear configuration. The input torque reduction at 72 is removed, and the input torque then returns to the level at point 74 , which corresponds to the input torque at the beginning of the inertia phase. The output shaft torque returns to the level shown at 76 , which corresponds to the input shaft torque level at 74 in the high gear configuration.
[0052] In contrast to the known upshift control strategy of FIG. 5 , FIG. 6 shows an embodiment of an upshift control method according to the present disclosure for a planetary transmission of the kind depicted in FIGS. 1-4 . As in the case of FIG. 5 , FIG. 6 is divided into a preparatory phase, a torque phase and an inertia phase. During the preparatory phase, a transmission controller 17 reduces the torque of an off-going clutch (OGC), as shown at 78 , to prepare for its release. It is usually desired to keep the off-going clutch (OGC) torque above that which would allow it to slip until the OCC has sufficient capacity to carry all the input torque. The controller 17 also adjusts the actuator position for the on-coming clutch (OCC) to prepare for its engagement.
[0053] During the torque phase, the controller 17 raises the on-coming clutch (OCC) torque for engagement of the OCC, according to a desired trajectory, shown as trajectory 82 . Actuator corrections, achieved by using torque sensor data, may create a wave-form trajectory, as shown at 83 . The clutches may be controlled by hydraulic actuators which control the torque of the clutches by applying pressure with the actuators. The corrections help to better match the on-coming clutch torque with the target torque and reduce errors due to unforeseen or uncharacterized variation in the clutch actuator transfer function between the actuator pressure and the clutch torque.
[0054] As shown at 84 , engine torque is used to fill the torque hole. Therefore, input torque is increased at 84 while the off-going clutch (OGC) torque is further reduced, as shown at 86 , while not allowing slip of the OGC. When the off-going clutch (OGC) is locked, torque transmitted from the input shaft to the output shaft is reduced by the on-coming clutch (OCC) torque capacity at 82 . Thus, by keeping the off-going clutch (OGC) locked, the transmission controller 17 can actively manage the torque level that drives the output shaft by adjusting only the on-coming clutch (OCC) torque at 82 .
[0055] The output shaft torque τ os can be algebraically described as follows:
[0000] τ os =G on τ on +G off τ off , (1)
[0056] where τ on is OCC torque capacity as reflected at the transmission gearing input, τ off is OGC torque transmitted (which would be equal to the capacity if clutch is slipping) as reflected at the transmission gearing input, G off is gear ratio of the low gear, and G on is gear ratio of the high gear. Equation (1) can be rearranged as:
[0000]
τ
on
=
τ
os
-
G
off
τ
off
G
on
(
2
)
[0057] Rewriting τ os as τ os,des , Equation (2) can be expressed as:
[0000]
τ
on
=
τ
os
,
des
-
G
off
τ
off
G
on
,
(
3
)
[0058] where τos,des is a desired output shaft torque.
[0059] The governing Equation (3) provides a systematic self-calibration of a level of OCC torque capacity τ on for achieving a desired output torque profile τ os,des while OGC remains locked during the torque phase. More specifically, a torque profile can be specified to smoothly connect the output shaft torque 88 before the start of the torque phase and after the end of the torque phase, thereby eliminating or reducing the torque hole. OGC torque τ off can be estimated based on OGC actuator position or clamping force and the OCC torque capacity can be actively adjusted so that the OGC capacity is higher than the torque transmitted by the OGC until the transmitted torque reaches zero or some low threshold. Thus, for a given τ off , Equation (2) specifies a level of OCC torque capacity τ on of the OCC required for achieving a desired output shaft torque at 88 . The OGC transmits a part of the input torque 82 through the gear units to the output.
[0060] Output shaft torque is described as:
[0000] τ os =G off τ in +( G on −G off )τ on , (4)
[0061] where τ in is the input torque, for example from an engine through a torque converter. Replacing τ os with a desired torque profile τ os,des , Equation (4) can be rearranged as:
[0000]
τ
on
=
τ
os
,
des
-
G
off
τ
i
n
G
on
-
G
off
,
or
τ
i
n
=
τ
os
,
des
-
(
G
on
-
G
off
)
τ
on
G
off
(
5
)
[0062] Torque variables τ os and τ in can be represented as:
[0000] τ os,des =τ os 0 −Δτ os and τ in =τ in 0 +Δτ in , (6)
[0063] where τ os 0 and τ in 0 are the output shaft torque and input torque at the beginning of the torque phase, respectively. Δ τos and Δτ in represent the change in output shaft torque and input torque, respectively, at the elapsed time Δt after the torque phase begins. Substituting Equation (6) into Equation (5) yields:
[0000]
τ
on
=
Δ
τ
os
,
des
+
G
off
Δ
τ
i
n
G
off
-
G
on
(
7
)
[0000] OCC torque τ on can be written as:
[0000] τ on =Σ on 0 +Δτ on , (8)
[0064] where τ on 0 is the OCC torque capacity at the beginning of the torque phase and Δτ on is the change in OCC torque at Δt. Substituting Equation (8) into Equation (7) results in:
[0000]
Δ
τ
on
=
Δ
τ
os
,
des
-
G
off
Δ
τ
off
G
on
(
9
)
[0065] where Δτ off =τ in −Δτ on . Note that Equation (9) takes the same form as the Equation (3), which is the governing equation for determining a level of OCC torque capacity for achieving a desired output torque profile while OGC remains locked.
[0066] Therefore, the governing Equations (5), (7) and (9) provide a systematic strategy to self-calibrate a level of OCC torque capacity τ on for achieving a desired output torque profile τ os , des during the torque phase when OGC remains locked. More specifically, a torque profile τ os,des can be specified to smoothly connect output shaft torque 88 between point 90 of the preparatory phase and after point 92 of the torque phase, thereby eliminating or reducing the torque hole.
[0067] For a given τ in at 84 , Equation (5) specifies a level of OCC torque capacity τ on at 82 required for achieving the target profile τ os,des at 88 . Alternatively, for given τ on at 82 , Equation (5) may be used to systematically determine a target τ in at 84 required for achieving τ os,des at 88 . Once the target level is determined, τ in can be controlled by an engine, for example, through a combination of engine throttle control, spark timing control, intake and exhaust valve timing control, turbo boost control or through an auxiliary torque source such as an electric motor. Note that input torque control is coupled to OCC torque control in Equation (5).
[0068] The inertia phase begins at 92 when OGC is released. OGC transmits torque only at a non-significant level while OCC carries enough torque capacity, as shown at 96 , to slow down input speed, as shown at 101 , closer to that of output shaft at 102 multiplied by the ratio of the high gear. Input speed during the torque phase is shown at 100 in FIG. 6 . Under this condition, both Equation (3) and Equation (5) can be reduced to:
[0000]
τ
on
=
τ
os
,
des
G
on
(
10
)
[0069] Thus, the output shaft torque τ os 94 is primarily affected during the inertia phase by OCC torque capacity τ on at 96 during the inertia phase. At this time, OCC torque capacity may be decreased in a controlled manner until the end of the inertia phase. According to the present disclosure, Equation (10) is utilized to provide a target OCC torque capacity τ on during the inertia phase that is required to achieve a seamless output shaft torque profile τ os,des from the torque phase to the inertia phase. In addition, there is feedback as well as an effect of a change in engine torque.
[0070] FIG. 6 shows reduced input torque at 98 during the inertia phase. This is a common practice in a known shift control method. It reduces the inertia torque arising from deceleration of the input shaft during the inertia phase, thus enabling the OCC to engage within a target shift duration without requiring excessive torque capacity. The shift event completes when OCC is fully engaged to securely couple the input shaft to the output shaft through the high gear ratio, matching input speed 101 to output shaft speed 102 multiplied by the ratio of the high gear upon completion of a shift event. The engine torque reduction is removed at 104 , and the output shaft torque returns to the level at 106 that corresponds to an input torque level at 108 in the high gear configuration.
[0071] FIG. 7 shows a control flow chart of an embodiment of the disclosure when OGC is locked during a torque phase 110 . It describes a systematic approach to perform the shift control depicted in FIG. 6 . During the torque phase 110 , a controller first chooses a desired level of output shaft torque τ os,des , as represented by block 112 . The controller also chooses (in the case of a clutch) or estimates (in the case of a one-way clutch) the desired OGC torque capacity, as represented by block 114 . The OGC actuator is adjusted to ensure that the OGC does not slip, as represented by block 115 . If the OGC is a one-way clutch, the torque is determined by OCC torque capacity. If the OGC is a clutch or other friction element, the OGC torque capacity is adjusted through either closed loop control or open loop control of its actuator position or actuator force.
[0072] The controller calculates feed forward OCC torque (τ on,ff (k)) based on a measurement of off-going clutch (OGC) torque, as represented by block 116 . Alternatively, (τ on,ff )(k)) can be determined from calculated OGC torque based on torque measurements with torque sensors at other locations, such as an output shaft.
[0073] A feedback torque correction, (τ on,fb (k)), is calculated, as represented by block 117 based on a measurement of oncoming clutch (OCC) torque. Alternatively, (τ on,fb )(k)) can be determined from calculated OCC torque based on torque measurements with torque sensors at other locations, such as an output shaft. The feedback correction, as represented by block 117 , may be used to compensate for the inherent variability in the development of clutch torque. The increasing oncoming clutch (OCC) torque, shown at 82 in FIG. 6 , for a synchronous clutch-to-clutch upshift is based upon a theoretical model. In actual practice, the response of the clutch actuator to a pressure command is affected by environmental factors. The clutch torque variability may be due to temperature changes, viscosity changes, wear of mechanical elements in the actuator structure, debris, rate of cooling of actuator fluid, or any other unforeseen or uncharacteristic variation, or irregularities in the clutch actuator transfer function.
[0074] The controller calculates a feed forward incoming clutch torque, as represented by block 116 . The plot, as shown at 83 in FIG. 6 , is represented by an irregular dotted line torque correction superimposed over linear line 82 . The correction is a feedback term or signal that opposes transient torque disturbances. The correction feedback illustrated by dotted line 83 may be derived from torque sensor measurements, for example. The linear line 82 is a theoretical linear time trace of oncoming clutch pressure (OCC), or any suitable actuating parameter for the given clutch system, corresponding to the time trace shown at 58 in FIG. 5 . The control system of the present disclosure will decrease the torque transients so that a resultant oncoming clutch (OCC) pressure trace will resemble more closely the linear line 82 shown in FIG. 6 . The oncoming clutch torque correction is based on an actual torque value measured using one or more torque sensors 33 , 35 illustrated in FIG. 1 . Torque sensor 33 measures input shaft torque and torque sensor 35 measures output shaft torque. The torque sensor measurements can be used if the gear ratio associated with the off-going clutch (G off ) and the gear ratio associated with the oncoming clutch (G on ) are known. A calculation of a feed-forward oncoming clutch (OCC) torque, which is based upon the desired OGC torque, is represented by block 116 in FIG. 7 .
[0075] The oncoming clutch feedback torque can be calculated also using other sensors, such as an input shaft speed and an output shaft speed. Thus, the oncoming clutch feedback torque can be expressed based on the input shaft torque sensor reading, the output shaft sensor reading, the input shaft speed sensor reading and the output shaft speed sensor reading. Representative equations for accomplishing this are set out in the co-pending patent applications previously described; i.e., application Ser. No. 12/861,387 and Patent Publication 2010/0262344, which are assigned to the assignee of the present application.
[0076] The controller uses Equation (3) to self-calibrate the required level of OCC torque capacity, as represented by block 116 . Then the controller may adjust the OCC actuator to achieve the desired OCC torque capacity, as represented at 118 . Correcting for the difference between the commanded torque in a previous processor control loop (k−1) and the current measurement in the current processor control loop (k) is carried out at 118 in FIG. 7 .
[0077] Based on the commanded OCC torque capacity and the OGC torque (actual torque transmitted by the off-going clutch as reflected at the transmission gearing input), the controller calculates the input torque needed to maintain the current input speed acceleration, as represented by block 120 . The controller then adjusts the torque-producing device (usually an engine) to produce the calculated amount of input torque, as represented by block 122 .
[0078] The controller evaluates whether the end of the torque phase is reached based upon OGC torque becoming sufficiently small or less than a pre-specified threshold, τ off,thresh , as represented by block 126 . If the threshold OGC torque is not reached, or, in other words, the measured OCG torque is still greater than the pre-specified threshold, the controller repeats the control loop 124 . The controller re-estimates the desired output shaft torque, as represented by block 112 , and chooses (or estimates in case of a non-synchronous shift) OGC torque, as represented by block 114 , for the next control time step k+1, and so on. The end of the torque phase is reached when OGC torque becomes sufficiently small or less than a pre-specified threshold τ off,thresh at 126 .
[0079] When the end of the torque phase is reached, the controller releases OGC, (assuming the OGC is not a one-way clutch), as represented by block 128 and moves to the inertia phase control, as represented by block 130 . Equation (10) is utilized to determine a target OCC torque for a seamless output shaft torque transition from the torque phase to the inertia phase, as represented by block 130 .
[0080] FIG. 8 illustrates an alternate embodiment of the present disclosure to reduce or eliminate output shaft torque disturbances previously described. FIG. 8 shows a control flow chart of another embodiment of the synchronous shift control of the disclosure when OGC is locked during a torque phase to enable the shift control depicted in FIG. 6 . FIG. 8 illustrates a control strategy that varies from FIG. 7 in that the controller chooses a desired input torque, whereas in FIG. 7 , the controller chose a desired OGC torque.
[0081] During the torque phase, represented by block 132 in FIG. 8 , a controller first chooses a desired level of output shaft torque, as represented by block 134 , and also chooses the input torque, as represented by block 136 .
[0082] The controller brings the input torque to the desired level, as represented by block 137 , using any available control parameters. For example, if the torque-producing device is an engine, the controller may bring the input torque to the desired level by controlling a number of variables, including but not limited to: throttle position, spark/ignition timing, intake and exhaust valve timing, turbo boost, etc.
[0083] A feedback correction τ on,fb (k) based on measured OCC torque (torque sensor output) is determined, as represented by block 138 . Alternatively, τ on,fb (k) can be determined from calculated OCC torque based on torque measurements with torque sensors at other locations, such as an output shaft, for example. The feedback correction, as represented by block 138 , may be used to accommodate the variability in the development of clutch torque, as described above.
[0084] Next, the controller calculates a feed forward oncoming clutch torque, as represented by block 140 . As described above, the oncoming clutch torque correction is based on an actual torque value measured using one or more torque sensors 33 , 35 illustrated in FIG. 1 . Torque sensor 33 measures input shaft torque and torque sensor 35 measures output shaft torque. The torque sensor measurements can be used if the gear ratio associated with the off-going clutch (G off ) and the gear ratio associated with the oncoming clutch (G on ) are known. A calculation of a feed-forward oncoming clutch (OCC) torque, which is based upon the desired OGC torque, is represented by block 140 in FIG. 8 .
[0085] Next, the OCC actuator is adjusted at 230 to achieve τ on (k), which is equal to τ on,ff (k)++τ on,fb (k), as represented by block 142 . If the OGC is not a one-way clutch, and if the OGC has an actuator for capacity control, the controller may adjust or reduce OGC torque capacity, as represented by block 144 , while ensuring the OGC remains locked without inducing a slip. Alternatively, the controller may not reduce capacity, keeping the OGC locked as the transmitted torque decreases by way of the OCC “picking up” torque.
[0086] The controller evaluates whether the end of the torque phase is reached based upon OGC torque level, as represented by block 146 . As described above, the controller evaluates whether the end of the torque phase is reached based upon when OGC torque becomes sufficiently small or less than a pre-specified threshold, τ off,thresh, as represented by block 146 . If τ off is greater than a calibrated threshold, the control loop 147 is repeated, and the routine will return to the beginning and then repeat in the next control loop k+1. Otherwise, the OGC will be released, as represented by block 148 and moves to the inertia phase control, as represented by block 150 . Equation (10) is utilized to determine a target OCC torque for a relatively seamless output shaft torque transition from the torque phase to the inertia phase, as represented by block 150 .
[0087] FIG. 9 shows a control flow chart for a third possible embodiment of the synchronous shift control of the disclosure when OGC is locked during a torque phase. The control flow chart in FIG. 9 is somewhat similar to flow charts illustrated in FIG. 7 and FIG. 8 except, for example, that a desired target oncoming clutch torque is chosen following the start of the torque phase, represented at block 152 . The controller first chooses a desired level of output shaft torque, as represented by block 154 . The controller also chooses a desired OCC torque capacity (τ on (k)), as represented by block 156 .
[0088] Next, the OCC feedback correction is made, as represented by block 157 . The steps carried out at blocks 157 and 159 in FIG. 9 correspond, respectively, to the steps 138 and 142 described in FIG. 8 .
[0089] Then the controller utilizes Equation (5), as represented by block 158 , to self-calibrate the required level of input torque. Alternatively, Equation (7) or (9) may be utilized, in place of Equation (5), to calculate the required increment of input torque Δτin at the elapsed time Δt after the beginning of the torque phase based on Δτ on and Δτ os,des .
[0090] The controller brings the input torque to the desired level, as represented by block 160 , using any available control parameters. If the torque-producing device is an engine, for example, this could include any of the control techniques previously described. If the OGC is not a one-way clutch (OWC) and has an actuator for capacity control, as previously explained with respect to FIG. 8 , the controller may reduce OGC torque capacity, as represented at block 162 , without inducing a slip. Alternatively, as previously explained with respect to FIG. 8 , it may not reduce capacity, keeping the OGC locked as the transmitted torque decreases.
[0091] The controller evaluates whether the end of the torque phase is reached based upon OGC torque level using this relationship: τ off (k)<τ off,thresh , as represent by block 164 . If τ off (k) is not less than τ off,thresh, the control loop 155 is repeated. The controller then chooses the desired output shaft torque at 154 and the desired OCC torque at 156 , etc. for the next control time step k=k+1. The end of the torque phase is reached when OGC torque becomes less than a pre-specified threshold τ off,thresh . The controller releases OGC, as represent by block 166 , and moves to the inertia phase control. Equation (10) is used to determine a target OCC torque at 168 for relatively seamless output shaft torque transition from the torque phase to the inertia phase.
[0092] In executing the control strategy of the present disclosure, engine torque and input torque to the transmission are controlled accurately so that synchronization is established for clutch engagement and clutch release. At the end of the torque phase, this control will emulate the behavior of a transmission having an overrunning coupling rather than an off-going clutch, which affects a non-synchronous upshift. If the torque transition occurs too soon, the engine will tend to experience an engine speed “flare.” If the off-going clutch is released too late, the powertrain will experience a “tie up” of the clutches, which will cause a torque disturbance due to simultaneous engagement of the clutches. With the addition of the torque sensors, the duration of the torque phase may also be decreased as the sensor can give more instant feedback of the clutch torques and reduce the time needed to synchronize the clutch engagement and release. For example, FIG. 6 illustrates the torque phase being approximately 4 milliseconds, however, this time may be decreased.
[0093] The initial reduction in the capacity of an off-going clutch during the preparatory phase is made so that excessive off-going clutch capacity is avoided. It is only necessary to maintain an off-going clutch capacity to avoid slipping.
[0094] While exemplary embodiments are described above, it is not intended that these embodiments describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the disclosure. Additionally, the features of various implementing embodiments may be combined to form further embodiments of the invention.
|
A multiple ratio transmission having an input shaft, an output shaft and oncoming clutch and off-going clutch for effecting ratio upshifts is provided. The transmission also includes a transmission controller configured for controlling shifts. During the torque phase of a ratio upshift, the controller increases input torque. Next, the controller estimates an oncoming clutch target torque. The controller controls a torque input to ensure the off-going clutch remains locked. The controller measures an actual transmission value for a torque transmitting element of the transmission and corrects the oncoming clutch target torque using the actual transmission value whereby an increasing torque for the oncoming friction element is achieved with minimal torque transients along the output shaft during the upshift.
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This application is related to Application Serial No. 059,357 which was filed on June 8, 1987 now U.S. Patent No. 4,739,832.
Field of the Invention
This invention is related to the removal of fines from very viscous heavy oil.
BACKGROUND OF THE INVENTION
In the United States and Canada many formations contain very viscous oils. These oils are often removed via thermal enhanced oil recovery methods. Formation fines and particles are often entrained in the viscous oil. Because the oils are viscous, conventional gravel pack techniques can not be used to effectively remove the fines when the viscous oil is produced. Utilization of conventional gravel packs would greatly impede the flow of the viscous oils therethrough and would result in a loss of production. For this reason, these viscous oils are produced to the surface with the fines entrained therein. Once on the surface, the fines are removed from the oil and discarded.
Disposal of these fines may present an environmental problem. Several ways have been devised to utilize these fines. One way in which the fines have been utilized is for road building. To accomplish this, the fines are deposited on the roadbed. Since these fines may contain a significant amount of oil, pollution of the environment is a concern.
Therefore, what is needed is a method for disposing of fines obtained from very viscous oil which disposal will minimize environmental damage.
SUMMARY
This invention is directed to a method for disposing of fines obtained by producing very viscous hydrocarbonaceous fluids from a formation. In the practice of this invention, an aqueous slurry is made of said fines. This slurry is of a consistency sufficient to be utilized in a hydraulic fracturing fluid. Said slurry is incorporated into said fracturing fluid. Thereafter, said fracturing fluid is injected or pumped into the formation under pressure and conditions sufficient to fracture said formation. Subsequently, the formation is fractured and the recovered fines are disposed in said well.
It is therefore an object of the present invention to use formation fines in a beneficial manner so as to avoid harm to the environment.
It is another object of this invention to use a detrimental by-product to an economic advantage.
It is a yet further object of this invention to reduce harm to the environment caused by formation fines.
DESCRIPTION OF PREFERRED EMBODIMENTS
In the practice of this invention an aqueous slurry is made from formation fines. Fines which can be used herein are obtained during the recovery of substantially viscous oil from a formation. Viscous oil as defined herein are those having an API gravity of 19 degrees or less. Although the size of these fines will vary, it is preferred to use fines of a size of from about 80 to about 400 mesh U.S. Sieve. The size of the formation fines is not critical. Fresh or salt water may be used for making the slurry. Said slurry should be of a consistency sufficient to be utilized in the hydraulic fracturing fluid. Where a more viscous fracturing fluid, e.g., a gel, is to be used greater amounts of fines can be carried in a given quantity of fracturing fluid.
Once the desired consistency has been obtained, the slurry is mixed with the selected fracturing fluid. Pumping pressure is applied to the fracturing fluid with slurry therein for a time sufficient to fracture the formation when the formation conditions are considered. This pumping pressure is applied to at least one injection well which penetrates the formation. More than one injection well can be utilized if deemed necessary. One hydraulic fracturing method which can be utilized is described by Stowe et al. in U.S. Pat. No. 4,549,0608 which issued on Oct. 29, 1985. Yet another hydraulic fracturing method which can be used is one where propping material is scheduled into a formation. This method is described in U.S. Pat. No. 3,896,877 which issued to Vogt, Jr. et al. on July 29, 1975. These patents are hereby incorporated by reference.
After fracturing the formation to the extent desired, in one embodiment the pressure on the formation is released and additional fines containing slurry is pumped into the injection well for disposal. This fracturing and slurry pumping process can be repeated until the formation is unable to contain additional slurry containing fines. When this occurs, the entire process can be initiated in another well until the desired quantity of fines has been disposed of.
In another embodiment, after fracturing the formation, additional slurry with fines therein is not pumped into the injection well. Instead, a thermal oil recovery method, e.g., a steam flood is initiated. Utilizing this method allows the production of hydrocarbonaceous fluids to the surface via at least one production well. Several methods can be utilized for heating the formation. The preferred method for heating the formation is to use a steam-flood. A thermal oil recovery process wherein steam is utilized to remove viscous oil from a formation which can be employed herein is described in U.S. Pat. No. 4,598,770. This patent issued to Shu et al. on July 8, 1986 and is hereby incorporated by reference. Another thermal oil recovery method wherein steam is utilzed which can be employed herein is described in U.S. Pat. No. 4,593,759. It issued to Penick on June 10, 1986 and is incorporated by reference herein. Walton describes another thermal oil recovery process which can be used to recover hydrocarbonaceous fluids in U.S. Pat. No. 3,205,944. This patent issued on Sept. 14, 1965 and is hereby incorporated by reference. By this method hydrocarbons within the formation are auto-oxidized. Auto-oxidation occurs at a relatively low rate and the exothermic heat of reaction heats up the formation by a slow release of heat. Since during auto-oxidation, the temperature within the formation can be the ignition temperature of the hydrocarbon material within said formation, the auto-oxidation reactionis controlled to prevent combustion of the hydrocarbon material within the formation.
Obviously, many other variations and modifications of this invention as previously set forth may be made without departing from the spirit and scope of this invention as those skilled the art readily understand. Such variations and modifications are considered part of this invention and within the purview and scope of the appended claims.
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A process for disposing of fines produced with a substantially high viscosity oil. The viscosity of the oil will generally be less than 19 API degrees. Produced fines are mixed into a desired hydraulic fracturing fluid which fluid is used to fracture the formation. Once the formation has been fractured, additional fines in slurry form are pumped into the formation.
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TECHNICAL FIELD
The present invention is concerned with a novel process for the manufacture of azepines and with intermediates used in this process.
DETAILED DESCRIPTION
The present invention is concerned with a process for the manufacture of azepines of the formula ##STR2## wherein R 1 and R 2 are independently an acyl residue of an aromatic carboxylic acid.
The compounds of formula I include known, pharmacologically active compounds, for example, balanol (see Int. Patent Application WO 93/03730) and other phosphokinase inhibitors, for example, the compounds described in European Patent Application A-0 663 393. The process in accordance with the invention enables such compounds to be manufactured in a simpler and more economical manner than has been possible with previously known processes.
In the scope of the present invention, acyl residues R 1 and R 2 are selected from the group consisting of benzoic acid; benzoic acid substituted by the group selected from hydroxy, halogen, preferably fluorine, lower-alkyl and lower-alkoxy; benzoyl; and benzoyl substituted by the group selected from fluorine, lower-alkyl and lower-alkoxy. The term "lower" denotes groups with 1-6 C atoms. Compounds of formula I in which R 2 is p-hydroxybenzoyl or p-(2-fluoro-6-hydroxy-3-methoxybenzoyl)benzoyl and R 1 is p-hydroxybenzoyl or 4-hydroxy-3,5-dimethylbenzoyl are preferred. R 4 is an amino protecting group, preferably tert.-butoxycarbonyl.
In one embodiment of the present invention, the novel process for the manufacture of compounds of formula I comprises the catalytic asymmetric hydrogenation of a compound of the formula ##STR3## wherein R 3 is lower-alkyl and HX is an acid, to a compound of the formula ##STR4## Examples of acids HX for the acid addition salts of formula II and formula IV are inorganic acids, such as mineral acids, for example HCl, and organic acids, such as sulphonic acids, for example, p-toluenesulphonic acid and methanesulphonic acid.
The catalyst for the asymmetric hydrogenation is a complex of an optically active, preferably atropisomeric, diphosphine ligand with a metal of Group VIII of the periodic system, especially ruthenium. Such catalysts are described, for example, in European Patent Publication A-0 643 052.
As catalysts there come into consideration ruthenium-diphosphine complexes of the formulae
(RuL).sup.2+ (X.sup.0).sub.2 III-a
(RuLX.sup.2).sup.2+ (X.sup.0).sub.2 III-b
(RuLX.sup.1 X.sup.2).sup.+ X.sup.3 III-c
and
RuL(X.sup.4).sub.2 III-d
wherein
X 0 is selected from the group consisting of BF 4 --, ClO 4 --, B(phenyl) 4 --, SbF 6 --, PF 6 --, and Z 1 --SO 3 --;
X 1 is halide;
X 2 is benzene, hexamethylbenzene or p-cymene;
X 3 is selected from the group consisting of halide, ClO 4 --, B(phenyl) 4 --, SbF 6 --, PF 6 --, Z 1 --SO 3 -- and BF 4 --;
X 4 is selected from the group consisting of Z 2 --COO--, Z 3 --SO 3 --, allyl and CH 3 COCH═C(CH 3 )O--;
Z 1 is halogenated lower alkyl or halogenated phenyl;
Z 2 is selected from the group consisting of lower alkyl, phenyl, halogenated lower alkyl and halogenated phenyl;
Z 3 is lower alkyl or phenyl; and
L is an optically active, preferably atropiso-meric, diphosphine ligand.
Especially preferred ligands L are
MeOBIPHEP (6,6'-Dimethoxybiphenyl-2,2'-diyl)bis-(diphenylphosphine);
BIPHEMP (6,6'-Dimethylbiphenyl-2,2'-diyl)bis-(diphenylphosphine);
BINAP ((1,1'-Binaphthyl)-2,2'-diyl)bis-(diphenylphosphin);
pTol-BIPHEMP (6,6'-Dimethylbiphenyl-2,2'-diyl)bis(di-(p-tolyl)phosphine);
pAn-MeOBIPHEP 6,6'-Dimethoxy-P,P,P',P'-tetrakis-(4-methoxy-phenyl)-biphenyl-2,2'-bis-phosphine;
pDMA-MeOBIPHEP 6,6'-Dimethoxy-P,P,P',P'-tetrakis-(4-dimethylamino-phenyl)-biphenyl-2,2'-bis-phosphine;
pPhenyl-MeOBIPHEP (6,6'-Dimethoxybiphenyl-2,2'-diyl)-bis(bis-(biphenyl)-phosphine);
mTol-BIPHEMP (6,6'-Dimethylbiphenyl-2,2'-diyl)bis(di-(m-tolyl)phosphine);
Cy 2 -MeOBIPHEP P2,P2-Dicyclohexyl-6,6'-dimethoxy-P2',P2'-diphenyl-biphenyl-2,2'-bis-phosphine;
2-Furyl 2 -BIPHEMP P,P-Diphenyl-P',P'-di-2-furyl-(6,6'-dimethyl-biphenyl-2,2'-diyl)diphosphine;
(3,5-Me,4-MeO)-MeOBIPHEP 6,6'-Dimethoxy-P,P,P',P'-tetrakis-(dimethyl-4-methoxy-phenyl)-biphenyl-2,2'-bis-phosphine;
DiMeOBIPHEP (5,5',6,6'-Tetramethoxybiphenyl-2,2'-diyl)bis(diphenylphosphine);
TriMeOBIPHEP (4,4',5,5',6,6'-Hexamethoxybiphenyl-2,2'-diyl)bis(diphenylphosphine); and
2-Furyl-MeOBIPHEP (6,6'-Dimethoxybiphenyl-2,2'-diyl)bis-(di-2-furylphosphine).
These ligands are described in Patent Publications EP 643 052, EP 647 648, EP 582 692, EP 580 336, EP 690 065, EP 643 065, JP 523 9076.
Diacetoxy-ruthenium- (R)-6,6'-dimethoxybiphenyl-2,2'-diyl!bis(diphenylphosphine Ru(OAc) 2 (R)-MeOBIPHEP! is an especially preferred catalyst.
The ratio of ruthenium to ligand L in the complexes of formulae III-a to III-d is from about 0.5 mol to about 2 mol, preferably at about 1 mol of ruthenium per mol of ligand. The substrate/catalyst ratio (S/C; mol/mol) is from about 20 to about 30000, preferably from about 100 to about 5000.
The hydrogenation is carried out with the exclusion of oxygen in ethanol under an elevated pressure, for example, at pressures of from about 1 bar to about 100 bar, preferably from about 5 bar to about 70 bar, and at temperatures of from about 0° C. to about 80° C., preferably from about 20° C. to about 50° C.
The compound of formula IV is converted into a carboxylic acid compound of the formula ##STR5## wherein R 4 is a protecting group, preferably a tert.-butoxycarbonyl group. The ester group R 3 of the compound of formula IV is saponified using aqueous alkali, for example, sodium hydroxide solution, at room temperature. The carboxylic acid of formula V is then converted by known methods into an acid azide or acid amide containing compound of the formula ##STR6## wherein A is azido or amino. Subsequent degradation according to Curtius or Hofmann, yields an oxazolidone compound of the formula. ##STR7## The oxazolidone of formula VI is hydrolyzed to a compound having the formula ##STR8## in a manner known per se, for example, using aqueous-alcoholic alkali while heating to 70-90° C.
The hydroxy group and the amino group in the compound of formula VII are then acylated in a manner known per se, for example, by reaction with a reactive derivative of a carboxylic acid R 1 OH or R 2 OH, such as a mixed anhydride. When these carboxylic acids contain acylatable groups, such as OH groups, these groups are conveniently intermediately protected. Compounds of formula I in which R 1 and R 2 are different from one another can be obtained, for example, by N-acylating the amino group in the compound of formula VII selectively with 1 equivalent of R 1 OH and subsequently O-acylating with 1 equivalent of R 2 OH.
The protecting group R 4 can be removed in a manner known per se from the compound of formula VII. For example, when R 4 is tert-butoxycarbonyl group, R 4 can be removed by treatment with an acid, such as 2N HCl in a solvent such as ethyl acetate.
Another embodiment of the novel process for the manufacture of compounds of formula I, in accordance with the present invention, comprises
microbially reducing a compound of the formula ##STR9## wherein R 3 is lower alkyl and R 4 is a protecting group, to a compound having the formula ##STR10##
In principal, the reduction is not limited to a specific microorganism. Fungus strains (fungi), especially yeasts, are conveniently used as the microorganisms. An especially preferred microorganism is Hanseniaspora uvarum R 1052, especially the strain deposited on Jan. 16, 1996 at the Deutschen Sammiung von Mikroorganismen und Zelikulturen (DSMZ) under No. DSM 10 496.
The reduction of a compound III to a compound of formula IV can be carried out using intact cell cultures or using enzymes obtained from the microorganisms. The preferred microorganism, Hanseniaspora uvarum R 1052, can be cultivated in aerobic aqueous submersed cultures on usual nutrient substrates which contain carbon and nitrogen sources, for example, glucose or starch, and, respectively, soya meal, yeast extract or peptone, as well as inorganic salts, such as ammonium sulphate, sodium chloride or sodium nitrate. The cultivation can be carried out at temperatures of about 20-35° C., preferably at 27° C., in a pH range of about 3-9, preferably at about pH 5-7.
The compound of formula III is added to the culture of the microorganism in an organic solvent, for example, ethyl acetate. The course of the reduction can be followed by thin-layer chromatography of samples of the reaction medium. In general, the reaction takes about 8-12 hours. The reaction product, the compound of formula VIII, can be separated from the culture solution by extraction with a suitable organic solvent, for example, with ethyl acetate.
In the next reaction step, the compound of formula VIII is saponified, using aqueous alkali, for example, sodium hydroxide solution, at room temperature, to its corresponding carboxylic acid. The carboxylic acid is then converted using known methods into an acid azide or acid amide containing compound of the formula ##STR11## Subsequent degradation according to Curtius or Hofmann yields an oxazolidone compound of the formula ##STR12##
By alkaline hydrolysis of the oxazolidone IX, for example by using aqueous-alcoholic alkali while heating to 70-90° C., there is obtained a compound of the formula ##STR13## The hydroxy group and the amino group in the compound of formula X are then acylated in a manner known per se, for example, by reaction with a reactive derivative of a carboxylic acid R 1 COOH or R 2 COOH, such as a mixed anhydride. The compound of formula X is preferably N-acylated with an aromatic carboxylic acid of the formula R 1 COOH to a compound having the formula ##STR14## The compound of formula XI is then acylated with an aromatic carboxylic acid or a reactive derivative thereof, of the formula R 2 OH, in the presence of triphenylphosphine and diethyl azodicarboxylate, to yield a compound having the formula ##STR15##
The protecting group R 4 can be removed in a manner known per se from the compound of formula XII. For example, when R 4 is tert.-butoxycarbonyl group, R 4 can be removed by treatment with an acid, such as 2N HCl in a solvent such as ethyl acetate.
The intermediate compounds of the formulae II, IV, V, VI, VIII, VIIIa, IX, X and XI as well as the compound prepared in Example 12a and, respectively, 17 are novel and are likewise objects of the present invention.
The invention is illustrated in more detail by the following Examples, however is in no manner limited thereby. In these Examples, the abbreviations used have the following significance: "ee" is "enantiomeric excess", which is defined as percent of R-product minus percent of S-product; "dec." is "decomposition"; HPLC is high performance liquid chromatography.
EXAMPLE 1
Preparation of compounds of formula II and formula III
a) A solution of 218.3 g of di-tert-butyl dicarbonate in 250 ml of dichloromethane was added at 20-25° C. while stirring, in the course of 1 hour, to 101.2 g of piperidin-3-ol in 750 ml of dichloromethane. The reaction mixture was stirred at room temperature for a further 2 hours. Thereafter, a solution of 33.6 g of sodium bicarbonate and 11.9 g of potassium bromide in 1000 ml of deionized water was added and the reaction mixture was cooled to -2° C. After the addition of 0.39 g of 2,2,6,6-tetramethyl-piperidine 1-oxide, 560 g of 13.3% aqueous sodium hypochlorite solution were added at 0-5° C. in the course of 80 minutes. After stirring at -2° C. for a further 30 minutes, the excess sodium hypochlorite solution was added at 0-5° C. in the course of 80 minutes. After stirring at -2° C. for a further 30 minutes, the excess sodium hypochlorite was destroyed by the addition of about 10 ml of 38% aqueous sodium bisulphite solution. The reaction mixture was then warmed to 20° C. and the aqueous layer was separated and extracted with 500 ml of dichloromethane. Both organic phases were washed with 500 ml of 10% sodium chloride solution, combined and dried over sodium sulphate. After filtration and removal of the solvent under reduced pressure the oily residue was purified by distillation under reduced pressure which yielded 191.2 g of tert-butyl 3-oxo-piperidine-1-carboxylate as a colorless oil, boiling point 80-82° C./0.01 mbar.
b) 99.6 g of the compound obtained in paragraph a) were dissolved in 600 ml of diethyl ether. The solution was cooled to -70° C. and the white suspension was treated simultaneously and dropwise in the course of 1 hour with solutions of 62.0 ml of ethyl diazoacetate in 125 ml of diethyl ether and 69.0 ml of boron trifluoride etherate in 125 ml of diethyl ether, with the internal temperature being held at -70° C. After stirring at -70° C. for a further 1 hour the cooling bath was removed, the reaction mixture was warmed to 0° C. and treated with 375 ml of 10% sodium carbonate solution. The aqueous phase was separated and extracted with 250 ml of diethyl ether. The organic phases were washed with 250 ml of 10% sodium chloride solution, combined and dried over sodium sulphate. The solvent was removed under reduced pressure at 30° C. yielding ethyl 1-(tert-butoxycarbonyl)-4-oxo-azepan-3-carboxylate as a crude product in the form of a yellow oil, which was used in the next step without further purification.
c) 147.2 g of the product obtained in paragraph b) were dissolved in 1250 ml of dioxan and seeded with 0.1 g of ethyl 4-oxo-azepan-3-carboxylate hydrobromide. Thereafter, 175 ml of 5.7M HBr/ethyl acetate were added at room temperature, while stirring, in the course of 25 minutes. After further seeding with 0.1 g of ethyl 4-oxo-azepan-3-carboxylate hydrobromide, the suspension was stirred at room temperature for 5 hours. The crystals were filtered off, washed with ethyl acetate and dried at 50° C. and 25 mbar. The resulting 91.0 g of crude ethyl 4-oxo-azepan-3-carboxylate hydrobromide was dissolved in 1250 ml of 2-butanone while stirring and heating under reflux. The solution was cooled to 65° C. and seeded with 0.1 g of pure ethyl 4-oxo-azepan-3-carboxylate hydrochloride. After cooling to room temperature, the suspension was stirred at room temperature for 1 hour and at 0° C. for 3 hours. The crystals were filtered off, washed with 200 ml of 2-butanone (cooled to -10° C.) and dried at 50° C. and 25 mbar, yielding 68.2 g of white ethyl 4-oxo-azepan-3-carboxylate hydrobromide, melting point 127-130° C. (dec.).
d) 59.4 g of the compound obtained in paragraph b) were dissolved in 1000 ml of 1M HCl in dioxan and stirred at room temperature for 24 hours. After a reaction period of 1.5 hours the solution was seeded with about 25 mg of ethyl 4-oxo-azepan-3-carboxylate hydrochloride. The white suspension was filtered, washed with dioxan and dried at 50° C. and 25 mbar, yielding 31.3 g of ethyl 4-oxo-azepan-3-carboxylate hydrochloride in the form of white crystals, which contained about 0.4 mol of dioxan per mol of hydrochloride according to the NMR spectrum. The hydrochloride was recrystallized for further purification and in order to remove the dioxan. 31.3 g of ethyl 4-oxo-azepan-3-carboxylate hydrochloride were dissolved in 600 ml of 2-butanol at 80° C. and the solution was cooled to -20° C. in the course of 2 hours and stirred at -20° C. for 3 hours. The white suspension was filtered, washed with 2-butanol (cooled to -20° C.) and dried at 50° C. and 25 mbar to yield 22.9 g of ethyl 4-oxo-azepan-3-carboxylate hydrochloride in the form of white crystals, melting point 145-148° C. (dec.).
EXAMPLE 2
75.0 g of ethyl 4-oxo-azepan-3-carboxylate hydrochloride and 800 ml of ethanol were introduced into an autoclave. The autoclave was closed and the air was removed therefrom by repeated evacuation to about 0.1 bar and pressurization with argon (7 bar) and hydrogen (40 bar) while stirring. Thereafter, a solution of 226 mg of diacetoxy-rhuthenium (R)-6,6'-dimethoxybiphenyl-2,2-diyl)-bis(diphenylphosphine) in 20 ml of ethanol was fed into the autoclave at 2 bar hydrogen pressure with the exclusion of oxygen. Thereafter, hydrogen pressure was increased to 40 bar and the reaction mixture was hydrogenated while stirring at 30° C. for 19 hours and at 50° C. for 3 hours. Thereafter, the content of the autoclave was washed out with 200 ml of ethanol and the combined solutions were evaporated at 50° C./100 mbar and the brown residue was dried for 2 hours. The residue (75.9 g, consisting of about 80% 3R,4R and 20% 3S,4R isomers) was triturated with 450 ml of tetrahydrofuran at 24° C. for 19 hours and at 16° C. for 1 hour. The crystals were filtered off under suction, washed with tetrahydrofuran and dried to constant weight at 50° C./20 mbar for 3.5 hours. There were obtained 56.3 g of light beige crystals, which were again triturated with 225 ml of tetrahydrofuran as previously described. The crystals were removed by suction filtration and dried, yielding 55.1 g of ethyl (3R,4R)-4-hydroxy-azepan-3-carboxylate hydrobromide in the form of white crystals, which were enantiomerically pure according to HPLC.
EXAMPLE 3
As in Example 2, 23.2 g of ethyl 4-oxo-azepan-3-carboxylate hydrochloride in 90 ml of ethanol were hydrogenated with a solution of 36.1 mg of the ruthenium catalyst in 10 ml of ethanol under 40 bar hydrogen pressure at 30° C. for 21 hours and at 50° C. for 3 hours. The residue, consisting of about 80% 3R,4R and 20% 3S,4R isomers, was triturated with tetrahydrofuran and ethanol at 50° C. for half an hour and at room temperature for 4 hours. The crystals were filtered off under suction, washed with a small amount of tetrahydrofuran/ethanol and dried to constant weight at 50° C./20 mbar, to yield 13.3 g of enantiomerically pure ethyl (3R,4R)-4-hydroxy-azepan-3-carboxylate hydrochloride in the form of white crystals.
EXAMPLE 4
As in Example 2, 0.44 g of ethyl 4-oxo-azepan-3-carboxylate hydrochloride in 9 ml of ethanol was hydrogenated with a solution of 3.2 mg of di(η 2 -acetato)(η 4 -cycloocta-1,5-diene)-ruthenium(II) and 5.8 mg (R)-MeOBIPHEP in 1 ml of diethyl ether/THF 3/1 under 40 bar hydrogen pressure at 25° C. for 23.5 hours. The yellow hydrogenation solution was evaporated on a rotary evaporator at 40°/20 mbar. With a conversion of 83%, the residue consisted, according to HPLC analysis, of 65% ethyl (3R,4R)-4-hydroxy-azepan-3-carboxylate hydrochloride with an ee>99%.
EXAMPLE 5
The hydrogenations set forth in Table 1 were carried out in an analogous manner to Examples 2-4.
TABLE 1__________________________________________________________________________Asymmetric hydrogenation of ethyl 4-oxo-azepan-3-carboxylate.HX.sup.1)Ex T Press. Conv./ trans.sup.3) cisNo L X Solv. ° C. bar hr % ee % ee__________________________________________________________________________5a (S)--BINAP Cl 2) 25 40 62/23 78 >99 22 735b (R)-BIPHEMP Cl 2) 25 40 90/23 66 94 34 385c (R)-pToI- Cl 2) 25 40 93/23 72 >99 28 62 BIPHEMP5d (R)-p-An- Cl 2) 25 40 87/23 80 >99 20 77 MeOBIPHEP5e (R)-mToI- Cl 2) 25 40 90/24 58 97 42 47 BIPHEMP5f (R)-pDMA- Cl 2) 25 40 79/24 72 >99 28 95 MeOBIPHEP5g (R)-pPhenyl- Cl 2) 25 40 54/23 82 >99 18 26 MeOBIPHEP5h (S)-3,5-Me,4- Cl 2) 25 40 34/23 55 >99 45 61 MeO-MeOBIPHEP5i (R)-DiMeOBIPHEP Cl 2) 25 40 99/23 66 >99 34 865j (R)-MeOBIPHEP Br EtOH 40 100 99/21 76 >99 24 845k " Br EtOH 60 100 100/21 69 >99 31 855l (R)-2-Furyl- Br EtOH 40 100 76/29 64 98 36 95 MeOBIPHEP5m (R)-2-Furyl-2- Br EtOH 40 100 94/21 68 >99 32 69 Biphemp5n (R)-TriMeOBIPHEP Br EtOH 30 100 100/23 76 >99 24 955o (R)-Cy2- Cl EtOH 80 20 100/22 38 >99 62 92 MeOBIPHEP5p (R)-MeOBIPHEP Cl MeOH 30 100 100/22 75 >99 25 885q " Cl iPrOH " " 90/22 78 >99 22 845r " Cl AoOH 25 40 97/23 5 >99 95 94__________________________________________________________________________ .sup.1) Catalyst preparation analogously to Example 2 and 3. .sup.2) Catalyst preparation: in situ analogously to Example 4, solvent: ethanoldiethyl ethertetrahydrofuran 9:0.65:0.35. .sup.3) trans: compound IV or its enantiomer. Chiral diphosphine ligands with (R)configuration give (3R,4R)IV.
EXAMPLE 6
As in Example 3, 3.32 g of ethyl 4-oxo-azepan-3-carboxylate hydrochloride were hydrogenated in the presence of 6.3 mg of RuCl((R)-MeOBIPHEP)(C6H6)!Cl under 40 bar hydrogen pressure at 30° C. for 19 hours and at 50° for 3 hours. The yellow hydrogenation solution was evaporated on a rotary evaporator at 40°/20 mbar. With a conversion of 95% the residue consisted, according to HPLC analysis, of 79% ethyl (3R,4R)-4-hydroxy-azepan-3-carboxylate with an ee>99%.
EXAMPLE 7
A catalyst solution was prepared in a glove box (O 2 content<1 ppm) by dissolving 1.3 ml of a 0.03 molar ethanolic HBr solution and 16.1 mg of Ru(OAc)2((R)-MeOBIPHEP) in 10 ml of ethanol and stirring for 0.5 hour. Then, 0.53 g of ethyl 4-oxo-azepan-3-carboxylate hydrobromide and 2 ml of the catalyst solution prepared above were placed in 4 ml of ethanol in an autoclave and hydrogenated at 20° C. under 100 bar hydrogen pressure for 21 hours. The yellow hydrogenation solution was evaporated on a rotary evaporator at 40°/20 mbar. With a conversion of 76%, the residue consisted, according to HPLC analysis, of 58% ethyl (3R,4R)-4-hydroxy-azepan-3-carboxylate hydrobromide with an ee>99%.
EXAMPLE 8
A catalyst solution was prepared in a glove box (O 2 content<1 ppm) by dissolving 1.0 ml of a 0.04 molar ethanolic HBF4 solution and 32.1 mg of Ru(OAc)2((R)-MeOBIPHEP) in 10 ml of ethanol and stirring for 0.5 hour. Then, 0.53 g of ethyl 4-oxo-azepan-3-carboxylate hydrobromide and 1 ml of the catalyst solution prepared above were placed in 9 ml of ethanol in an autoclave and hydrogenated at 20° C. under 100 bar hydrogen pressure for 21 hours. The yellow hydrogenation solution was evaporated on a rotary evaporator at 40°/20 mbar. With a conversion of 44% the residue consisted according to HPLC analysis of 37% ethyl (3R,4R)-4-hydroxy-azepan-3-carboxylate hydrobromide with an ee>99%.
EXAMPLE 9
67.0 g of ethyl (3R,4)-4-hydroxy-azepan-3-carboxylate hydrobromide were suspended in 500 ml of tert-butyl methyl ether and treated with 30.4 g of triethylamine. Thereafter, a solution of 54.6 g of di-tert-butyl dicarbonate in 25 ml of tert-butyl methyl ether was added at room temperature in the course of 20 minutes. Thereafter, the mixture was stirred at room temperature for a further 2 hours.
500 ml of 2N NaOH were added to the white suspension and the reaction mixture was stirred vigorously at room temperature for 2 hours. The reaction mixture was then acidified with 175 ml of 6N HCl and, after phase separation, the aqueous phase was extracted twice with 100 ml of tert-butyl methyl ether. All organic phases were washed with 150 ml of 10% sodium chloride solution, combined and dried over sodium sulphate. After removal of the solvent under reduced pressure at 40° C. the crude hydroxyacid was dissolved in 260 ml of butyl acetate at about 85° C. After seeding with pure product the suspension was cooled to -20° C. in the course of 2 hours and stirred at this temperature overnight. The suspension was filtered, washed with 100 ml of hexane and dried at 50° C. and 25 mbar, yielding 55.9 g of (3R,4R)-4-hydroxy-azepan-1,3-dicarboxylic acid 1-tert-butyl ester, melting point 121.5-122.5° C.
EXAMPLE 10
300 ml of ethyl acetate and 20.9 ml of triethylamine were added to 38.9 g of the compound prepared in Example 9. The solution was heated to reflux, then 32.4 ml of diphenylphosphoryl azide were added in the course of 30 minutes and the heating under reflux was continued for a further 2 hours. After cooling to room temperature the reaction mixture was treated with 300 ml of ethyl acetate and washed with 150 ml of 5% sodium hydrogen carbonate solution and twice with 150 ml of water. The aqueous phases were extracted twice with 300 ml of ethyl acetate. The combined organic phases were dried over sodium sulphate and evaporated at 45° C. under reduced pressure. The crude crystalline residue was dissolved in 300 ml of butyl acetate, seeded with pure product, cooled to -20° C. in the course of about 3 hours and stirred overnight. The suspension was filtered, washed with butyl acetate (pre-cooled to -20° C.) and dried at 60° C. and 25 mbar to yield 29.9 g of (3aR,8aR)-5-tert-butoxycarbonyl-2-oxo-octahydro-oxazolo 4,b-c!azepine, melting point 152.5-153.5° C.
EXAMPLE 11
25.6 g of the compound prepared in Example 10 were added to 250 ml of methanol and 250 ml of 2N NaOH. The reaction mixture was heated to reflux and held at this temperature for 3 hours. After cooling, 265 ml of solvent were distilled off at 50° C. and 150 mbar and the residue was extracted three times with 200 ml of ethyl acetate each time. The three organic phases were washed with 50 ml of 10% sodium chloride solution, combined and dried over sodium sulphate. After removal of the solvent the viscous oil obtained as the residue was dissolved in 100 ml of cyclohexane at 60° C., seeded with pure product, cooled to room temperature in the course of 2 hours and stirred overnight. The suspension was filtered, washed with 40 ml of cyclohexane and dried at 50° C. and 25 mbar, yielding 21.5 g of tert-butyl (3R,4R)-3-amino-4-hydroxy-azepan-1-carboxylate, melting point 99-100.5° C.
EXAMPLE 12
a) 4.58 g of p-toluenesulphonyl chloride dissolved in 24 ml of dichloromethane were added at room temperature in the course of 10 minutes to 4.66 g of 4-tert-butoxybenzoic acid and 6.11 g of 4-dimethylaminopyridine in 30 ml of dichloromethane. After stirring at room temperature for 2 hours, 2.30 g of the compound prepared in Example 6 in 6 ml of dichloromethane were added in the course of 10 minutes. Thereafter, the mixture was stirred at room temperature for 16 hours. The reaction mixture was washed twice with 20 ml of 1N NaOH each time and then with 40 ml of 1N HCl and 40 ml of water. All aqueous phases were extracted with 20 ml of dichloromethane. The combined organic phases were dried over sodium sulphate and the solvent was removed under reduced pressure. The residual white foam was chromatographed over 300 g of silica gel with 6.5 l of hexane-ethyl acetate (2:1). Fractions of 250 ml were collected. Fractions 8-25 were combined and the solvent was evaporated under reduced pressure, there being obtained 5.91 g of a white foam which was dissolved in 80 ml of heptane at 60° C. After stirring at -20° C. overnight the crystals were filtered off, washed with cold heptane and dried at 50° C. and 25 mbar to yield 5.34 g of tert-butyl (3R,4R)-3-(4-tert-butoxy-benzoylamino)-4-(4-tert-butoxy-benzoyloxy)-azepan-1-carboxylate, melting point 125.5-127.5° C.
b) 20.0 ml of 5M HCl in ethyl acetate were added at room temperature and while stirring to 5.83 g of the compound obtained in paragraph a) dissolved in 30 ml of ethyl acetate. The reaction mixture was stirred at room temperature overnight and the white precipitate was filtered off and washed three times with 5 ml of ethyl acetate each time and dried at 50° C./25 mbar for 16 hours. The white powder obtained was dissolved in 50 ml of water and stirred at 50° C. for 1 hour. The solution was then lyophilized and yielded 3.97 g of pure 3-(4-hydroxy-benzoylamino)-4-(4-hydroxy-benzoyloxy)-hexahydroazepine hydrochloride.
EXAMPLE 13
Hanseniaspora uvarum R 1052 was cultivated for 3 days at 27° C. in a Petri dish containing a solid nutrient substrate. After 3 days, 100 ml of liquid nutrient medium in a 500 ml shaking flask was seeded with a loop of this culture. This pre-culture was shaken at 27° C. for 18 hours. The cells grew to a density of 5×10 8 cells/ml (stationary phase). The entire pre-culture was used to inoculate a reactor which contained 7500 ml of nutrient medium (containing 1 % yeast extract Difco: Bacto Yeast Extract # 0127-17-9, 1% Pepton Difco: Bacto Peptone # 0118-17-0 and 2% glucose in deionized water). After 18 hours, 750 ml of 50% glucose solution and immediately thereafter 29 g of the compound prepared in Example 1b dissolved in 20 ml of ethyl acetate were added in the course of 25 minutes. After 12 hours the culture solution was extracted twice with 2000 ml of ethyl acetate each time. The combined organic phases were dried over sodium sulphate. The solvent was removed under reduced pressure at 30° C. to yield 30.1 g of ethyl (3R,4S)-1-(tert-butoxycarbonyl)-4-hydroxy-azepan-3-carboxylate as a viscous orange oil.
EXAMPLE 14
a) A mixture of 28.7 g of the compound prepared in Example 13 in 200 ml of tert-butyl methyl ether and 200 ml of 2N NaOH was stirred vigorously at room temperature for 4 hours and then at 50° C. for 20 hours. After cooling, the aqueous phase was extracted twice with 100 ml of tert-butyl methyl ether each time. The organic phases were discarded. The aqueous phase was acidified cautiously with about 70 ml of 6N HCl and extracted once with 200 ml of tert-butyl methyl ether and twice with 100 ml of tert-butyl methyl ether each time. All three organic phases were washed once with 50 ml of 10% sodium chloride solution, combined and dried over sodium sulphate. After removal of the solvent under reduced pressure (40° C./25 mbar) the brown viscous oil was dissolved in 60 ml of isopropyl ether at 60° C. and left to crystallize at -20° C. for 16 hours. The crystals were filtered off, washed with a small amount of isopropyl ether, cooled to -20° C. and dried at 40° C. for hours and 25 mbar, yielding 12.0 g of (3R,4S)-4-hydroxy-azepan-1,3-dicarboxylic acid 1-tert-butyl ester of melting point 98.5-101.5° C.
b) 140 ml of ethyl acetate, 9.8 ml of triethylamine and 15.9 ml of diphenylphosphoryl azide were added to 18.1 g of the compound obtained in paragraph a). The solution was heated to reflux for 2 hours, cooled, diluted with 140 ml of ethyl acetate and washed with 70 ml of 5% sodium hydrogen carbonate solution and twice with 70 ml of water each time. The three aqueous phases were separated and washed three times with 140 ml of ethyl acetate. The combined organic phases were dried over sodium sulphate and the solvent was removed at 45° C./25 mbar. The crude crystalline residue was dissolved in 140 ml of butyl acetate at about 80° C., seeded with pure product, cooled and stirred at -20° C. for 6 hours. The suspension was filtered, washed with butyl acetate (cooled to -20° C.) and dried at 60° C. and 25 mbar overnight, to yield 13.3 g of tert-butyl (3aR,8aS)-2-oxo-octahydro-oxazolo 4,b-c!azepine-5-carboxylate of melting point 158-159° C.
EXAMPLE 15
200 ml of methanol and 200 ml of 2N NaOH were added to 20.5 g of the compound prepared in Example 14b). The reaction mixture was heated to reflux and left at this temperature for 4 hours. After cooling, 200 ml of methanol were distilled off at 50° C. and 150 mbar and the residue was extracted three times with 160 ml of ethyl acetate each time. The organic phases were washed with 40 ml of 10% sodium chloride solution, combined and dried over sodium sulphate. After removal of the solvent, the viscous oil obtained as the residue was dissolved in 80 ml of methylcyclohexane at 50° C., seeded with pure product, cooled and stirred at 0° C. for 4 hours. The crystals were filtered off, washed with 20 ml of methylcyclohexane and dried at 50° C. and 25 mbar overnight, yielding 17.4 g of tert-butyl (3R,4S)-3-amino-4-hydroxy-azepan-1-carboxylate, melting point 64-67° C.
EXAMPLE 16
9.06 g of p-toluenesulphonyl chloride in 75 ml of dichloromethane were added at room temperature to 11.5 g of 4-(tert-butoxy)-benzoic acid and 13.1 g of 4-dimethylaminopyridine in 100 ml of dichloromethane. The reaction mixture was stirred for a further 2 hours. The solution was then added in the course of 1 hour to 11.5 g of the compound prepared in Example 10 dissolved in 50 ml of dichloromethane. After stirring at room temperature for 1 hour, the reaction mixture was washed with 100 ml of 1N NaOH, 100 ml of 1N HCl and 100 ml of water. All aqueous phases were extracted with 50 ml of dichloromethane. The combined organic phases were dried over sodium sulphate and the solvent was separated under reduced pressure. The foam-like residue was dissolved in 400 ml of hot heptane and left to crystallize at room temperature overnight. The crystals were washed with 25 ml of heptane and dried at 50°/25 mbar to yield 17.3 g of tert-butyl (3R,4S)-3-(4-tert-butoxy-benzoylamino)-4-hydroxy-azepan-1-carboxylate of melting point 131.5-132.5° C.
EXAMPLE 17
262 mg of diethyl azadicarboxylate in 2 ml of tetrahydrofuran were added while stirring to 407 mg of the compound prepared in Example 16, 253 mg of 4-(tert-butoxy)-benzoic acid and 394 g of triphenylphosphine in 8 ml of tetrahydrofuran. After stirring at 50° C. for 4hours, the solvent was removed under reduced pressure and the residue was taken up in 20 ml of cyclohexane and washed once with 20 ml of water and twice with 10 ml of 70% methanol/water each time. The aqueous-alcoholic phase was extracted twice with 10 ml of cyclohexane each time. The combined cyclohexane phases were dried over sodium sulphate and the solvent was removed under reduced pressure. The residual viscous oil was dissolved in 10 ml of hot heptane, seeded with pure end product and left to crystallize at room temperature for 18 hours and yielded 241 mg of tert-butyl (3R,4R)-3-(4-tert-butoxy-benzoylamino)-4-(4-tert-butoxy-benzoyloxy)-azepan-1-carboxylate of melting point 126-128° C. This compound can be reacted further as in Example 12b.
EXAMPLE 18
12.91 g of p-toluenesulphonyl chloride dissolved in 15 ml of dichloromethane were added at room temperature in the course of 15 minutes to 1.94 g of 4-(tert-butoxy)-benzoic acid and 2.63 g of 4-dimethylaminopyridine in 20 ml of dichloromethane. The reaction mixture was stirred for 2 hours and added in the course of 1 hour to 2.30 g of tert-butyl (3R,4R)-3-amino-4-hydroxy-azepan-1-carboxylate dissolved in 10 ml of dichloromethane. After stirring for 1 hour the reaction mixture was washed with 20 ml of 1N NaOH, 20 ml of 1N HCl and 20 ml of water. All aqueous phases were washed in succession with 10 ml of dichloromethane. The combined organic phases were dried over sodium sulphate, filtered and the solvent was evaporated. The foam-like residue obtained was dissolved in 80 ml of hot heptane and crystallized at room temperature overnight. The crystals were washed with 10 ml of heptane and dried to yield 3.23 g of tert-butyl (3R,4R)-3-(4-tert-butoxy-benzoylamino)-4-hydroxy-azepan-1-carboxylate, m.p. 134-135° C.
EXAMPLE 19
572 mg of p-toluenesulphonyl chloride in 3.5 ml of dichloromethane were added at room temperature in the course of 10 minutes to 679 mg of 4-benzoyl-benzoic acid and 764 mg of 4-dimethylaminopyridine in 5 ml of dichloromethane. After further stirring at room temperature for 2 hours 1016 mg of tert-butyl (3R,4R)-3-(4-tert-butoxy-benzoylamino)-4-hydroxy-azepan-1-carboxylate in 2.5 ml of dichloromethane were added in the course of 10 minutes while stirring. Thereafter, the reaction mixture was stirred at room temperature for a further 2.5 hours and washed with 6 ml of 1N NaOH, 6 ml of 1N HCl and 6 ml of water. All aqueous phases were extracted in succession with 6 ml of dichloromethane. The combined organic phases were dried over sodium sulphate and the solvent was evaporated. The crude product was chromatographed over 100 g of silica gel with 1.41 of hexane/ethyl acetate (2:1). Fractions of 100 ml were collected. Fractions 5-9 were combined and the solvent was evaporated. There were obtained 1.48 g of a white foam, which was crystallized from 50 ml of hot heptane, to yield 1.24 g of tert-butyl (3R,4R)-3-(4-tert-butoxy-benzoylamino)-4-(4-benzoyl-benzoyloxy)-azepan-1-carboxylate, m.p. 145-148° C., as a white powder.
EXAMPLE 20
3.0 ml of 5N HCl in ethyl acetate were added at room temperature while stirring to 922 mg of the azepine prepared in Example 19 in 4.0 ml of ethyl acetate. The reaction mixture was stirred at room temperature overnight and the precipitate was filtered off, washed three times with 2 ml of ethyl acetate and dried at 50° C./25 mbar for 16 hours yielding 0.70 g of 3-(4-hydroxy-benzoylamino)-4-(4-benzoyl-benzoyloxy)-hexahydroazepine hydrochloride.
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A novel process for the manufacture of compounds of the formula ##STR1## wherein R 1 and R 2 independently represent aroyl. The present invention also concerns novel intermediates used in the novel process for making compounds of formula I.
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CROSS-REFERENCE TO RELATED APPLICATION
This application claims priority from Japanese Patent Application No. 2014-071835, filed on Mar. 31, 2014, which is incorporated herein by reference in its entirety.
TECHNICAL FIELD
Aspects described herein relate to a photosensitive body cartridge for an electrophotographic image forming apparatus.
BACKGROUND
A known image forming apparatus includes a printer that includes a photosensitive drum and a scraper roller for scraping and collecting foreign matter adhering to a surface of a photosensitive drum.
In such a printer, a drum gear is attached to an end portion of a shaft of the photosensitive drum, and a scraper-roller gear is attached to a rotating shaft of the scraper roller. A driving force is transmitted from the drum gear to the scraper-roller gear via a plurality of idle gears. A peripheral speed of the scraper roller relative to the photosensitive drum is increased to collect or remove foreign matter from the surface of the photosensitive drum effectively.
SUMMARY
In a first example aspect, a drum cartridge includes a photosensitive drum rotatable about an axis, a first cleaning roller including a first shaft extending in a direction extending along the axis, and a second cleaning roller including a second shaft extending in the direction, the second cleaning roller including a surface contacting a surface of the first cleaning roller, the second cleaning roller spaced apart from the photosensitive drum. The drum cartridge further includes a bearing through which the first shaft and the second shaft are inserted, a first cleaning gear rotatable with the first cleaning roller, and a second cleaning gear rotatable with the second cleaning roller and meshing with the first cleaning gear. The drum cartridge further includes a drum gear being rotatable with the photosensitive drum, a first idle gear meshing with the drum gear, and a second idle gear meshing with the first idle gear. The drum cartridge includes a coupling joining the second cleaning gear and the second idle gear, the coupling being rotatable in unison with the second cleaning gear and the second idle gear
In a further example aspect, a method is disclosed that includes receiving, at a drum gear, a first rotational force applying a first rotational speed to a photosensitive drum, and transmitting a second rotational force to a first cleaning gear to rotate a first cleaning roller at a second rotational speed. Transmitting the second rotational force to the first cleaning roller includes rotating a first idle gear in response to rotation of the drum gear, the first idle gear engaged by the drum gear, rotating a second idle gear in response to rotation of the first idle gear, the second idle gear engaged by the first idle gear, rotating a second cleaning gear rotationally coupled to the second idle gear, and applying the second rotational force to the first cleaning gear from the second cleaning gear.
A variety of additional aspects will be set forth in the description that follows. The aspects can relate to individual features and to combinations of features. It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the broad inventive concepts upon which the embodiments disclosed herein are based.
DESCRIPTION OF THE DRAWINGS
For a more complete understanding of the present disclosure, needs satisfied thereby, and the objects, features, and advantages thereof, reference now is made to the following descriptions taken in connection with the accompanying drawings.
FIG. 1 is a central cross-sectional view depicting a drum cartridge in an illustrative embodiment according to one or more aspects of the disclosure.
FIG. 2 is a central cross-sectional view depicting an image forming apparatus in which the drum cartridge depicted in FIG. 1 is installed in the illustrative embodiment according to one or more aspects of the disclosure.
FIG. 3 is a perspective view depicting the drum cartridge depicted in FIG. 1 as viewed from the left rear in the illustrative embodiment according to one or more aspects of the disclosure.
FIG. 4A is a right side view depicting a rear portion of the drum cartridge depicted in FIG. 1 in the illustrative embodiment according to one or more aspects of the disclosure, wherein a pair of release levers is located at a first position.
FIG. 4B is a side sectional view depicting of the rear portion of the drum cartridge depicted in FIG. 1 in the illustrative embodiment according to one or more aspects of the disclosure, wherein the pair of release levers is located at the first position.
FIG. 5A is a right side view depicting of the rear portion of the drum cartridge depicted in FIG. 1 in the illustrative embodiment according to one or more aspects of the disclosure, wherein the pair of release levers is located at a second position.
FIG. 5B is a side sectional view depicting of the rear portion of the drum cartridge depicted in FIG. 1 in the illustrative embodiment according to one or more aspects of the disclosure, wherein the pair of release levers is located at the second position.
FIG. 6 is a cross-sectional view taken along line A-A in FIG. 4A in the illustrative embodiment according to one or more aspects of the disclosure.
FIG. 7A is a partial perspective view depicting the drum cartridge depicted in FIG. 1 as viewed from the right front in the illustrative embodiment according to one or more aspects of the disclosure, wherein a cover frame is removed from the drum cartridge.
FIG. 7B is a cross sectional view of FIG. 7A , passing through the centers of first and second rollers in their diametric directions in the illustrative embodiment according to one or more aspects of the disclosure, wherein a base frame is omitted for convenience in drawing.
FIG. 8A is a perspective view depicting a first electrode and a second electrode depicted in FIG. 7A as viewed from the right rear in the illustrative embodiment according to one or more aspects of the disclosure.
FIG. 8B is a perspective view depicting the first electrode and the second electrode depicted in FIG. 7A as viewed from the left front in the illustrative embodiment according to one or more aspects of the disclosure.
FIG. 9 is a disassembled perspective view depicting a drive unit depicted in FIG. 3 as viewed from the upper right in the illustrative embodiment according to one or more aspects of the disclosure.
FIG. 10 is a disassembled perspective view depicting the drive unit depicted in FIG. 3 as viewed from the right rear in the illustrative embodiment according to one or more aspects of the disclosure, wherein a drum frame is omitted for convenience in drawing.
FIG. 11A is a right side sectional view depicting the drive unit depicted in FIG. 3 in the illustrative embodiment according to one or more aspects of the disclosure.
FIG. 11B is a top plan view depicting a power transmission mechanism depicted in FIG. 11A in the illustrative embodiment according to one or more aspects of the disclosure, wherein a drum frame and a gear holder are omitted for convenience in drawing.
FIG. 12 is a perspective view depicting the drum cartridge depicted in FIG. 1 as viewed from the left rear in the illustrative embodiment according to one or more aspects of the disclosure.
FIG. 13A illustrates an initial state of the drum cartridge depicted in FIG. 1 with respect to a main body of the image forming apparatus in a procedure to install the drum cartridge in the main body in the illustrative embodiment according to one or more aspects of the disclosure.
FIG. 13B illustrates an intermediate state of the drum cartridge with respect to the main body in the installation procedure, subsequent to the initial state depicted in FIG. 13A , in the illustrative embodiment according to one or more aspects of the disclosure.
FIG. 14A illustrates an intermediate state of the drum cartridge with respect to the main body in the installation procedure, subsequent to the initial state depicted in FIG. 13B , in the illustrative embodiment according to one or more aspects of the disclosure.
FIG. 14B illustrates a state of the drum cartridge with respect to the main body in the installation procedure at the time of completion of the installation of the drum cartridge in the main body in the illustrative embodiment according to one or more aspects of the disclosure.
DETAILED DESCRIPTION
In general, the present disclosure relates to a photosensitive body cartridge useable in an electrophotographic image forming apparatus.
In a known printer, the scraper roller may be configured to come into contact with and move away from the photosensitive drum. The scraper roller may be urged toward the photosensitive drum by an urging spring. With this configuration, while the scraper roller is allowed to move slightly away from the photosensitive drum, the photosensitive drum and the scraper roller are in contact with each other at all times. Nevertheless, due to slight movement of the scraper roller away from the photosensitive drum, a state of engagement of teeth of any two gears disposed between the drum gear and the scraper roller gear in the gear train may be changed. This may cause variation in the peripheral speed of the scraper roller relative to the photosensitive drum, whereby foreign matter adhering to the surface of the photosensitive drum might not be removed therefrom evenly. However, some embodiments of the disclosure address such issues by providing a drum cartridge in which cleaning is performed on a surface of a photosensitive drum with stability and certainty. In the drum cartridge according to some aspects of the disclosure, cleaning may be performed on the surface of the photosensitive drum with stably and certainty. Such features can be accomplished, for example, via use of a coupling provided between gears provided in the drum cartridge that accommodates such movement of a roller.
1. Overview of Drum Cartridge
As depicted in FIG. 1 , a drum cartridge 1 has a generally rectangular frame shape having a bottom in plan view. The drum cartridge 1 is an example of a photosensitive body cartridge. The drum cartridge 1 includes a photosensitive drum 2 , a scorotron charger 3 , a transfer roller 4 , and a cleaning unit 5 .
In the description below, the side on which the photosensitive drum 2 is disposed in the drum cartridge 1 is defined as the rear of the drum cartridge 1 and the opposite side of the drum cartridge 1 is defined as the front of the drum cartridge 1 . The right and left of the drum cartridge 1 are defined with reference to the front of the drum cartridge 1 . More specifically, the orientation of the drum cartridge 1 is defined with reference to directional arrows appended in each drawing.
As depicted in FIG. 4B , a direction that a pair of roller shaft guides 201 extends, hereinafter, is referred to as “extending direction”. As depicted in FIG. 13A , a direction that the drum cartridge 1 is attached to and detached from the main body 12 , hereinafter, is referred to as “attaching and detaching direction”.
The photosensitive drum 2 has a generally cylindrical shape extending in the right-left direction. The photosensitive drum 2 is supported at a rear end portion of the drum cartridge 1 .
The scorotron charger 3 is disposed above the photosensitive drum 2 and is spaced apart from the photosensitive drum 2 .
The transfer roller 4 is disposed below the photosensitive drum 2 . The transfer roller 4 is in contact with a lower surface of photosensitive drum 2 .
The cleaning unit 5 is disposed behind the photosensitive drum 2 . The cleaning unit 5 includes a first roller 6 , a second roller 7 , a sponge scraper 8 , and a storage 9 . The first roller 6 is an example of a first cleaning roller. The second roller 7 is an example of a second cleaning roller.
The first roller 6 is disposed above and behind the photosensitive drum 2 . The first roller 6 is in contact with an upper rear surface of the photosensitive drum 2 .
The second roller 7 is disposed above and behind the first roller 6 . The second roller 7 is in contact with an upper rear surface of the first roller 6 .
The sponge scraper 8 is disposed above the second roller 7 . The sponge scraper 8 is in contact with an upper surface of the second roller 7 .
The storage 9 has a generally box shape with its upper front portion opened. The storage 9 is disposed below the second roller 7 .
2. Usage of Drum Cartridge
As depicted in FIG. 2 , the drum cartridge 1 is installed in an image forming apparatus 11 and used therein.
The image forming apparatus 11 may be an electrophotographic monochrome printer. The image forming apparatus 11 includes a main body 12 , a process cartridge 13 , a scanner unit 14 , and a fixing unit 15 . The main body 12 is an example of an apparatus body.
The main body 12 has a generally box shape. The main body 12 has an opening 16 defined therein and includes a front cover 17 , a sheet feed tray 18 , and a sheet discharge tray 19 .
The opening 16 is defined in a front end portion of the main body 12 . The opening 16 provides communication between the inside and the outside of the main body 12 in the front-rear direction to allow the process cartridge 13 to pass therethrough.
The front cover 17 is disposed at a front end of the main body 12 . The front cover 17 has a generally flat plate shape. The front cover 17 extends in the upper-lower direction and is supported by a front wall of the main body 12 so as to be pivotable on its lower end portion. The front cover 17 is configured to expose or close the opening 16 .
The sheet feed tray 18 is disposed at a bottom portion of the main body 12 . The sheet supply tray 27 is configured to accommodate therein one or more sheets P.
The sheet discharge tray 19 is defined at a front half portion of an upper wall of the main body 12 . The sheet discharge tray 19 is recessed relative to an upper surface of the main body 12 for supporting one or more sheets P thereon.
The process cartridge 13 is positioned at a substantially middle position of the main body 12 in the upper-lower direction. The process cartridge 13 is configured to be installed in and detached from the main body 12 . The process cartridge 13 includes the drum cartridge 1 and a developing cartridge 20 .
The developing cartridge 20 is attached to the drum cartridge 1 while being positioned in front of the photosensitive drum 2 . The developing cartridge 20 includes a developing roller 21 , a supply roller 22 , a layer thickness regulating blade 23 , and a toner container 24 .
The developing roller 21 is rotatably supported at a rear end portion of the developing cartridge 20 . The developing roller 21 has a generally cylindrical shape extending in the right-left direction. The developing roller 21 is in contact with a front surface of the photosensitive drum 2 .
The supply roller 22 is disposed in front of and below the developing roller 2 . The supply roller 22 has a generally cylindrical shape extending in the right-left direction and is rotatably supported by the developing cartridge 20 . The supply roller 22 is in contact with an lower-front surface of the developing roller 21 .
The layer thickness regulating blade 23 is disposed in front of and above the developing roller 21 . The layer thickness regulating blade 23 is in contact with an front surface of the developing roller 21 .
The toner container 24 is disposed in front of the supply roller 22 and the layer thickness regulating blade 23 . The toner container 24 is configured to store toner therein.
The scanner unit 14 is disposed above the process cartridge 13 . The scanner unit 14 is configured to emit a laser beam toward the photosensitive drum 2 based on image data.
The fixing unit 15 is disposed behind the process cartridge 13 . The fixing unit 15 includes a heating roller 26 and a pressing roller 27 . The pressing roller 27 is in pressure contact with a lower-rear surface of the heating roller 26 .
As the image forming apparatus 11 starts an image forming operation, the scorotron charger 3 charges a surface of the photosensitive drum 2 uniformly and the scanner unit 14 exposes the surface of the photosensitive drum 4 with a laser beam. Thus, an electrostatic latent image based on image data is formed on the surface of the photosensitive drum 2 .
The supply roller 22 supplies toner to the developing roller 21 from the toner container 24 . Meanwhile, toner is positively charged between the developing roller 21 and the supply roller 22 and is then carried by the developing roller 21 , and the layer-thickness regulating blade 23 regulates a layer thickness of toner carried by the developing roller 21 .
The developing roller 21 then supplies the toner carried thereon to the surface of the photosensitive drum 2 , i.e., the electrostatic latent image formed on the surface of the photosensitive drum 2 . Thus, the photosensitive drum 2 carries a toner image on the surface thereof.
Rollers rotate to convey sheets P, one by one, to between the photosensitive drum 2 and the transfer roller 4 at a predetermined timing from the sheet feed tray 18 . The transfer roller 4 transfers the toner image formed on the surface of the photosensitive drum 2 onto a sheet P while the sheet P passes between the photosensitive drum 2 and the transfer roller 4 .
Then, the heating roller 26 and the pressing roller 27 apply heat and pressure, respectively, to the sheet P to thermally fix the toner image transferred onto the sheet P while the sheet P passes therebetween. After the toner image is fixed on the sheet P, the sheet P is discharged onto the sheet discharge tray 19 .
The surfaces of the first and second rollers 6 and 7 are charged to positive potential that is higher than the potential of the surface of the photosensitive drum 2 . More specifically, the surfaces of the first and second rollers 6 and 7 are charged such that the surface of the second roller 7 has positive potential higher than the positive potential of the first roller 6 .
The first roller 6 removes paper dust from the surface of the photosensitive drum 2 when contacting the paper dust. That is, the first roller 6 cleans the surface of the photosensitive drum 2 . The second roller 7 then removes the paper dust from the first roller 6 when contacting the paper dust.
Thereafter, the sponge scraper 8 scrapes and removes the paper dust from the second roller 7 and the collected paper dust is stored in the storage 9 .
3. Details of Drum Cartridge
As depicted in FIGS. 1 and 3 , the drum cartridge 1 includes a drum frame 31 , the photosensitive drum 2 , the scorotron charger 3 , the transfer roller 4 , the cleaning unit 5 , and a drive unit 32 .
(1) Drum Frame
As depicted in FIG. 3 , the drum frame 31 includes a base frame 35 and a cover frame 36 .
The base frame 35 has a generally rectangular shape in plan view and has a bottom. The base frame 35 is made of resin material, for example, polystyrene (“PS”). The base frame 35 includes a right sidewall 38 , a left sidewall 39 , a bottom wall 40 , a rear wall 41 , and a front wall 42 that are integrated with each other.
The right sidewall 38 has a generally L-shaped plate shape in side view. The right sidewall 38 includes a rear portion 45 and a front portion 46 .
As depicted in FIG. 4A , the rear portion 45 constitutes a rear portion of the right sidewall 38 . The rear portion 45 has a generally rectangular plate shape in side view. An upper surface of the rear portion 45 extends upward and rearward. As depicted in FIG. 7A , the rear portion 45 includes a first guide recess 47 , a second guide recess 48 , and a recess 49 .
As depicted in FIGS. 4A and 7A , the first guide recess 47 is recessed downward relative to the upper surface of the rear portion 45 of the right wall 38 and has a generally U-shape.
The second guide recess 48 is recessed downward relative to the upper surface of the rear portion 45 of the right wall 38 and has a generally U-shape. The second guide recess 48 is disposed in front of the first guide recess 47 .
The recess 49 is disposed at a front end portion of the rear portion 45 . The recess 49 extends to a substantially middle portion of the rear portion 45 in the up-down direction and has a generally rectangular shape in side view. An upper portion of the recess 49 protrudes upward from the rear portion 45 of the right wall 38 and has a semicircular shape in side view. The recess 49 has a drum-shaft pass-through hole 50 .
As depicted in FIGS. 6 and 7A , the drum-shaft pass-through hole 50 penetrates through a substantially central portion of the recess 49 in the upper-lower direction and in the front-rear direction and has a circular shape in side view. The drum-shaft pass-through hole 50 has a diameter that is slightly larger than a diameter of a drum shaft 86 of the photosensitive drum 2 .
As depicted in FIG. 1 , the front portion 46 constitutes a front portion of the right sidewall 38 . The front portion 46 extends frontward from a lower front end of the rear portion 45 and has a generally rectangular plate shape in side view.
As depicted in FIG. 3 , the left sidewall 39 is disposed to the left of the right sidewall 38 and is spaced apart from the right sidewall 38 . The left sidewall 39 has a generally L-shaped plate shape in side view. The left sidewall 39 includes a rear portion 51 and a front portion 52 .
The rear portion 51 constitutes a rear portion of the left sidewall 39 . As depicted in FIGS. 9 and 12 , the rear portion 51 has a crank-like shape in plan view. The rear portion 51 includes a first portion 53 , a second portion 54 , and a third portion 55 .
The first portion 53 constitutes a front portion of the rear portion 51 of the left sidewall 39 . As depicted in FIG. 9 , the first portion 53 has a generally rectangular plate shape in side view. The first portion 53 has a larger-diameter through hole 56 .
The larger-diameter through hole 56 penetrates through a substantially middle portion of the first portion 53 in side view and has a circular shape in side view. The larger-diameter through hole 56 has a diameter that is larger than the diameter of the drum-shaft pass-through hole 50 of the right sidewall 38 . The center of the larger-diameter through hole 56 is coincide with the center of the drum-shaft pass-through hole 50 of the right sidewall 38 of the base frame 35 as viewed in the right-left direction.
As depicted in FIGS. 9 and 12 , the second portion 54 constitutes a rear portion of the rear portion 51 of the left sidewall 39 . The second portion 54 is disposed to the right of the first portion 53 . The second portion 54 has a generally rectangular plate shape in side view. The second portion 54 includes a first retaining portion 57 and a semicircular portion 58 .
The first retaining portion 57 has a generally rectangular plate shape in front view. The first retaining portion 57 protrudes leftward from a rear end of the second portion 54 . The first retaining portion 57 has a through hole in its middle portion for catching a first hook 179 of a gear holder 151 .
The semicircular portion 58 is disposed at a substantially middle portion of the second portion 54 in the front-rear direction. The semicircular portion 58 is recessed downward relative to an upper surface of the second portion 54 and has a generally semicircular shape in side view.
The third portion 55 is disposed between a rear end portion of the first portion 53 and a front end portion of the second portion 54 . The third portion 55 has a generally rectangular plate shape in bottom view.
As depicted in FIG. 3 , the front portion 52 constitutes a front portion of the left sidewall 39 of the base frame 35 . The front portion 52 extends frontward from a lower front end of the rear portion 51 of the left sidewall 39 and has a generally rectangular plate shape in side view.
The bottom wall 40 is disposed such that its front portion is disposed between a lower end portion of the right sidewall 38 and a lower end portion of the left sidewall 39 and its rear portion is disposed between a substantially middle portion of the right sidewall 38 in the up-down direction and a substantially middle portion of the left sidewall 39 in the up-down direction as depicted in FIGS. 1 and 12 . The bottom wall 40 has a crank-like shape in side view, and has a generally plate shape extending in the right-left direction. As depicted in FIGS. 1 and 4B , the bottom wall 40 includes a transfer-roller supporting portion 61 and a pair of guide ribs 62 .
The transfer-roller supporting portion 61 is disposed in a rearward position at a middle portion of the bottom wall 40 . The transfer-roller supporting portion 61 is recessed downward in the bottom wall 40 and has a generally U shape in side view. The transfer-roller supporting portion 61 supports the transfer roller 4 therein so as to be rotatable.
As depicted in FIG. 4B , the guide ribs 62 are spaced apart from each other in the right-left direction at a rear end portion of the bottom wall 40 . The guide ribs 62 are disposed at right and left end portions, respectively, of the bottom wall 40 . The guide ribs 62 protrude upward from an upper surface of the bottom wall 40 and have a generally rectangular plate shape in side view. Upper surfaces of the guide ribs 62 extend along the extending direction.
As depicted in FIGS. 1 and 3 , the rear wall 41 of the base frame 35 is disposed between a rear end portion of the right sidewall 38 and a rear end portion of the left sidewall 39 . A lower end of the rear wall 41 is contiguous to a rear end of the bottom wall 40 . The rear wall 41 has a generally rectangular plate shape in rear view. As depicted in FIGS. 4B and 7A , the rear wall 41 includes a pair of release-lever supporting bosses 63 .
The release-lever supporting bosses 63 are disposed above and to the rear of the guide ribs 62 , respectively, of the bottom wall 40 and at right and left end portions, respectively, of an upper end portion of the rear wall 41 . The release-lever supporting bosses 63 protrude rightward and leftward from the right and left end portions, respectively, of the rear wall 41 . The release-lever supporting bosses 63 have a generally cylindrical shape.
As depicted in FIGS. 1 and 3 , the front wall 42 of the base frame 35 is disposed between a front end portion of the right sidewall 38 and a front end portion of the left sidewall 39 . A lower end of the front wall 42 is contiguous to a front end of the bottom wall 40 . The front wall 42 has a generally rectangular plate shape in front view.
The cover frame 36 is disposed above a rear end portion of the base frame 35 while covering the photosensitive drum 2 . As depicted in FIGS. 4A and 9 , the cover frame 36 includes a right sidewall 65 , a left sidewall 66 , and a top wall 67 , which are integrated with each other.
As depicted in FIG. 4A , the right sidewall 65 has a rectangular plate in side view. A lower surface of the right sidewall 65 extends along the extending direction. The right sidewall 65 includes a first concave portion 69 , a second concave portion 70 , and a projecting portion 71 .
The first concave portion 69 is recessed upward relative to the lower surface at a rear end portion of the right sidewall 65 . The first concave portion 69 has a generally U shape.
The second concave portion 70 is defined in front of the first concave portion 69 and is recessed upward relative to the lower surface of the right sidewall 65 . The second concave portion 70 also has a generally U shape.
The projecting portion 71 is disposed in front of the second concave portion 70 . The projecting portion 71 extends downward from the right sidewall 65 and has a generally rectangular plate shape in side view. The projecting portion 71 has a drum-shaft pass-through hole 72 .
The drum-shaft pass-through hole 72 penetrates through a substantially central portion of the projecting portion 71 in the upper-lower direction and in the front-rear direction and has a circular shape in side view. The drum-shaft pass-through hole 72 has a diameter that is slightly larger than the diameter of the drum shaft 86 of the photosensitive drum 2 .
As depicted in FIG. 9 , the left sidewall 66 of the cover frame 36 has a generally rectangular plate shape in side view. The left sidewall 66 includes a first positioning boss 73 , a second positioning boss 74 , and a semicircular portion 75 .
The first positioning boss 73 protrudes leftward from a rear end portion of a left surface of the left sidewall 66 and has a generally cylindrical shape.
The second positioning boss 74 protrudes leftward from a front end portion of the left surface of the left sidewall 66 and has a generally cylindrical shape.
The semicircular portion 75 is disposed in front of the first positioning boss 73 and is recessed upward relative to a lower surface of the left sidewall 66 . The semicircular portion 75 has a generally semicircular shape in side view.
As depicted in FIGS. 1 and 3 , the top wall 67 of the cover frame 35 is disposed between an upper end portion of the right sidewall 65 and an upper end portion of the left sidewall 66 . As depicted in FIG. 1 , the top wall 67 includes a charger supporting portion 77 and a rear portion 78 .
The charger supporting portion 77 constitutes a front portion of the top wall 67 . The charger supporting portion 77 extends in the right-left direction and has an inverted U-shape in side view. The charger supporting portion 77 includes the scorotron charger 3 .
The rear portion 78 constitutes a rear portion of the top wall 67 . The rear portion 78 has a generally rectangular plate shape in plan view extending in the right-left direction. As depicted in FIGS. 4B and 9 , the rear portion 78 includes a second retaining portion 80 , and a pair of guide ribs 81 .
The second retaining portion 80 is disposed at a left rear end portion of the rear portion 78 of the top wall 67 . The second retaining portion 80 penetrates through the rear portion 78 of the top wall 67 in the up-down direction for catching a second hook 180 of the gear holder 151 therein.
As depicted in FIG. 4B , the guide ribs 81 of the cover frame 36 are disposed at the rear portion 78 of the top wall 67 and are spaced apart from each other in the right-left direction. The guide ribs 81 are disposed at right and left end portions, respectively, of the rear portion 78 of the top wall 67 . The guide ribs 81 protrude downward from a lower surface of the rear portion 78 and have a generally triangular shape in side view. Lower surfaces of the guide ribs 81 extend the extending direction.
As depicted in FIG. 3 , the drum frame 31 includes the base frame 35 and the cover frame 36 , in which the cover frame 36 is assembled to the base frame 35 .
More specifically, the cover frame 36 is assembled to the base frame 35 such that, in the up-down direction, the right sidewall 65 of the cover frame 36 overlaps the rear portion 45 of the right sidewall 38 of the base frame 35 , the left sidewall 66 of the cover frame 36 overlaps the rear portion 51 of the left sidewall 39 of the base frame 35 , and a rear end portion of the rear portion 78 of the cover frame 36 overlaps the rear wall 41 of the base frame 35 .
In this state, as depicted in FIGS. 4A and 6 , in the right end portion of the drum frame 31 , a lower end of the right sidewall 65 of the cover frame 36 is in contact with an upper end of the rear portion 45 of the right sidewall 38 of the base frame 35 and the projecting portion 71 of the right sidewall 65 of the cover frame 36 overlaps the right sidewall 38 of the base frame 35 as viewed in the right-left direction. Further, the drum-shaft pass-through hole 50 of the base frame 35 is coincide with the drum-shaft pass-through hole 72 of the cover frame 36 in the right-left direction.
As depicted in FIG. 4A , the first guide recess 47 of the right sidewall 38 of the base frame 35 faces the first concave portion 69 of the right sidewall 65 of the cover frame 36 in the up-down direction. Thus, the first guide recess 47 and the first concave portion 69 constitute a second-electrode receiving portion 202 for receiving a contact portion 145 of a second electrode 118 . That is, the second-electrode receiving portion 202 extends in the up-down direction across a boundary of the base frame 35 and the cover frame 36 .
The second guide recess 48 of the right sidewall 38 of the base frame 35 faces the second concave portion 70 of the right sidewall 65 of the cover frame 36 in the up-down direction. Thus, the second guide recess 48 and the second concave portion 70 constitute a first-electrode receiving portion 203 for receiving a contact portion 145 of a first electrode 117 . The first-electrode receiving portion 203 is an example of a guide. That is, the first-electrode receiving portion 203 extends in the up-down direction across the boundary of the base frame 35 and the cover frame 36 .
As depicted in FIGS. 6 and 9 , in the left portion of the drum frame 31 , a lower end of the left sidewall 66 of the cover frame 36 is in contact with an upper end of the left sidewall 39 of the base frame 35 .
In this state, as depicted in FIG. 9 , the semicircular portion 58 of the left sidewall 39 of the base frame 35 faces the semicircular portion 75 of the left sidewall 66 of the cover frame 35 in the up-down direction. Thus, the semicircular portion 58 of the left sidewall 39 of the base frame 35 and the semicircular portion 75 of the left sidewall 66 of the cover frame 35 define an opening 200 in which an Oldham coupling 155 is disposed.
As depicted in FIG. 4B , the upper surfaces of the guide ribs 62 of the bottom wall 40 of the base frame 35 face the lower surfaces of the guide ribs 81 , respectively, of the top wall 67 of the cover frame 36 while being spaced apart therefrom at a certain interval in the attaching and detaching direction. Thus, the pair of guide ribs 62 and the pair of guide ribs 81 constitute a pair of roller shaft guides 201 .
In the drum frame 31 configured as described above, as depicted in FIGS. 1 and 3 , a first accommodating portion 204 is defined by the rear portion 45 of the right sidewall 38 of the base frame 35 , the rear portion 51 of the left sidewall 39 of the base frame 35 , the rear portion of the bottom wall 40 of the base frame 35 , the rear wall 41 of the base frame 35 , and the cover frame 36 . The first accommodating portion 204 is configured to accommodate therein the photosensitive drum 2 and the cleaning unit 5 .
In the drum frame 31 , a second accommodating portion 205 is further defined by the front portion 46 of the right sidewall 38 of the base frame 35 , the front portion 52 of the left sidewall 39 of the base frame 35 , a front portion of the bottom wall 40 of the base frame 35 , and the front wall 42 of the base frame 35 . The second accommodating portion 205 is disposed in front of the first accommodating portion 204 and is configured to accommodate therein the developing cartridge 20 .
(2) Photosensitive Drum
As depicted in FIG. 6 , the photosensitive drum 2 includes a drum body 83 , a pressing member 84 , a bearing member 85 , and a drum shaft 86 . The drum shaft 86 is an example of a first rotating shaft.
The drum body 83 has a generally cylindrical shape extending in the right-left direction. The drum body 83 is disposed between the right sidewall 38 and the left sidewall 39 of the base frame 35 . More specifically, the drum body 83 includes a metal base tube and a photosensitive resin layer. The base tube has a generally cylindrical shape extending in the right-left direction. The photosensitive layer covers a surface of the base tube.
The pressing member 84 is disposed at a right end portion of the drum body 83 . The pressing member 84 includes a right flange 88 , a frictional member 89 , and a compression spring 90 .
The right flange 88 has a generally cylindrical shape with its left end closed. The right flange 88 has an outside diameter that is substantially the same as an inside diameter of the drum body 83 . The right flange 88 has a through hole in its central portion of the closed end. The through hole allows the drum shaft 86 to pass therethrough. The right flange 88 is fixed to the right end portion of the drum body 83 so as not be relatively rotatable.
The frictional member 89 has a generally cylindrical shape with its right end closed. The frictional member 89 has an outside diameter that is slightly smaller than an inside diameter of the right flange 88 . The frictional member 89 has a through hole in its central portion of the closed end. The through hole allows the drum shaft 86 to pass therethrough. The frictional member 89 is fitted to a right end portion of the right flange 88 so as to be slidable therein in the right-left direction.
The compression spring 90 is a coil spring extending in the right-left direction. The compression spring 90 is disposed between the closed end of the right flange 88 and the closed end of the frictional member 89 in a compressed state.
Therefore, the compression spring 90 presses the drum body 83 leftward via the right flange 88 while pressing the frictional member 89 rightward.
The bearing member 85 is disposed at a left end portion of the drum body 83 . The bearing member 85 includes a first left flange 91 and a second left flange 92 .
The first left flange 91 includes a shaft pass-through portion 93 and a flange gear 94 , which are integrated with each other.
The shaft pass-through portion 93 has generally cylindrical shape with its left end closed. The shaft pass-through portion 93 has an outside diameter that is substantially the same as the inside diameter of the drum body 83 . The shaft pass-through portion 93 has a through hole in its central portion of the closed end. The through hole allows the drum shaft 86 to pass therethrough.
The flange gear 94 protrudes leftward from the left end of the shaft pass-through portion 93 contiguously and has a generally cylindrical shape. The flange gear 94 has an outside diameter that is larger than an outside diameter of the shaft pass-through portion 93 .
The second left flange 92 is made of resin material, for example, polyacetal resin (“POM”). The second left flange 92 includes a drum gear 96 , a disc portion 97 , an engagement portion 98 , and a smaller-diameter cylindrical portion 99 . The drum gear 96 is an example of a photosensitive body gear.
The drum gear 96 has a generally cylindrical shape extending in the right-left direction. The drum gear 96 has an outside diameter that is larger than an outside diameter of the flange gear 94 .
The disc portion 97 protrudes inwardly from a substantially central portion of the drum gear 96 in the diametric direction of the drum gear 96 .
The engagement portion 98 protrudes rightward from a right surface of the disc portion 97 and has a generally cylindrical shape. The engagement portion 98 has an outside diameter that is substantially the same as the inside diameter of the flange gear 94 . The engagement portion 98 has an inside diameter that is larger than the diameter of the drum shaft 86 and an outside diameter of the smaller-diameter cylindrical portion 99 .
The smaller-diameter cylindrical portion 99 is hollow and penetrates through the center of the disc portion 97 in the right-left direction. The smaller-diameter cylindrical portion 99 has an outside diameter that is slightly smaller than an inside diameter of the larger-diameter through hole 56 of the left sidewall 39 of the base frame 35 . The smaller-diameter cylindrical portion 99 has an inside diameter that is substantially the same as the outside diameter of the drum shaft 86 . A left end of the smaller-diameter cylindrical portion 99 is located further to the left than a left end of the drum gear 96 .
The drum shaft 86 extends in the right-left direction while passing through the center of the photosensitive drum 2 in the diametric direction. The drum shaft 86 has a generally cylindrical shape. The drum shaft 86 penetrates through the through hole of the pressing member 84 and the smaller-diameter cylindrical portion 99 of the bearing member 85 .
The photosensitive drum 2 is rotatably positioned at a front portion of the first accommodating portion 204 of the drum frame 31 while a right end portion of the drum shaft 86 penetrates through the drum-shaft pass-through hole 72 of the right sidewall 65 and the drum-shaft pass-through hole 50 of the right sidewall 38 of the base frame 35 and a left end portion of the drum shaft 86 penetrates through the larger-diameter through hole 56 of the left sidewall 39 of the base frame 35 .
In this state, the smaller-diameter cylindrical portion 99 of the bearing member 85 is positioned within the larger-diameter through hole 56 of the left sidewall 39 as viewed in the right-left direction.
(3) Scorotron Charger
As depicted in FIGS. 1 and 4B , the scorotron charger 3 is supported by the charger supporting portion 77 of the cover frame 36 . Thus, the scorotron charger 3 is disposed above the photosensitive drum 2 and is spaced apart from the photosensitive drum 2 . The scorotron charger 3 includes a charging wire 101 , a grid 102 , a wire cleaner 103 , a charger electrode 104 , and a grid electrode 105 , as depicted in FIG. 4A .
As depicted in FIG. 1 , the charging wire 101 extends in the right-left direction while being supported by the right sidewall 65 and the left sidewall 66 of the cover frame 36 . The charging wire 101 is disposed above the photosensitive drum 2 and is spaced apart from the photosensitive drum 2 .
The grid 102 has a U shape in side view. The grid 102 is disposed so as to surround the charging wire 101 from below.
As depicted in FIGS. 4B and 9 , the wire cleaner 103 is disposed at an upper end portion of the charger supporting portion 77 and is supported so as to be slidable in the right-left direction for cleaning the charging wire 101 . The wire cleaner 103 has a generally rectangular plate shape in plan view. The wire cleaner 103 includes a cleaner 106 and a protrusion 107 .
As depicted in FIG. 4B , the cleaner 106 is disposed inside the grid 102 . The cleaner 106 includes a cleaning member, e.g., a sponge or a nonwoven fabric, which pinches the charging wire 101 . The cleaner 106 is movable along the charging wire 101 .
As depicted in FIG. 9 , the protrusion 107 protrudes leftward from a substantially middle portion of a left end portion of the cleaner 106 in the front-rear direction.
As depicted in FIG. 4A , the charger electrode 104 is electrically connected with the charging wire 101 . The charger electrode 104 is exposed via the front end portion of the left sidewall 66 of the cover frame 36 .
The grid electrode 105 is electrically connected with the grid 102 . The grid electrode 105 is exposed via a substantially middle portion of the left sidewall 66 of the cover frame 36 in the front-rear direction.
(4) Cleaning Unit
As depicted in FIGS. 1 and 4B , the cleaning unit 5 includes the first roller 6 , the second roller 7 , the sponge scraper 8 , the storage 9 , a pair of bearings 114 , a pair of urging members 115 , a pair of release levers 116 , the first electrode 117 , and the second electrode 118 .
The first roller 6 is disposed at a front end portion of the cleaning unit 5 . The first roller 6 includes a first-roller shaft 121 and a first-roller body 122 .
The first-roller shaft 121 has a generally cylindrical shape in the right-left direction. The first-roller shaft 121 has a diameter that is smaller than the width of the roller shaft guides 201 . Each of right and left end portions of the first-roller shaft 121 is inserted into the roller shaft guides 201 , respectively, from inside in the right-left direction.
The first-roller body 122 covers a substantially middle portion of the first-roller shaft 121 in the right-left direction and has a generally cylindrical shape. A lower-front surface of the first-roller body 122 is in contact with an upper-rear surface of the photosensitive drum 2 .
The second roller 7 is disposed above and behind the first roller 6 . The second roller 7 includes a second-roller shaft 124 and a second-roller body 125 , which are integrated with each other.
The second-roller shaft 124 has a generally cylindrical shape extending in the right-left direction. The second-roller shaft 124 has a diameter that is smaller than a diameter of the first-roller shaft 121 and the width of the roller shaft guides 201 . Each of right and left end portions of the second-roller shaft 124 is inserted into the roller shaft guides 201 , respectively, from inside in the right-left direction.
The second-roller body 125 protrudes outward in a diametric direction of the second-roller shaft 124 from a substantially middle portion of the second-roller shaft 124 in the right-left direction. The second-roller body 125 has a diameter that is larger than a diameter of the second-roller shaft 124 .
The bearings 114 are disposed within the corresponding roller shaft guides 201 , respectively. As depicted in FIGS. 7A and 7B , each of the bearings 114 includes a first-roller-shaft pass-through portion 127 , a second-roller-shaft pass-through portion 128 , and a connecting portion 129 .
The first-roller-shaft pass-through portion 127 has a generally cylindrical shape extending in the right-left direction. The first-roller-shaft pass-through portion 127 has an inside diameter that is substantially the same as an outside diameter of the first-roller shaft 121 .
The second-roller-shaft pass-through portion 128 is disposed above and behind the first-roller-shaft pass-through portion 127 . The second-roller-shaft pass-through portion 128 has a generally cylindrical shape extending in the right-left direction. The second-roller-shaft pass-through portion 128 includes a protrusion 130 (refer to FIG. 7B ).
The protrusion 130 protrudes upwardly rearward from an upper rear surface of the second-roller-shaft pass-through portion 128 . The protrusion 130 has a generally cylindrical shape.
The connecting portion 129 connects a lower front end portion of the first-roller-shaft pass-through portion 127 and an upper rear end portion of the second-roller-shaft pass-through portion 128 . The connecting portion 129 extends in the extending direction and has a generally rectangular column shape.
The bearings 114 support the first-roller shaft 121 of the first roller 6 such that the first roller 6 is rotatable while both end portions of the first-roller shaft 121 pass through the first-roller-shaft pass-through portions 127 of the bearings 114 , respectively. The bearings 114 further support the second-roller shaft 124 of the second roller 7 such that the second roller 7 is rotatable while both end portions of the second-roller shaft 124 pass through the second-roller-shaft pass-through portions 128 of the bearings 114 , respectively.
As described above, the bearings 114 support the first roller 6 and the second roller 7 in the roller shaft guides 201 , respectively, such that the first roller 6 and the second roller 7 are rotatable.
That is, the pair of bearings 114 is configured to be movable along the extending direction along with the first roller 6 and the second roller 7 .
The urging members 115 are coil springs that extend in the extending direction. In each of the urging member 115 , a lower front end portion is fitted to the protrusion 130 of a corresponding one of the bearings 114 and an upper rear end portion is in contact with an upper end portion of an inner surface of the rear wall 41 of the base frame 35 .
With this configuration, the urging members 115 urge the respective bearings 114 downwardly frontward. That is, the urging members 115 are configured to urge the first roller 6 toward the photosensitive drum 2 such that the first roller 6 is kept in contact with the photosensitive drum 2 .
As depicted in FIG. 3 , the release levers 116 are disposed at both end portions of the drum frame 31 in the right-left direction. As depicted in FIGS. 4B and 7A , each of the release levers 116 includes a proximal portion 132 , a hook 133 , and a handle 134 .
The proximal portion 132 has a generally obtuse triangular plate shape in side view. The proximal portion 132 has an obtuse-angled portion at its upper rear end in side view. The proximal portion 132 has an engagement hole 135 .
The engagement hole 135 is defined in the obtuse-angled portion of the proximal portion 132 and has a circular shape in side view. The engagement hole 135 penetrates through the proximal portion 132 . The engagement hole 135 has a diameter that is substantially the same as a diameter of the release-lever supporting bosses 63 of the rear wall 41 .
The hook 133 is contiguous to a front end portion of the proximal portion 132 in side view. The hook 133 has a generally arc shape in side view. The hook 133 extends downward and curved in side view from a front end of the proximal portion 132 . The radius of curvature of an inner surface of the hook 133 is slightly larger than a diameter of the second-roller shaft 124 .
The handle 134 is contiguous to a rear end of the proximal portion 132 in side view. That is, the handle 134 is disposed opposite to the hook 133 with respect to the engagement hole 135 . The handle 134 has a generally rectangular plate shape in rear view and extends in a direction perpendicular to a direction that the proximal portion 132 extends.
The release levers 116 are supported by the release-lever supporting bosses 63 of the rear wall 41 via the engagement holes 135 , respectively. This configuration enables the release levers 116 to pivot on the respective release-lever supporting bosses 63 .
More specifically, the pair of release levers 116 is pivotable between a first position and a second position. When the pair of release levers 113 is located at the first position, as depicted in FIG. 4B , the handles 134 extend along a rear surface of the rear wall 41 and the hooks 133 are located above the second-roller-shaft pass-through portions 128 of the bearings 114 with being spaced apart therefrom. When the pair of release levers 113 is located at the second position, as depicted in FIG. 5B , the handles 134 are located distant from the rear wall 41 and the hooks 133 are caught on the second-roller-shaft pass-through portions 128 of the bearings 114 , respectively.
As depicted in FIG. 4B , when the pair of release levers 116 is located at the first position, the pair of bearings 114 is urged downwardly frontward by the pair of urging members 115 and thus the first roller 6 comes into contact with the upper rear surface of the photosensitive drum 2 . As depicted in FIG. 5B , in response to the pivoting of the pair of release levers 116 from the first position to the second position, the pair of bearings 114 move upwardly rearward against the urging force of the pair of urging members 115 and thus the first roller 6 is separated from the photosensitive drum 2 . The pair of release levers 116 is located at the first position at all times as depicted in FIG. 4B .
As depicted in FIG. 7A , the first electrode 117 is disposed at a right end portion of the cleaning unit 5 . The first electrode 117 is made of conductive resin. The first electrode 117 is configured to supply first cleaning bias to the first roller 6 by establishing an electrical connection with a third apparatus electrode 193 of the main body 12 . As depicted in FIGS. 8A and 8B , the first electrode 117 includes a roller-shaft supporting portion 137 , a contact portion 138 , and a connecting plate 139 .
The roller-shaft supporting portion 137 has a generally cylindrical shape with its right end closed. The roller-shaft supporting portion 137 has an inside diameter that is substantially the same as the diameter of the first-roller shaft 121 .
The contact portion 138 may be a drop-shaped hollow cylinder with its right end closed in side view. The contact portion 138 includes a curved portion 140 , a first straight portion 141 , and a second straight portion 142 . A portion that constitutes a lower peripheral surface of the contact portion 138 and has a semicircular shape in side view is defined as the curved portion 140 . A portion that constitutes a peripheral surface of the contact portion 138 and extends obliquely upward toward the rear from a front end of the curved portion 140 is defined as the first straight portion 141 . A portion that constitutes a peripheral surface of the contact portion 138 and extends obliquely upward toward the front from a rear end of the curved portion 140 is defined as the second straight portion 142 . The first straight portion 141 and the second straight portion 142 extend such that a distance therebetween becomes narrower toward their tips and their tips are in contact with each other. Therefore, the upper end of the first straight portion 141 is contiguous to the upper end of the second straight portion 142 .
The connecting plate 139 connects a lower right end portion of the roller-shaft supporting portion 137 and an upper left end portion of the contact portion 138 . The connecting plate 139 has a generally rectangular plate shape in side view.
As depicted in FIGS. 7A and 7B , the first electrode 117 is disposed such that the roller-shaft supporting portion 137 receives a left end portion of the first-roller shaft 121 so as to be rotatable and the contact portion 138 is positioned in the first-electrode receiving portion 203 as depicted in FIG. 4A .
The contact portion 138 of the first electrode 117 is disposed such that the contact portion 138 is positioned at a relatively lower position in the first-electrode receiving portion 203 when the pair of release levers 116 is located at the first position, i.e., when the first roller 6 is in contact with the upper rear surface of the photosensitive drum 2 .
In this state, the curved portion 140 of the first electrode 117 is in contact with a lower portion of an inner surface of the first-electrode receiving portion 203 , and the first straight portion 141 and the second straight portion 142 of the first electrode 117 are not in contact with any portion of the inner surface of the first-electrode receiving portion 203 and are spaced apart from the inner surface of the first-electrode receiving portion 203 .
During movement of the pair of release levers 116 from the first position to the second position, the contact portion 138 of the first electrode 117 moves upward in the first-electrode receiving portion 203 while slightly turning substantially clockwise in right side view.
When the pair of release levers 116 is located at the second position, i.e., when the first roller 6 is separated from the photosensitive drum 2 , the curved portion 140 of the first electrode 117 is in contact with a front portion of the inner surface of the first-electrode receiving portion 203 , and the first straight portion 141 and the second straight portion 142 of the first electrode 117 are not in contact with any portion of the inner surface of the first-electrode receiving portion 203 and are spaced apart from the inner surface of the first-electrode receiving portion 203 .
As described above, the first electrode 117 moves along the up-down direction in the first-electrode receiving portion 203 while slightly turning in side view in response to the movement of the pair of release levers 116 between the first position and the second position. That is, the first electrode 117 moves along a direction intersecting the direction that the first roller 6 moves, i.e., along a direction intersecting the extending direction while slightly turning.
As depicted in FIG. 7A , the second electrode 118 is disposed at a right end portion of the cleaning unit 5 and in front of and below the first electrode 117 . The second electrode 118 is made of conductive resin. The second electrode 118 is configured to supply second cleaning bias to the second roller 7 by establishing an electrical connection with a fourth apparatus electrode 194 of the main body 12 . As depicted in FIGS. 8A and 8B , the second electrode 118 includes a roller-shaft supporting portion 144 , a contact portion 145 , and a connecting plate 146 .
The roller-shaft supporting portion 144 has a generally cylindrical shape with its right end closed. The roller-shaft supporting portion 144 has an inside diameter that is substantially the same as the diameter of the second-roller shaft 124 .
The contact portion 145 may be a drop-shaped hollow cylinder with its right end closed in side view. The contact portion 145 includes a curved portion 147 , a first straight portion 148 , and a second straight portion 149 . A portion that constitutes a lower peripheral surface of the contact portion 145 and has a semicircular shape in side view is defined as the curved portion 147 . A portion that constitutes a peripheral surface of the contact portion 145 and extends obliquely upward toward the rear from a front end of the curved portion 147 is defined as the first straight portion 148 . A portion that constitutes a peripheral surface of the contact portion 145 and extends obliquely upward toward the front from a rear end of the curved portion 147 is defined as the second straight portion 149 . The first straight portion 148 and the second straight portion 149 extend such that a distance therebetween becomes narrower toward their tips and their tips are in contact with each other. Therefore, the upper end of the first straight portion 148 is contiguous to the upper end of the second straight portion 149 .
The connecting plate 146 connects a lower right end portion of the roller-shaft supporting portion 144 and an upper left end portion of the contact portion 145 . The connecting plate 146 has a generally rectangular plate shape in side view. The connecting plate 146 has a dimension in the up-down direction that is shorter than a dimension of the connecting plate 139 of the first electrode 117 in the up-down direction.
As depicted in FIGS. 7A and 7B , the second electrode 118 is disposed such that the roller-shaft supporting portion 144 receives a left end portion of the second-roller shaft 124 so as to be rotatable and the contact portion 145 is positioned in the second-electrode receiving portion 202 as depicted in FIG. 4A .
The contact portion 145 of the second electrode 118 is disposed such that the contact portion 145 is positioned at a relatively lower position in the second-electrode receiving portion 202 when the pair of release levers 116 is located at the first position, i.e., when the first roller 6 is in contact with the upper rear surface of the photosensitive drum 2 .
In this state, the curved portion 147 of the second electrode 118 is in contact with a lower portion of an inner surface of the second-electrode receiving groove 202 , and the first straight portion 148 and the second straight portion 149 of the second electrode 118 are not in contact with any portion of the inner surface of the second-electrode receiving portion 202 and are spaced apart from the inner surface of the second-electrode receiving groove 202 .
During movement of the pair of release levers 116 from the first position to the second position, i.e., during movement of the first roller 6 away from the photosensitive drum 2 and upwardly rearward movement of the second roller 7 along with the first roller 6 , the contact portion 145 of the second electrode 118 moves upward in the second-electrode receiving portion 202 while slightly turning substantially clockwise in right side view.
When the pair of release levers 116 is located at the second position, i.e., when the first roller 6 is separated from the photosensitive drum 2 , the curved portion 147 of the second electrode 118 is in contact with a front portion of the inner surface of the second-electrode receiving groove 202 , and the first straight portion 148 and the second straight portion 149 of the second electrode 118 are not in contact with any portion of the inner surface of the second-electrode receiving portion 202 and are spaced apart from the inner surface of the second-electrode receiving groove 202 .
As described above, the second electrode 118 moves along the up-down direction in the second-electrode receiving portion 202 while slightly turning in side view in response to the movement of the pair of release levers 116 between the first position and the second position. That is, the second electrode 118 moves along a direction intersecting the direction that the second roller 7 moves, i.e., along a direction intersecting the extending direction while slightly turning.
In other words, the second electrode 118 behaves substantially the same in the second-electrode receiving portion 202 as the first electrode 117 behaves in the first-electrode receiving portion 203 .
(5) Drive Unit
As depicted in FIGS. 9 and 10 , the drive unit 32 is disposed at the left end of the drum cartridge 1 . The drive unit 32 includes a power transmission mechanism 150 and a gear holder 151 .
(5-1) Power Transmission Mechanism
The power transmission mechanism 150 is configured to transmit driving force to the photosensitive drum 2 and the first roller 6 . The driving force is inputted from a drive source (not depicted) of the main body 12 of the image forming apparatus 1 . The drive source is an example of an external drive source. The power transmission mechanism 150 includes the flange gear 94 , the drum gear 96 , a first idle gear 154 , the Oldham coupling 155 , a first roller gear 156 , and a transfer roller gear 157 (refer to FIG. 6 ). The first roller gear 156 is an example of a first cleaning gear.
The flange gear 94 is supported by the left end portion of the drum body 83 so as not to be rotatable relative to the drum body 83 . As depicted in FIG. 12 , the flange gear 94 is disposed to the right of the second portion 54 of the rear portion 51 of the left sidewall 39 of the base frame 35 .
As depicted in FIGS. 6 and 12 , the drum gear 96 is fitted to the flange gear 94 so as not to be rotatable relatively. The drum gear 96 is interposed between the first portion 53 and the second portion 54 of the rear portion 51 of the left sidewall 39 of the base frame 35 in the right-left direction. A lower rear portion of the drum gear 96 is exposed from the drum frame 31 and meshes with a drive gear (not depicted) of the main body 12 . This configuration enables transmission of driving force from the drive source (not depicted) to the drum gear 96 via the drive gear (not depicted) of the main body 12 . That is, the drum gear 96 is configured to input driving force transmitted from the drive source (not depicted) of the main body 12 to the photosensitive drum 2 . The drum gear 96 rotates counterclockwise in right side view as depicted in FIG. 11A .
As depicted in FIGS. 9 and 10 , the first idle gear 154 has a generally cylindrical shape extending in the right-left direction. A lower front portion of the first idle gear 154 meshes with an upper rear portion of the drum gear 96 as depicted in FIGS. 11A and 11B . The first idle gear 154 rotates clockwise in right side view as depicted in FIG. 11A .
As depicted in FIGS. 9 and 10 , the Oldham coupling 155 includes a larger-diameter hub 160 , a smaller-diameter hub 161 , and a slider 162 .
The larger-diameter hub 160 constitutes a left portion of the Oldham coupling 155 . The larger-diameter hub 160 includes a second idle gear 164 , a closed portion 165 , and a projection 166 , which are integrated with each other. The larger-diameter hub 160 further has a through hole 167 . The second idle gear 164 is an example of a third intermediate gear.
The second idle gear 164 has a generally cylindrical shape extending in the right-left direction. The second idle gear 164 has a diameter that is smaller than an outside diameter of the drum gear 96 and is larger than an outside diameter of the first idle gear 154 . A front portion of the second idle gear 164 meshes with a rear portion of the first idle gear 154 as depicted in FIGS. 11A and 11B . The second idle gear 164 rotates counterclockwise in right side view as depicted in FIG. 11A .
As depicted in FIGS. 9 and 10 , the closed portion 165 has a generally disc shape in side view and closes a left end of the second idle gear 164 .
As depicted in FIG. 10 , the projection 166 protrudes rightward from a right surface of the closed portion 165 and extends along a diametric direction of the closed portion 165 .
As depicted in FIGS. 9 and 10 , the through hole 167 penetrates through substantially centers of the closed portion 165 and the projection 166 in side view. The through hole 167 has a generally circular shape in side view.
The smaller-diameter hub 161 constitutes a right portion of the Oldham coupling 155 . The smaller-diameter hub 161 includes a second roller gear 168 , a disc portion 169 , and a projection 170 , which are integrated with each other. The second roller gear 168 is an example of a second cleaning gear.
The second roller gear 168 constitutes a right portion of the smaller-diameter hub 161 , and has a generally cylindrical shape extending in the right-left direction. The second roller gear 168 has a diameter that is smaller than a diameter of the second idle gear 164 . The second roller gear 168 is attached to the left end portion of the second-roller shaft 124 so as not to be rotatable relatively. That is, the second roller gear 168 is configured to input driving force to the second roller 7 . The driving force is transmitted from the drive source (not depicted) of the main body 12 .
The disc portion 169 constitutes a substantially middle portion of the second roller gear 168 in the right-left direction. The disc portion 169 is disposed to the left of the second roller gear 168 adjacently. The disc portion 169 is coaxial with the second roller gear 168 . The disc portion 169 has a diameter that is larger than a diameter of the second roller gear 168 and is smaller than the diameter of the second idle gear 164 .
The projection 170 constitutes a right portion of the second roller gear 168 . The projection 170 protrudes leftward from a left surface of the disc portion 169 and extends in a diametric direction of the disc portion 169 .
The slider 162 is interposed between the larger-diameter hub 160 and the smaller-diameter hub 161 . The slider 162 has a generally cylindrical shape extending in the right-left direction. The slider 162 has a first groove 172 and a second groove 173 .
The first groove 172 is recessed rightward relative to a left surface of the slider 162 and extends along a diametric direction of the slider 162 . The first groove 172 has a width that is slightly wider than a width of the projection 166 of the larger-diameter hub 160 .
The second groove 173 is recessed leftward relative to a right surface of the slider 162 and extends along the diametric direction of the slider 162 . The second groove 173 has a width that is slightly wider than a width of the projection 170 of the smaller-diameter hub 161 . The second groove 173 extends in a direction perpendicular to a direction that the first groove 172 extends as viewed in the right-left direction.
The first groove 172 of the slider 162 receives therein the projection 166 of the larger-diameter hub 160 and the second groove 173 of the slider 162 receives therein the projection 170 of the smaller-diameter hub 161 , thereby constituting the Oldham coupling 155 . That is, the Oldham coupling 155 includes the second idle gear 164 and the second roller gear 168 .
With this configuration, the slider 162 slides relative to the projection 166 of the larger-diameter hub 160 and the projection 170 of the smaller-diameter hub 161 , whereby the second idle gear 164 and the second roller gear 168 rotate interlocked with each other even when their rotating axes are deviated. Thus, driving force inputted into the second idle gear 164 is surely transmitted to the second roller gear 168 . As depicted in FIG. 11A , the second roller gear 168 rotates counterclockwise in right side view in a similar manner to the second idle gear 164 .
The Oldham coupling 155 is disposed such that the Oldham coupling 155 extends across the inside and the outside of the first accommodating portion 204 of the drum frame 31 via the opening 200 .
As depicted in FIGS. 10 and 11B , the first roller gear 156 has a generally cylindrical shape extending in the right-left direction. The first roller gear 156 has a diameter that is larger than the diameter of the second roller gear 168 . The first roller gear 156 is attached to the left end portion of the first-roller shaft 121 so as not to be rotatable relatively. As depicted in FIGS. 11A and 11B , the first roller gear 156 is disposed between the drum gear 96 and the Oldham coupling 155 in the extending direction. An upper front portion of the first roller gear 156 overlaps a lower rear portion of the first idle gear 154 as viewed in the right-left direction. An upper rear portion of the first roller gear 156 meshes with a lower front portion of the second roller gear 168 . That is, the first roller gear 156 is configured to input driving force, which is transmitted from the drive source of the main body 12 , to the first roller 6 . As depicted in FIG. 11A , the first roller gear 156 rotates clockwise in right side view.
As depicted in FIG. 6 , the transfer roller gear 157 is disposed at a left end portion of the transfer roller 4 . The transfer roller gear 157 has a generally cylindrical shape extending in the right-left direction. An upper portion of the transfer roller gear 157 meshes with a lower portion of the flange gear 94 .
(5-2) Gear Holder
As depicted in FIGS. 9 and 10 , the gear holder 151 is a separate part from the drum frame 31 . The gear holder 151 is disposed to the left of the power transmission mechanism 150 in the drive unit 32 . The gear holder 151 has a generally rectangular plate shape in side view. The gear holder 151 is made of, for example, resin material, e.g., acrylonitrile butadiene styrene (“ABS”), or metal. The material, e.g., polyacetal resin (“POM”), used for the gear holder 151 has higher heat resistance and higher abrasion resistance to the material used for the second left flange 92 than the material, e.g., polystyrene (“PS”), used for the base frame 35 . The gear holder 151 includes a drum-shaft supporting portion 176 , a first-idle-gear supporting portion 177 , a larger-diameter-hub supporting portion 178 , a first hook 179 , and a second hook 180 . The gear holder 151 further has a first boss hole 181 and a second boss hole 182 .
The drum-shaft supporting portion 176 protrudes rightward from the right surface of the gear holder 151 at a lower front portion of the gear holder 151 . The drum-shaft supporting portion 176 has a generally cylindrical shape. The drum-shaft supporting portion 176 has an outside diameter that is substantially the same diameter of the larger-diameter through hole 56 in the left sidewall 39 of the base frame 35 . The drum-shaft supporting portion 176 has an inside diameter that is substantially the same as the diameter of the drum shaft 86 .
The first-idle-gear supporting portion 177 is disposed at a substantially middle portion of the gear holder 151 in the front-rear direction and above and behind the drum-shaft supporting portion 176 . The first-idle-gear supporting portion 177 protrudes rightward from the right surface of the gear holder 151 and has a generally cylindrical shape. The drum-shaft supporting portion 176 has a diameter that is substantially the same as an inside diameter of the first idle gear 154 .
The larger-diameter-hub supporting portion 178 is disposed at the rear portion of the gear holder 151 and at a substantially middle portion of the gear holder 151 in the front-rear direction. The larger-diameter-hub supporting portion 178 is further disposed behind and below the first-idle-gear supporting portion 177 . The larger-diameter-hub supporting portion 178 protrudes rightward from the right surface of the gear holder 151 and has a generally cylindrical shape. The larger-diameter-hub supporting portion 178 has a diameter that is substantially the same as a diameter of the through hole 167 of the larger-diameter hub 160 .
The first hook 179 is disposed at a lower rear end portion of the gear holder 151 and behind and below the larger-diameter-hub supporting portion 178 . The first hook 179 protrudes rightward from the right surface of the gear holder 151 . The first hook 179 is bent at a particular portion and further extends rearward.
The second hook 180 is disposed at a substantially middle portion of the gear holder 151 in the front-rear direction. The second hook 180 is further disposed behind and above the first-idle-gear supporting portion 177 and in front of and above the larger-diameter-hub supporting portion 178 . The second hook 180 protrudes rightward from the right surface of the gear holder 151 . The second hook 180 is bent at a particular portion and further extends upward.
The first boss hole 181 is defined in an upper rear end portion of the gear holder 151 . The first boss hole 181 penetrates through the gear holder 151 and has an oval shape in side view.
The second boss hole 182 is defined in an upper front end portion of the gear holder 151 . The second boss hole 182 penetrates through the gear holder 151 and has a circular shape in side view.
The wire-cleaner retaining portion 183 is disposed at an upper end portion of the gear holder 151 and between the second boss hole 182 and the first-idle-gear supporting portion 177 . The wire-cleaner retaining portion 183 has a generally rectangular shape in side view and includes an opening that penetrates through the gear holder 151 .
The gear holder 151 is attached to the drum frame 31 from the left and covers the power transmission mechanism 150 .
More specifically, the gear holder 151 supports the first idle gear 154 and the larger-diameter hub 160 including the second idle gear 164 while the first-idle-gear supporting portion 177 penetrates through the first idle gear 154 and the larger-diameter-hub supporting portion 178 penetrates through the through hole 167 of the larger-diameter hub 160 of the Oldham coupling 155 .
The drum-shaft supporting portion 176 receives the drum shaft 86 of the photosensitive drum 2 while passing through the larger-diameter through hole 56 of the left sidewall 39 of the base frame 35 .
A left end surface of the drum-shaft supporting portion 176 is flush with the right surface of the first portion 53 of the rear portion 51 . Thus, the left end surface of the drum-shaft supporting portion 176 contacts a left end surface of the smaller-diameter cylindrical portion 99 of the second left flange 92 of the bearing member 85 .
The first boss hole 181 receives the first positioning boss 73 of the left sidewall 66 of the cover frame 36 and the second boss hole 182 receives the second positioning boss 74 of the left sidewall 66 of the cover frame 36 , thereby positioning the gear holder 151 with respect to the drum frame 31 .
The first hook 179 is caught on the first retaining portion 57 of the second portion 54 of the rear portion 51 of the left sidewall 39 and the second hook 180 is caught on the second retaining portion 80 of the rear portion 78 of the top wall 67 of the cover frame 36 . That is, the gear holder 151 connects the base frame 35 and the cover frame 36 with each other.
As described above, the gear holder 151 is assembled to the drum frame 31 while protecting the power transmission mechanism 150 .
As depicted in FIG. 6 , a lower portion of the gear holder 151 overlaps an upper portion of the left sidewall 39 as viewed in the right-left direction.
When the wire cleaner 103 of the scorotron charger 3 is located at a left end portion of the charger supporting portion 77 , the protrusion 107 of the wire cleaner 103 is in engagement with the wire-cleaner retaining portion 183 .
With this configuration, the position of the wire cleaner 103 is fixed while the wire cleaner 103 is not used.
(5-3) Transmission of Driving Force from Drive Source
As depicted in FIGS. 11A and 11B , as driving force is transmitted to the drum gear 96 from the drive gear (not depicted) of the main body 12 , the drum gear 96 rotates counterclockwise in right side view. The drum gear 96 thus transmits the driving force to the first idle gear 154 .
As the driving force is transmitted to the first idle gear 154 from the drum gear 96 , the first idle gear 154 rotates clockwise in right side view. The first idle gear 154 thus transmits the driving force to the second idle gear 164 of the larger-diameter hub 160 of the Oldham coupling 155 .
In the Oldham coupling 155 , as the driving force is transmitted to the second idle gear 164 of the larger-diameter hub 160 from the first idle gear 154 , the larger-diameter hub 160 rotates counterclockwise in right side view. The larger-diameter hub 160 thus transmits the driving force to the smaller-diameter hub 161 via the slider 162 .
As the driving force is transmitted to the smaller-diameter hub 161 from the larger-diameter hub 160 , the second roller gear 168 of the smaller-diameter hub 161 rotates counterclockwise in right side view in a similar manner to the second idle gear 164 . The second roller gear 168 of the smaller-diameter hub 161 thus transmits the driving force to the first roller gear 156 .
As the driving force is transmitted to the first roller gear 156 from the first roller gear 156 , the first roller gear 156 rotates clockwise in right side view.
Thus, the photosensitive drum 2 , which is configured to rotate in response to input of driving force to the drum gear 96 , rotates counterclockwise in right side view and the first roller 6 , which is configured to rotate clockwise in right side view in response to input of driving force to the first roller gear 156 , rotates clockwise in right side view. That is, the photosensitive drum 2 and the first roller 6 rotate in the same direction at their contacting point.
As described above, the number of rotations of the first roller gear 156 with respect to the number of rotations of the drum gear 96 is reduced via the first idle gear 154 , the second idle gear 164 , and the second roller gear 168 of the power transmission mechanism 150 . Thus, a ratio of a peripheral speed of the first roller 6 relative to the photosensitive drum 2 becomes approximately 0.3. In other words, the first idle gear 154 , the second idle gear 164 , and the second roller gear 168 constitute a reduction mechanism.
The photosensitive drum 2 rotates while being pressed toward the left. Therefore, the left end surface of the smaller-diameter cylindrical portion 99 of the photosensitive drum 2 is rubbed against the right end surface of the drum-shaft supporting portion 176 of the power transmission mechanism 150 .
As described above, the smaller-diameter cylindrical portion 99 of the second left flange 92 is made of polyacetal resin (“POM”) and the drum-shaft supporting portion 176 of the gear holder 151 is made of acrylonitrile butadiene styrene (“ABS”). The smaller-diameter cylindrical portion 99 of the second left flange 92 is made of polyacetal resin (“POM”) and the left sidewall 39 of the base frame 35 of the drum frame 31 is made of polystyrene (“PS”). A threshold value that the rubbing surfaces of the smaller-diameter cylindrical portion 99 and the drum-shaft supporting portion 176 deform or melt due to heat generated by friction is higher than a threshold value that the rubbing surfaces of the smaller-diameter cylindrical portion 99 of the second left flange 92 and the left sidewall 39 of the base frame 35 of the drum frame 31 deform or melt due to heat generated by friction.
4. Details of Main Body of Image Forming Apparatus
As depicted in FIG. 14B , the main body 12 includes a first apparatus electrode 191 , a second apparatus electrode 192 , the third apparatus electrode 193 , and the fourth apparatus electrode 194 .
The first apparatus electrode 191 is disposed such that the first apparatus electrode 191 is in contact with the charger electrode 104 in the right-left direction in a state where the drum cartridge 1 is installed and positioned at a particular position in the main body 12 .
The second apparatus electrode 192 is disposed such that the second apparatus electrode 192 is in contact with the grid electrode 105 in the right-left direction in the state where the drum cartridge 1 is installed in the main body 12 .
The third apparatus electrode 193 is disposed such that the third apparatus electrode 193 is in contact with the contact portion 138 of the first electrode 117 in the right-left direction in the state where the drum cartridge 1 is installed and positioned at the particular position in the main body 12 .
The fourth apparatus electrode 194 is disposed such that the fourth apparatus electrode 194 is in contact with the contact portion 145 of the second electrode 118 in the right-left direction in the state where the drum cartridge 1 is installed and positioned at the particular position in the main body 12 .
The first apparatus electrode 191 , the second apparatus electrode 192 , the third apparatus electrode 193 , and the fourth apparatus electrode 194 are configured to be movable in the right-left direction and are urged leftward at all times. The first apparatus electrode 191 , the second apparatus electrode 192 , the third apparatus electrode 193 , and the fourth apparatus electrode 194 are electrically connected with a power supply (not depicted) of the main body 12 .
5. Installation and Removal of Drum Cartridge with Respect to Main Body of Image Forming Apparatus
A procedure to install the drum cartridge 1 to the main body 12 of the image forming apparatus 1 will be described.
In order to install the drum cartridge 1 to the main body 12 , as a first step, as depicted in FIG. 2 , an operator positions the developing cartridge 20 in the second accommodating portion 205 of the drum cartridge 1 to assemble the process cartridge 13 .
Then, the operator opens the front cover 17 and inserts the process cartridge 13 into the main body 12 via the opening 16 from an upper front position with respect to the main body 12 .
In response to this, as depicted in FIG. 13A , the first apparatus electrode 191 moves upwardly frontward relative to the drum cartridge 1 so as to be situated below the grid electrode 105 while sliding over the right surface of the right sidewall 65 of the cover frame 36 .
Further, the second apparatus electrode 192 moves upwardly frontward relative to the drum cartridge 1 so as to be situated behind the curved portion 147 of the contact portion 145 of the second electrode 118 while sliding over the right surface of the right sidewall 38 of the base frame 35 and the right surface of the right sidewall 65 of the cover frame 36 .
Meanwhile, the third apparatus electrode 193 and the fourth apparatus electrode 194 are not in contact with the right sidewall 38 and are situated behind the drum cartridge 1 .
Then, the operator further inserts the process cartridge 13 into the main body 12 . In response to this, as depicted in FIG. 13B , the first apparatus electrode 191 moves upwardly frontward relative to the drum cartridge 1 so as to be situated behind the grid electrode 105 while sliding over the right surface of the right sidewall 65 of the cover frame 36 .
Further, the second apparatus electrode 192 overrides the contact portion 145 of the second electrode 118 from the curved portion 147 and further moves upwardly frontward relative to the drum cartridge 1 so as to be situated on the right surface of the contact portion 145 of the second electrode 118 while sliding over the contact portion 145 of the second electrode 118 .
The third apparatus electrode 193 moves upwardly frontward relative to the drum cartridge 1 so as to be situated at a lower rear end portion of the right sidewall 38 of the base frame 35 while sliding over the right surface of the right sidewall 38 of the base frame 35 .
Meanwhile, the fourth apparatus electrode 194 is not in contact with the right sidewall 38 and is situated behind the drum cartridge 1 .
The operator further inserts the process cartridge 13 into the main body 12 . In response to this, as depicted in FIG. 14A , the first apparatus electrode 191 moves upwardly frontward relative to the drum cartridge 1 so as to be situated behind the charger electrode 104 while sliding over the right surface of the right sidewall 65 of the cover frame 36 .
The second apparatus electrode 192 crosses the contact portion 145 of the second electrode 118 and further moves upwardly frontward relative to the drum cartridge 1 so as to be situated behind the grid electrode 105 while sliding over the right surface of the right sidewall 65 of the cover frame 36 .
The third apparatus electrode 193 moves upwardly frontward relative to the drum cartridge 1 so as to be situated behind the curved portion 140 of the contact portion 138 of the first electrode 117 while sliding over the right surface of the right sidewall 38 of the base frame 35 .
The fourth apparatus electrode 194 moves upwardly frontward relative to the drum cartridge 1 so as to be situated behind the curved portion 147 of the contact portion 145 of the second electrode 118 while sliding over the right surface of the right sidewall 38 of the base frame 35 and the right surface of the right sidewall 65 of the cover frame 36 .
The operator further inserts the process cartridge 13 into the main body 12 . In response to this, as depicted in FIG. 14B , the first apparatus electrode 191 moves upwardly frontward relative to the drum cartridge 1 while sliding over the right surface of the right sidewall 65 of the cover frame 36 . When the process cartridge 13 reaches the particular position, the first apparatus electrode 191 comes into contact with the charger electrode 104 from the right.
The second apparatus electrode 192 moves upwardly frontward relative to the drum cartridge 1 while sliding over the right surface of the right sidewall 65 of the cover frame 36 . When the process cartridge 13 reaches the particular position, the second apparatus electrode 192 comes into contact with the grid electrode 105 from the right.
The third apparatus electrode 193 overrides the contact portion 138 of first electrode 117 from the curved portion 140 and further moves upwardly frontward relative to the drum cartridge 1 while sliding over the contact portion 138 of first electrode 117 . When the process cartridge 13 reaches the particular position, the third apparatus electrode 193 comes into contact with the contact portion 138 of the first electrode 117 from the right.
The fourth apparatus electrode 194 overrides the contact portion 145 of the second electrode 118 from the curved portion 147 and further moves upwardly frontward relative to the drum cartridge 1 while sliding over the contact portion 145 of the second electrode 118 . When the process cartridge 13 reaches the particular position, the fourth apparatus electrode 194 comes into contact with the contact portion 145 of the second electrode 118 from the right.
Through the above-described procedure, the installation of the process cartridge 13 in the main body 12 is completed.
In order to remove the drum cartridge 1 from the main body 12 , the installation procedure is performed in reverse.
More specifically, as depicted in FIG. 2 , the operator opens the front cover 17 and pulls the process cartridge 13 to the upper front position with respect to the main body 12 via the opening 16 . The operator then detaches the developing cartridge 20 from the process cartridge 13 . Thus, the removal of the drum cartridge 1 from the main body 12 is completed.
6. Effects
(1) According to the drum cartridge 1 , as depicted in FIGS. 11A and 11B , driving force transmitted to the drum gear 96 from the drive source of the main body 12 is further transmitted to the first roller gear 156 via the first idle gear 154 and the Oldham coupling 155 . With this configuration, a ratio of the peripheral speed of the first roller 6 relative to the photosensitive drum 2 may be widely changed.
According to the above-described embodiment, the Oldham coupling 155 is provided for transmitting driving force from the first idle gear 154 to the first roller gear 156 . Therefore, even when the first roller 6 moves slightly relative to the photosensitive drum 2 due to their rotations, the Oldham coupling 155 may absorb the deviation of the rotating axes of the gears, whereby driving force transmitted from the outside of the drum cartridge 1 may be transmitted to the first roller 6 stably.
Accordingly, a ratio of the peripheral speed of the first roller 6 relative to the photosensitive drum 2 may be widely changed. Further, driving force may be transmitted from the photosensitive drum 2 to the first roller 6 stably without an occurrence of the deviation of the rotating axes among the gears. Thus, instability in rotation of the photosensitive drum 2 caused due to the deviation of the rotating axes among the gears may be restricted, whereby an image may be formed on a sheet P with stable quality.
Accordingly, cleaning may be performed on the surface of the photosensitive drum 2 using the first roller 6 with stably and certainty.
(2) According to the drum cartridge 1 , as depicted in FIGS. 11A and 11B , the rotating speed of the first roller 6 relative to the photosensitive drum 2 may be reduced using the first idle gear 154 , the second idle gear 164 , and the second roller gear 168 .
Thus, cleaning of the surface of the photosensitive drum 2 may be performed evenly using the first roller 6 as compared with a case where the rotating speed of the first roller 6 is increased relative to the rotating speed of the photosensitive drum 2 .
(3) According to the drum cartridge 1 , as depicted in FIG. 11A , the first roller gear 156 is disposed between the drum gear 96 and the Oldham coupling 155 , whereby space may be used effectively.
Thus, the first roller gear 156 , the drum gear 96 , and the Oldham coupling 155 may be assembled effectively.
(4) According to the drum cartridge 1 , as depicted in FIGS. 1 and 10 , the provision of the second roller 7 may enhance the ability to remove and collect paper dust.
Further, the Oldham coupling 155 includes the second roller gear 168 for inputting driving force to the second roller 7 , thereby restricting an increase of a parts count.
(5) According to the drum cartridge 1 , as depicted in FIGS. 11A and 11B , the second idle gear 164 is further disposed in the driving force transmitting route from the drum gear 96 to the first roller gear 156 , whereby a ratio of the peripheral speed of the first roller 6 relative to the photosensitive drum 2 may be surely widely changed.
(6) According to the drum cartridge 1 , as depicted in FIG. 11A , as viewed in the right-left direction, the first idle gear 154 and the first roller gear 156 partially overlap each other, thereby restricting an increase in size of the drum cartridge 1 .
(7) According to the drum cartridge 1 , as depicted in FIGS. 10 and 11A , the gear holder 151 may improve the stability of the engagement between the first idle gear 154 and the second idle gear 164 .
With this configuration, driving force may be surely transmitted from the first idle gear 154 to the second idle gear 164 . Thus, the driving force may be further surely transmitted from the drum gear 96 to the first roller gear 156 .
Further, the deviation of rotating axes among the gears may be restricted. Therefore, instability in rotation of the photosensitive drum 2 may be restricted and thus image formation may be implemented with stability.
(8) According to the drum cartridge 1 , as depicted in FIG. 11A , the second idle gear 164 and the first idle gear 154 , which have the respective diameters that are smaller than the diameter of the drum gear 96 , may reduce the rotating speed of the first roller 6 relative to the photosensitive drum 2 .
Thus, while a reduction in size of the drum cartridge 1 is achieved, the rotating speed of the first roller 6 relative to the photosensitive drum 2 may be reduced and cleaning may be performed on the surface of the photosensitive drum 2 with certainty.
(9) According to the drum cartridge 1 , as depicted in FIGS. 1 and 11B , while the photosensitive drum 2 and the first roller 6 rotate in the same direction at their contacting point, a ratio of the peripheral speed of the first roller 6 relative to the photosensitive drum 2 may be widely changed and cleaning may be performed on the surface of the photosensitive drum 2 using the first roller 6 with certainty.
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A drum cartridge and a method are disclosed. An example of the drum cartridge includes a photosensitive drum, a first cleaning roller, and a second cleaning roller. The drum cartridge includes a first cleaning gear rotatable with the first cleaning roller, a second cleaning gear rotatable with the second cleaning roller and engaging with the first cleaning gear, a drum gear being rotatable with the photosensitive drum, a first idle gear engaging with the drum gear, a second idle gear engaging with the first idle gear, and a coupling joining the second cleaning gear and the second idle gear, the coupling being rotatable in unison with the second cleaning gear and the second idle gear.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to an electronic controlled stitch pattern sewing machine for sewing a stitch pattern on a workpiece based on stitch pattern data previously stored in a memory.
2. Prior art
Various types of stitch pattern sewing machine have been proposed as prior arts. For example, electronic controlled stitch pattern sewing machines have been disclosed in U.S. Pat. Nos. 4,388,884 and 4,413,574. In these arts, the sewing machine is equipped with a memory device for storing stitch pattern data assigned by X-Y coordinates corresponding to each of patterns such as letters and symbols to be sewn, and is also provided with a keyboard for selecting desired patterns from the stitch pattern data stored in the memory and for determining the size and the arrangement of the selected patterns. Moreover, the sewing machine has a function to determine whether or not the arranged patterns can fit within a predetermined sewing region confined by an embroidery frame. If they do not fit within the predetermined sewing region, a warning is given to the operator in advance so that a collision between the needle and the embroidery frame can be prevented.
These prior arts, however, include some shortcomings. For the purpose of sewing operation which is sewing the stitch patterns from one end of the extent of desired sewing region to the other end thereof, the operator is required to calculate an enlargement ratio or a contraction ratio of the patterns to make the size of the patterns close to that of the desired sewing region. Moreover, in the case that a plurality of patterns are arranged to be sewn, the operator must measure the size of the stitch pattern area and calculate a modification ratio, i.e., an enlargement or a contraction ratio of the arranged patterns to make the size of the pattern area close to that of the desired sewing region.
For another type, a pattern sewing machine having a CRT display is disclosed in U.S. Pat. No. 4,622,907. In this art, the size of the embroidery frame and the arrangement of the patterns to be sewn can be shown on the CRT display. This case, however, also requires the calculation of the enlargement/contraction ratio of the patterns to match the sewn pattern to the full extent of the sewing region.
In U.S. patent application Ser. No. 932,747 (now U.S. Pat. No. 4,742,786) bearing the same assignee as the present invention, which is filed on Nov. 18, 1986 and has been allowed, a kind of automatic modification system is described. The feature of this art is seen in an optional curve which is provided by an operator. Patterns to be stitched are automatically arranged along the curve so that the patterns extend from one end of the curve to the other end. However, this prior art describes only an automatic enlargement means but makes no mention of a contraction means.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a stitch pattern sewing machine which has a function to automatically modify stitch pattern data so that the size of the stitch pattern area matches the size of a previously determined sewing region.
Another object of the present invention is to provide a stitch pattern sewing machine in which all of the operations including selection, arrangement and modification of the pattern are realized by a simple keyboard operation so that work efficiency can be highly improved.
In order to achieve those and other objects, a stitch pattern sewing machine of the invention comprises: stitch forming means including a reciprocal needle for forming a stitch on the workpiece; workpiece holding means for holding the workpiece; drive means for causing relative movement between the needle and the workpiece holding means; memory means for storing stitch pattern data of the stitch pattern to be sewn on the workpiece; first calculation means for calculating a size of a stitch pattern area which is an envelope of the stitch pattern based on the stitch pattern data stored in the memory means; designation means for designating an optional size of a sewing region on said workpiece held by said workpiece holding means; second calculation means for calculating a ratio of the size of the sewing region to the size of the stitch pattern area; modification means for modifying the stitch pattern data based on the ratio so that the size of the stitch pattern area comes close to the size of the sewing region; and control means for controlling the drive means based on the stitch pattern data modified by the modification means.
BRIEF DESCRIPTION OF THE DRAWINGS
By way of example, and to make the description clearer, reference is made to the accompanying drawings in which:
FIG. 1 is a block diagram showing an electrical construction of a stitch pattern sewing machine of the present invention;
FIG. 2 is a schematic view illustrating a mechanical construction of the stitch pattern sewing machine and its peripheral equipment of the present invention;
FIG. 3 is a flowchart of a pattern modification routine to be executed in a first embodiment of the present invention;
FIG. 4 shows one state of a pattern shown on a display according to the first embodiment of the present invention;
FIG. 5 illustrates another state of a pattern shown on a display in the first embodiment;
FIG. 6 is a flowchart of a pattern modification process according to a second embodiment of the present invention;
FIG. 7 shows one state of a pattern shown on a display according to a second embodiment of the present invention; and
FIG. 8 illustrates another state of a pattern shown on a display in the second embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Set forth is an explanation of a first embodiment of the present invention with reference to FIGS. 1 through 5.
As shown in FIG. 2, a machine body 4 including a machine bed 2 and an arm 3 is set on a machine table 1. A needle plate 5 which has a needle hole 6 in the center of the plate is provided on the machine bed 2. The upper surface of the machine bed 2 is flush with that of the machine table 1 to make a workpiece supporting surface. A needle bar 8 having a needle 7 is provided at the lower end of the machine arm 3 to be vertically movable. The needle bar 8 is actuated by the rotation of a machine motor (not shown). The needle 7 on the needle bar 8 cooperates with a loop taker (not shown) to provide the stitch forming means.
On the above-mentioned workpiece supporting surface, a workpiece holder as a workpiece holding means which is composed of an outer embroidery frame 9 (hereafter referred to as an outer frame) and an inner embroidery frame 10 (inner frame) is provided. A cloth as a workpiece is held between the outer frame 9 and the inner frame 10. The workpiece holder is moved in both X- and Y-axis directions relative to the needle 7 by driving an X-axis pulse motor 23 and a Y-axis pulse motor 24 shown in FIG. 1.
To one side of the machine table 1, there is connected a control unit 14 including: a keyboard 13 for selecting and arranging patterns and for setting a sewing region 26; a display 12 for displaying a stitch pattern, its envelope area (stitch pattern area), an input sewing region, and a maximum sewing region 25 which is confined by the inner frame 10; and an external memory 11.
An electrical construction of the present embodiment will be described based on FIG. 1.
A central processing unit (CPU) 15 executes various control processes as well as calculations. A program memory (ROM) 16 for storing a control program shown in the flowchart of FIG. 3 and a work memory (RAM) 17 for storing selected and arranged stitch pattern data are connected to the CPU 15.
The CPU 15 is connected via an interface 18 with the keyboard 13 and with the external memory 11. By operating the keyboard 13, signals corresponding to respective commands are transmitted to the CPU 15. The outer memory 11 stores a plurality of stitch pattern data and display data for displaying the patterns on the display 12 corresponding to each of pattern characters such as letters and symbols to be sewn. The stitch pattern data is a set of relative position data of the needle 7 with respect to the workpiece held by the workpiece holder. Each of the relative position data corresponds to one of the stitches composing a stitch pattern and is composed of an X-axis component Dx and a Y-axis component Dy.
The CPU 15 is also connected via another interface 19 with a pulse motor drivers 20 and 21 and with a display driver 22. The pulse motor drivers 20 and 21 are respectively connected with an X-axis pulse motor 23 and a Y-axis pulse motor 24. The pulse motors 23 and 24 are controlled by drive control signals generated by the CPU 15 based on the stitch pattern data. The drive means is composed of 20, 21, 23 and 24. The display driver 22 is connected with the display 12 which is actuated by display control signal generated by the CPU 15 based on the display data.
The process steps to be executed in the present embodiment will be described in detail with reference to the flowchart of FIG. 3.
At step 1 (steps are hereafter referred to as S), a pattern selection signal is input to the CPU 15 via the interface 18 by operating the keyboard 13. Then, the stitch pattern data and the display data corresponding to the pattern selection signal are read out from the external memory 11 and are transferred to the work memory 17 by the CPU 15. This process is repeated until all pattern to be sewn are selected. When all patterns are selected, the stitch pattern data and the display data corresponding to each of the selected patterns are stored in the work memory 17. Subsequently, by operating the keyboard 13, arrangement of patterns including position setting, enlargement/contraction, rotation, and so on are carried out by the operator. At this time, the arrangement command signals are transmitted via the interface 18 to the CPU 15 so that the CPU 15 modifies the stitch pattern data and the display data stored in the work memory 17 in accordance with the arrangement signals. After that, the display data corresponding to each of the pattern are read out from the work memory 17 and the CPU 15 outputs display control signal corresponding to the display data via the interface 19 to the display driver 22 so that the whole pattern area is always displayed on the display 12. When the selection and arrangement of the patterns are accomplished, the program proceeds to S2.
At S2, each stitch pattern data stored in the work memory 17 is read out by the CPU 15 so that an X-axis length Mx and a Y-axis length My of each pattern are computed on the basis of the X-axis component Dx and the Y-axis component Dy of the relative position data. Moreover, the CPU 15 calculates the size of a pattern area 27 (an envelope of the all patterns) based on the above-mentioned X-axis length Mx and Y-axis length My of each pattern. Thus, an X-axis length Lx and a Y-axis length Ly of the pattern area 27 are determined and are stored in the work memory 17. The pattern area 27 is shown on the display 12 based on the lengths Lx and Ly.
Reference is now made to FIG. 4. When a pattern "ABC", in which a letter "A" is rotated by 90° to the left, is sewn on a workpiece in the X-axis direction, the total X-axis length Lx of the pattern area 27 is calculated by adding respective X-axis lengths Mx of the characters "A", "B" and "C". The Y-axis length Ly of the pattern area 27 is determined by selecting the longest one among the Y axis lengths My of each character "A", "B" and "C". Based on the calculated X- and Y-axis lengths Lx and Ly, the pattern area 27 of the pattern ABC is shown on the display 12.
At S3, it is determined whether a sewing region setting signal composed of four vertex coordinate data is input. When the sewing region setting signal is input by operating the keyboard 13, the vertex coordinate data are stored in the work memory 17 by the CPU 15. Then, the program proceeds to S4.
At S4, the CPU 15 reads out the four vertex coordinate data of the sewing region 26 stored in the work memory 17 so as to calculate an X-axis length Ex and a Y-axis length Ey of the sewing region 26. The calculated data are stored in the work memory 17. At the same time, the sewing region 26 is shown on the display 12.
FIG. 4 illustrates a picture shown on the screen of the display 12 at S4 when the letters "A", "B" and "C" are selected to be sewn and "A" is rotated by 90° to the left at S1 and the sewing region 26 is set at S3. On the screen, a maximum sewing region 25, the pattern "ABC" to be sewn, the pattern area 27 and the sewing region 26 are simultaneously displayed. The pattern is displayed with its standard point (lower left end vertex) at the current needle position P.
At subsequent S5, the CPU 15 determines whether or not an auto-adjustment command signal is input. If the signal is input by operating the keyboard 13, the program proceeds to S6.
At S6, the X- and Y-axis lengths Lx and Ly of the pattern area 27 and the X- and Y-axis lengths Ex and Ey of the sewing region 26 are read out from the work memory 17 by the CPU 15. Based on these values, the CPU 15 calculates a ratio Rx of the X-axis length Ex of the sewing region 26 to that of the stitch pattern area 27 (Rx=Ex/Lx) and a ratio Ry of the Y-axis length of the sewing region 26 to that of the stitch pattern area 27 (Ry=Ey/Ly). The calculated ratios Rx and Ry are stored in the work memory 17, and the program proceeds to S7.
At S7, the above-calculated ratios Rx and Ry are read out from the work memory 17. In accordance with Rx and Ry, the relative position data Dx and Dy of each stitch pattern data are modified and stored in the work memory 17. The modification accords with the equations Dx=Rx·Dx and Dy=Ry·Dy, respectively. At this step, the X- and Y-axis lengths of the pattern area 27 become equal to those of the sewing region 26. Namely, Lx=Ex and Ly=Ey. Moreover, the display data are also modified based on the above-mentioned ratios Rx and Ry.
At S8, the coordinates of the current position P of the needle and those of the lower left end vertex Q of the sewing region are compared by the CPU 15. Then, a distance Sx in the X-axis direction and a distance Sy in the Y-axis direction between the points P and Q are calculated and stored in the work memory 17. The modified pattern is shown on the display 12 with the standard point at the point Q. As a result of the modification and the movement, the picture on the display 12 shown in FIG. 4 is changed as shown in FIG. 5. Namely, the pattern area 27 matches the sewing region 26 and the pattern "ABC" is modified by contracting in the X-axis direction and extending in the Y-axis direction.
At subsequent S9, the CPU 15 determines whether or not a sewing command signal is input from the keyboard 13. If YES, the program proceeds to S10.
At S10, the distances Sx and Sy between the current needle position P and the standard point Q in both X- and Y-axis directions are read out from the work memory 17. The pulse motors 23 and 24 are actuated in accordance with the distances Sx and Sy so that the embroidery frame 9 is moved in the X- and Y-axis directions to bring the standard point Q (lower left end vertex of the sewing region) to the current needle position P. Then at S11, the machine 4 is driven and tee CPU 15 drives the pulse motors 23 and 24 according to the modified stitch pattern data. Thus, the pattern "ABC" shown in FIG. 5 is sewn on the workpiece.
In the present embodiment, since the maximum sewing region 25, the sewing region 26, the stitch pattern area 27 and the pattern to be sewn are simultaneously shown on the display 12, the operator can easily recognize the stitching position of the pattern.
Next, the second embodiment of the present invention will be described with reference to FIGS. 6 through 8.
The electrical and mechanical construction of the stitch pattern sewing machine of the second embodiment is the same as that of the first embodiment. The difference is seen in the flowchart of FIG. 3. Namely, S12 and S13 of FIG. 6 are substituted for S7 of the first embodiment.
In FIG. 3, after the ratios Rx and Ry are calculated at S6, the program proceeds to S12 in the second embodiment. At S12, the ratios Rx and Ry are read out from the work memory 17 to be compared with each other. Here the smaller one is selected as a modification ratio R and is stored in the work memory 17. Then, the program proceeds to S13.
At S13, each pattern stitching data and the modification ratio R are read out from the work memory 17. Based on the ratio R, the relative position data Dx and Dy for each of the stitch pattern data are modified in accordance with the equations Dx=R·Dx and Dy=R·Dy. The modified data are stored in the work memory 17. At this step, either the X- or the Y-axis length of the pattern area 27 becomes equal to the length of the corresponding axis of the stitching region 26. As a result, the figure of the pattern is adjusted to remain similar to the one arranged at S1. Moreover, the display data is also modified based on the modification ratio R. After the execution of S12 and S13, the program proceeds to S8 and the steps S9 through S11 follow as in the first embodiment.
The pictures on the display 12 at S4 and at S8 are respectively shown in FIGS. 7 and 8. Namely, FIG. 7 illustrates the figure of the pattern before the auto-adjustment command is input by the operator. FIG. 8 shows the modified figure of the pattern.
As is apparent from FIG. 8, only the X-axis length of the pattern area 27 is equal to that of the sewing region 26, because the ratio Rx is smaller than the ratio Ry so that Rx is selected as the modification ratio R. Since the modification ratio R is common in X- and Y-directions, the figure of the original pattern "ABC", as shown in FIG. 7, remains similar to that after modified, as shown in FIG. 8.
In the second embodiment, since the ratio Rx of the X-axis length of the pattern area 27 to that of the sewing region 26 and the ratio Ry of the Y-axis length of the pattern area 27 to that of the sewing region 26 are compared and smaller one is selected as the modification ratio R, the pattern is automatically modified so that the modified pattern remains similar to the original pattern and can fit within the sewing region 26.
While the invention has been particularly shown and described with reference to two preferred embodiments, it will be understood by those skilled in the art that various other changes in form and detail may be made without departing from the spirit and scope of the invention. For example, the form of the sewing region may be set other than a rectangle, e.g., a circle and so on. Moreover, while the present invention is embodied by an electronic controlled stitch pattern sewing machine, it may be embodied by other types of automatic pattern sewing machines.
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An electronic controlled stitch pattern sewing machine for sewing a desired pattern in a predetermined sewing region by automatically adjusting the size of the pattern by a simple keyboard operation. The pattern sewing machine includes first calculation means for calculating a size of a stitch pattern area, a sewing region designation means, a second calculation means for calculating a ratio of the size of the sewing region to that of the pattern area, modification means for modifying the stitch pattern data based on the ratio and control means for controlling drive means to cause relative movement between a needle and workpiece holder based on the modified stitch pattern data.
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BOTANICAL/COMMERICAL CLASSIFICATION
Rosa hybrida /Hybrid Tea Rose.
VARIETAL DENOMINATION
cv. ‘Delstriro’.
SUMMARY OF THE INVENTION
The new variety of Rosa hybrida Hybrid Tea rose plant was discovered in a greenhouse at Hyères, France, during 1999 and is a spontaneous mutation of unknown causation of the ‘Delego’ variety (U.S. Plant Pat. No. 9,915). Had the new variety of present invention not been discovered and preserved it would have been lost to mankind.
It was found through careful study that the new variety of Hybrid Tea rose plant of the present invention exhibits the following combination of characteristics:
(a) From a physical point of view forms green mature wood, displays a bushy growth habit, and forms attractive long lasting clear red striped with darker red double flowers, and
(b) From the biological point of view forms semi-vigorous to vigorous vegetation, produces flowers in abundance, exhibits the ability readily to be forced, and is resistant to diseases.
The new variety well meets the needs of the horticultural industry and is particularly well suited for growing in the greenhouse for the production of attractive long-lasting cut flowers which are clear red striped with dark red.
The new variety can be readily distinguished from other varieties in view of the combination of characteristics described herein. For instance, the new variety can be readily distinguished from its ‘Delego’ variety parent by the display of striped red flowers while those of the parent variety are unstriped red.
The new variety exhibits relatively straight stems, rigid and substantially straight peduncles, an excellent ability to be forced under greenhouse growing conditions, and a good vase life for the distinctive clear red striped with dark red blossoms.
The new variety has been found to undergo asexual propagation and can be readily reproduced by conventional routes, such as budding (i.e., eye grafting), the rooting of cuttings and tissue culture. This asexual reproduction by budding as performed at Hyéres, France, has demonstrated that the characteristics of the new variety are stable and are strictly transmissible from one generation to another.
The new variety has been named the ‘Delstriro’ variety.
BRIEF DESCRIPTION OF THE PHOTOGRAPH
The accompanying photograph shows as nearly true as it is reasonably possible to make the same in a color illustration of this character typical specimens of the plant parts of the new variety. The rose plants of the new variety were grown under glass in the South of France.
FIG. 1 —illustrates a specimen of a young shoot;
FIG. 2 —illustrates a specimen of a floral bud at the opening of the sepals;
FIG. 3 —illustrates a specimen of a floral bud at the opening of the petals;
FIG. 4 —illustrates specimens of a flower in the course of opening;
FIG. 5 —illustrates a specimen of an open flower—plan view—obverse;
FIG. 6 —illustrates a specimen of an open flower plan view—reverse;
FIG. 7 —illustrates a specimen of a fully open flower—plan view—obverse;
FIG. 8 —illustrates a specimen of a fully open flower—plan view—reverse;
FIG. 9 —illustrates a specimen of a floral receptacle showing the arrangement of the stamens and pistils;
FIG. 10 —illustrates a specimen of a floral receptacle showing the arrangement of the pistils (stamens and sepals removed);
FIG. 11 —illustrates a specimen of a flowering stem;
FIG. 12 —illustrates a specimen of a main branch;
FIG. 13 —illustrates a specimen of a leaf with three leaflets—plan view—upper surface;
FIG. 14 —illustrates a specimen of a leaf with five leaflets—plan view—upper surface;
FIG. 15 —illustrates a specimen of a leaf with three leaflets—plan view—under surface; and
FIG. 16 —illustrates a specimen of a leaf with five leaflets—plan view—under surface.
DETAILED DESCRIPTION
The chart used in the identification of the colors is that of The Royal Horticultural Society (R.H.S. Colour Chart-1991). The description is based on the observation of plants grown under glass in the South of France.
Class: Hybrid tea.
Plant:
Height.— Plants which were pruned to a height of 20 to 30 cm produce floral stems having a length of approximately 40 to 100 cm, and an average length of approximately 70 cm.
Width.— Approximately 50 to 60 cm.
Habit.— Bushy.
Branches:
Color.— Young shoots: when approximately 20 cm long, exhibit green coloration, Yellow-Green Group 146D. Floral stems: Yellow-Green Group 144A to 146B. Mature wood: Yellow-Green Group 146A.
Diameter.— Commonly approximately 8 to 11 mm (average 9 mm).
Thorns.— Configuration: convex on the upper edge and concave on the under edge. Quantity, length and frequency: on a typical floral stem having a length of 70 cm, there commonly are no thorns on the 30 cm below the bud, for the next 20 cm no or very few thorns, and for the last 20 cm some thorns irregularly arranged having lengths of approximately 3 mm to 1 cm and an average length of approximately 56 mm. On a young shoot having a length of approximately 30 cm, there commonly are no thorns. Color: on floral stems the coloration of the thorns is Greyed-Red Group 181A, and on mature wood the thorns are Greyed-Orange Group 165A and 165B.
Leaves.— Number: typical for the class and commonly number approximatey 90 to 100. Size: Terminal leaflets commonly are approximately 60 to 90 mm (average 70 mm) in length and approximately 40 to 63 mm (average 46 mm) in width. Stipules: adnate, medium in size, and commonly 30 to 40 mm (average 35 mm) in length, approximately 7 to 9 mm (average 8 mm) in width at the mid-point, and approximately 18 to 22 mm (average 20 mm) at the distal end.
Leaflets.— Number: 3, 5, and 7. Shape: rounded to cordate at the base of the terminal leaflet and convex in cross section. Serration: present, single, and irregular. General appearance: consistent with medium glossiness. Petiole: commonly bears some prickles (often 1 to 3 per petiole), and the inner surface is grooved with non-glandular edges. Petiole color on young shoot: Greyed-Orange Group 173A with green and bronze coloration. Petiole color on floral stem: Yellow-Green Group 146A on the upper surface and Yellow-Green Group 146C on the under surface. Petiole color on mature wood: Yellow-Green Group 146A on the upper surface and Yellow-Green Group 146C on the under surface. Petiole length of terminal leaflet: approximately 16 to 22 l mm, approximately 19 mm on average, with a standard deviation of 0.22 mm. Terminal leaflet length: approximately 60 to 90 mm, approximately 70 mm on average, with a standard deviation of 0.67 mm. Terminal leaflet width: approximately 40 to 63 mm, approximately 46 mm on average, with a standard deviation of 0.41 mm. Terminal leaflet shape at base: rounded. Leaflet color of young shoot: Yellow-Green Group 147A with some bronze coloration on the upper surface and Greyed-Purple Group 183C with some green coloration on the middle of the under surface. Leaflet color on floral stem: Green Group 139A on the upper surface and Yellow-Green Group 147B on the under surface. Leaflet color of mature wood: Yellow-Green Group 147A on the upper surface, and Yellow-Green Group 147B on the under surface. Venation: in a typical alternately arranged pattern, and the coloration commonly is Yellow-Green Group 151A at the distal end and Greyed-Yellow Group 160A at the proximal end.
Inflorescence:
Number of flowers.— Generally one per stem when grown under forced greenhouse conditions; however, sometimes during forced culture an axillary eye or eyes below the flower develop to form 1 or 2 flowers.
Peduncle.— Erect, stiff, Yellow-Green Group 144A in coloration with some small hairs, and approximately 85 to 115 mm in length (average approximately 100 mm).
Sepals.— Configuration: Two sepals commonly possess no extensions, and three sepals commonly possess medium to strong extensions. The extensions are denticulate and commonly are long to very long. The sepal length commonly is 50 to 70 mm (average 60 mm). Color: Yellow-Green Group 147B on the upper surface and Yellow-Green Group 146B on the under surface.
Buds.— Shape: ovate in longitudinal section just before the opening of the sepals. Size before calyx breaks: the bud lengths are approximately 28 to 31 mm, with an average length of approximately 30 mm. Color as calyx breaks: Red Group 45BA striped with Red Group 53A. Size after calyx breaks: the bud lengths are approximately 38 to 45 mm, with an average length of approximately 40 mm. Color after calyx breaks: inside: Red Group 45B striped with Red Group 53A.
Flower.— Time: when growing in the greenhouse in the winter at a temperature of approximately 16 to 25° C. flowering occurs in approximately 50 days. Shape: irregularly rounded when viewed from above. Form: double, flattened convex at the upper part when viewed from the side, and flattened convex to convex at the lower part when viewed from the side. Diameter: medium to large, approximately 10 to 12 cm, and approximately 11 cm on average, with a standard deviation of 0.5 cm. Petal number: commonly approximately 31 to 39, and an average of approximately 36. Petal size (second row from outside): the length is approximately 55 to 65 mm with a mean of approximately 59 mm, and a standard deviation of 0.4 mm; and the width is approximately 55 to 69 mm with a mean of approximately 53 mm, and a standard deviation of 6 mm. Petal shape: the first row of petals commonly exhibits a broad ovate configuration, the undulation of the petal margins is average, and the reflexing of the margins is average. Petal color: the following description of a nearly fully open flower was made while observing a rose grown in the greenhouse during April which had been undergoing opening for three days. Petal color (middle zone): on the inner surface Red Group 50A striped with Red Group 53A, and on the outer surface Red Group 53C and 53D with darker striping of Red Group 53B or 53C. Petal color (marginal zone): on the inner surface Red Group 50A striped with Red Group 53A, and on the outer surface Red Group 53C and 53D with darker striping of Red Group 53B and 53C. Petal spot at base: small in size, and can be absent when the plant is grown outdoors. Color of spot inner side: Yellow Group 9C. Color of spot outer side: Green-Yellow Group 1D. Stamens: approximately 136 in number and are somewhat regularly arranged. Filaments: medium in length, not all possess an anther, when the flower is partially open Yellow-Orange Group 14A and 17B in coloration, and when the flower is fully open Red Group 37C and Yellow Group 8B in coloration. Anthers: medium in size, all open at approximately the same time, and the immature coloration is Yellow-Orange Group 14C. Pollen: sparse in quantity and Yellow-Orange Group 21A in coloration. Pistils: approximately 147 in number. Styles: medium in length and Red Group 52A in coloration. Stigmas: Yellow-Orange Group 18B, and generally are present at the same level as the anthers, but a few anthers may be higher. Hips: in longitudinal section they are in the shape of a funnel and are approximately 23 mm in diameter. Seeds: none to date. Petal drop: the petals detach cleanly. Fragrance: slight. Lasting quality: long. When cut and placed in a vase, the flowers commonly last approximately 5 to 6 days. Hips: rarely formed and are funnel-shaped when formed.
Development:
Vegetation.— Semi-vigorous to vigorous.
Blooming.— Very abundant and almost continuous.
Aptitude to forcing.— Excellent.
Resistance to diseases.— Good under greenhouse conditions, as well as when grown outdoors.
Winter hardiness.— Not determined since the variety is primarily intended for cut flower production under greenhouse growing conditions.
Drought tolerance.— Not determined since the variety has been tested under standard greehouse growing conditions with adequate water to date.
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A new and distinct variety of Hybrid Tea rose plant is provided that abundantly and nearly continuously forms attractive double flowers which are clear red striped with darker red. The plant is well suited for cut flower production when grown in the greenhouse. The flowers exhibit a good vase life and possess petals that detach cleanly. The plant exhibits a bushy growth habit, forms semi-vigorous to vigorous vegetation, and is well suited for greenhouse forcing when producing cut flowers. Additionally, the plant displays good disease resistance.
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CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. application Ser. No. 12/554,036 filed Sep. 4, 2009, which is a continuation of U.S. application Ser. No. 11/655,337 filed Jan. 19, 2007, which in turn claims priority under 35 U.S.C. §119(e) to U.S. Provisional Application Ser. No. 60/761,428 filed Jan. 23, 2006.
FIELD OF THE INVENTION
[0002] The present invention relates to thiazolium dyes, laundry care compositions comprising one or more thiazolium dyes, processes of making such dyes and laundry care compositions and methods of using same.
BACKGROUND OF THE INVENTION
[0003] Fabrics, typically lighter colored fabrics such as white fabrics, that are worn and/or laundered typically discolor. For example, white fabrics which are repeatedly laundered can exhibit a yellowing in color appearance which causes the fabric to look older and worn. In an effort to overcome such fabric discoloration, certain laundry detergent products include a hueing or bluing dye which attaches to fabric during the laundry wash and/or rinse cycle. Unfortunately, such hueing or bluing dye typically tends to accumulate on the fabric, thus giving the fabric an undesirable bluish tint. As a result, a chlorine treatment is generally employed to reduce the aforementioned accumulation of bluing dyes. While a chlorine treatment can be effective, it is an additional, inconvenient step in the laundry process. Additionally, a chlorine treatment is costly and harsh on fabrics-contributing to increased fabric degradation. Accordingly, a need exists for improved laundry care products which can counter the undesirable discoloration of fabrics, including the yellowing of white fabrics.
SUMMARY OF THE INVENTION
[0004] The present invention relates to thiazolium dyes, laundry care compositions comprising one or more thiazolium dyes, processes of making such dyes and laundry care compositions and methods of using same. The dyes, compositions and methods of the present invention are advantageous in providing improved hueing of fabric, including whitening of white fabric, while avoiding significant build up of bluing dyes on the fabric.
DETAILED DESCRIPTION OF THE INVENTION
Definitions
[0005] As used herein, the term “laundry care composition” includes, unless otherwise indicated, granular, powder, liquid, gel, paste, bar form and/or flake type washing agents and/or fabric treatment compositions.
[0006] As used herein, the term “fabric treatment composition” includes, unless otherwise indicated, fabric softening compositions, fabric enhancing compositions, fabric freshening compositions and combinations there of. Such compositions may be, but need not be rinse added compositions.
[0007] As used herein, the articles including “the”, “a” and “an” when used in a claim, are understood to mean one or more of what is claimed or described.
[0008] As used herein, the terms “include”, “includes” and “including” are meant to be non-limiting.
[0009] As used herein, the term polyether is defined as at least two repeating ether units that are chemically bound via the ethers' oxygen atoms. Such polyethers may be derived from materials including but not limited to ethylene oxide, propylene oxide, butylene oxide, hexylene oxide, glycidol, epichlorohydrin, pentanerythritol, glucose or combinations thereof.
[0010] As used herein capped polyether means a polyether that terminates in an alkyl or aryl moiety, including but not limited to a moiety selected from methyl, ethyl, butyl, isopropyl, tertiary butyl, amyl, benzyl, pentyl, and acetyl moieties.
[0011] As used herein “EO” stands for an ethylene oxide moiety.
[0012] As used herein “PO” stands for a propylene oxide moiety.
[0013] The test methods disclosed in the Test Methods Section of the present application should be used to determine the respective values of the parameters of Applicants' inventions.
[0014] Unless otherwise noted, all component or composition levels are in reference to the active portion of that component or composition, and are exclusive of impurities, for example, residual solvents or by-products, which may be present in commercially available sources of such components or compositions.
[0015] All percentages and ratios are calculated by weight unless otherwise indicated. All percentages and ratios are calculated based on the total composition unless otherwise indicated.
[0016] It should be understood that every maximum numerical limitation given throughout this specification includes every lower numerical limitation, as if such lower numerical limitations were expressly written herein. Every minimum numerical limitation given throughout this specification will include every higher numerical limitation, as if such higher numerical limitations were expressly written herein. Every numerical range given throughout this specification will include every narrower numerical range that falls within such broader numerical range, as if such narrower numerical ranges were all expressly written herein.
[0017] All documents cited are, in relevant part, incorporated herein by reference; the citation of any document is not to be construed as an admission that it is prior art with respect to the present invention.
Laundry Care Compositions
[0018] In one aspect, a laundry care composition that may comprise a laundry care ingredient and a suitable thiazolium dye is disclosed. Suitable thiazolium dyes include thiazolium dyes that exhibit good tinting efficiency during a laundry wash cycle without exhibiting excessive undesirable build up after laundering. Thus, undesirable bluing after repeated washings with the detergent compositions of the invention is avoided and costly and harsh chlorine treatments are unnecessary. Suitable thiazolium dyes include those thiazolium dyes that are described under the heading “Suitable Thiazolium Dyes” of the present specification.
[0019] In one aspect, the laundry care compositions disclosed in the present specification can employ the thiazolium dyes disclosed in the present specification as detailed by Formulae V through VIII of the present specification.
[0020] In one aspect suitable thiazolium dyes include thiazolium dye molecules numbers 1-80 as detailed in Tables 1 and 2 of the present specification.
[0021] In one aspect, suitable thiazolium dyes include thiazolium dye molecules numbers 1, 4, 5, 7, 8, 12, 13, 15, 16, 17, 21, 24, 25, 26, 30, 31, 33, 36, 38, 40, 45 and 48 as detailed in Tables 1 and 2 of the present specification.
[0022] In one aspect, suitable thiazolium dyes include thiazolium dye molecules numbers 12, 13, 15, 16, 24, 25, 26, 30, 31, 33, 36, 38, 40, 45 and 48 as detailed in Tables 1 and 2 of the present specification.
[0023] In one aspect, the laundry care compositions disclosed in the present specification can employ combinations of any of the suitable thiazolium dyes disclosed in the present specification.
[0024] In one aspect, the laundry care compositions disclosed in the present specification can employ a non-hueing dye in combination with the thiazolium dye. The non-hueing dye may be selected from non-hueing dyes disclosed in U.S. Patent Application 2005/028820 A1, U.S. Pat. No. 4,137,243, U.S. Pat. No. 4,601,725 and U.S. Pat. No. 4,871,371. While not being bound by theory, it is believed that the combination of both a thiazolium dye and a non-hueing dye allows for flexibility to color blend to a desired hue.
[0025] In one aspect, the laundry care compositions disclosed in the present specification can employ a non-hueing dye, that may be non-substantive in nature, in combination with the thiazolium dye. The combination of both a thiazolium dye and a non-hueing dye can allow customization of product color and fabric tint. In one aspect, Acid Blue 7 may be employed as a non-hueing, non-tinting dye.
[0026] In one aspect, any of the components, including the suitable thiazolium dyes, may be employed in the laundry care compositions in an encapsulated form. Such encapsulates may comprise one or more of such components.
[0027] In one aspect a laundry care compositions comprising a thiazolium dye and a laundry care ingredient and having a hueing efficiency of greater than 10 but less than 40, from about 15 to about 35, or even from about 15 to about 30 and a wash removability of from about 30% to about 85%, from about 40% to about 85%, from about 50% to about 85% are disclosed.
[0028] Suitable laundry care ingredients include, but are not limited to, those materials described in the present specification as useful aspects of the present invention, including adjunct materials as described in the present specification.
Liquid, Laundry Detergent Compositions
[0029] In one aspect, the laundry care compositions disclosed herein, may take the form of liquid, laundry detergent compositions. In one aspect, such compositions may be a heavy duty liquid composition. Such compositions may comprise a sufficient amount of a surfactant to provide the desired level of one or more cleaning properties, typically by weight of the total composition, from about 5% to about 90%, from about 5% to about 70% or even from about 5% to about 40% and a sufficient of suitable thiazolium dye that is described under the heading “Suitable Thiazolium Dyes” of the present specification, to provide a tinting effect to fabric washed in a solution containing the detergent, typically by weight of the total composition, from about 0.0001% to about 0.05%, or even from about 0.001% to about 0.01%.
[0030] The liquid detergent compositions comprise an aqueous, non-surface active liquid carrier. Generally, the amount of the aqueous, non-surface active liquid carrier employed in the compositions herein will be effective to solubilize, suspend or disperse the composition components. For example, the compositions may comprise, by weight, from about 5% to about 90%, from about 10% to about 70%, or even from about 20% to about 70% of an aqueous, non-surface active liquid carrier.
[0031] The most cost effective type of aqueous, non-surface active liquid carrier may be water. Accordingly, the aqueous, non-surface active liquid carrier component may be generally mostly, if not completely, water. While other types of water-miscible liquids, such alkanols, diols, other polyols, ethers, amines, and the like, have been conventionally been added to liquid detergent compositions as co-solvents or stabilizers, for purposes of the present invention, the utilization of such water-miscible liquids may be minimized to hold down composition cost. Accordingly, the aqueous liquid carrier component of the liquid detergent products herein will generally comprise water present in concentrations ranging from about 5% to about 90%, or even from about 20% to about 70%, by weight of the composition.
[0032] The liquid detergent compositions herein may take the form of an aqueous solution or uniform dispersion or suspension of surfactant, thiazolium dye, and certain optional other ingredients, some of which may normally be in solid form, that have been combined with the normally liquid components of the composition, such as the liquid alcohol ethoxylate nonionic, the aqueous liquid carrier, and any other normally liquid optional ingredients. Such a solution, dispersion or suspension will be acceptably phase stable and will typically have a viscosity which ranges from about 100 to 600 cps, more preferably from about 150 to 400 cps. For purposes of this invention, viscosity is measured with a Brookfield LVDV-II+ viscometer apparatus using a #21 spindle.
[0033] Suitable surfactants may be anionic, nonionic, cationic, zwitterionic and/or amphoteric surfactants. In one aspect, the detergent composition comprises anionic surfactant, nonionic surfactant, or mixtures thereof.
[0034] Suitable anionic surfactants may be any of the conventional anionic surfactant types typically used in liquid detergent products. Such surfactants include the alkyl benzene sulfonic acids and their salts as well as alkoxylated or non-alkoxylated alkyl sulfate materials.
[0035] Exemplary anionic surfactants are the alkali metal salts of C 10-16 alkyl benzene sulfonic acids, preferably C 11-14 alkyl benzene sulfonic acids. In one aspect, the alkyl group is linear. Such linear alkyl benzene sulfonates are known as “LAS”. Such surfactants and their preparation are described for example in U.S. Pat. Nos. 2,220,099 and 2,477,383. Especially preferred are the sodium and potassium linear straight chain alkylbenzene sulfonates in which the average number of carbon atoms in the alkyl group is from about 11 to 14. Sodium C 11 -C 14 , e.g., C 12 , LAS is a specific example of such surfactants.
[0036] Another exemplary type of anionic surfactant comprises ethoxylated alkyl sulfate surfactants. Such materials, also known as alkyl ether sulfates or alkyl polyethoxylate sulfates, are those which correspond to the formula: R′—O—(C 2 H 4 O) n —SO 3 M wherein R′ is a C 8 -C 20 alkyl group, n is from about 1 to 20, and M is a salt-forming cation. In a specific embodiment, R′ is C 10 -C 18 alkyl, n is from about 1 to 15, and M is sodium, potassium, ammonium, alkylammonium, or alkanolammonium. In more specific embodiments, R′ is a C 12 -C 16 , n is from about 1 to 6 and M is sodium.
[0037] The alkyl ether sulfates will generally be used in the form of mixtures comprising varying R′ chain lengths and varying degrees of ethoxylation. Frequently such mixtures will inevitably also contain some non-ethoxylated alkyl sulfate materials, i.e., surfactants of the above ethoxylated alkyl sulfate formula wherein n=0. Non-ethoxylated alkyl sulfates may also be added separately to the compositions of this invention and used as or in any anionic surfactant component which may be present. Specific examples of non-alkoyxylated, e.g., non-ethoxylated, alkyl ether sulfate surfactants are those produced by the sulfation of higher C 8 -C 20 fatty alcohols. Conventional primary alkyl sulfate surfactants have the general formula: ROSO 3 − M+ wherein R is typically a linear C 8 -C 20 hydrocarbyl group, which may be straight chain or branched chain, and M is a water-solubilizing cation. In specific embodiments, R is a C 10 -C 15 alkyl, and M is alkali metal, more specifically R is C 12 -C 14 and M is sodium.
[0038] Specific, nonlimiting examples of anionic surfactants useful herein include: a) C 11 -C 18 alkyl benzene sulfonates (LAS); b) C 10 -C 20 primary, branched-chain and random alkyl sulfates (AS); c) C 10 -C 18 secondary (2,3) alkyl sulfates having formulae (I) and (II):
[0000]
[0000] wherein M in formulae (I) and (II) is hydrogen or a cation which provides charge neutrality, and all M units, whether associated with a surfactant or adjunct ingredient, can either be a hydrogen atom or a cation depending upon the form isolated by the artisan or the relative pH of the system wherein the compound is used, with non-limiting examples of preferred cations including sodium, potassium, ammonium, and mixtures thereof, and x is an integer of at least about 7, preferably at least about 9, and y is an integer of at least 8, preferably at least about 9; d) C 10 -C 18 alkyl alkoxy sulfates (AE x S) wherein preferably x is from 1-30; e) C 10 -C 18 alkyl alkoxy carboxylates preferably comprising 1-5 ethoxy units; f) mid-chain branched alkyl sulfates as discussed in U.S. Pat. No. 6,020,303 and U.S. Pat. No. 6,060,443; g) mid-chain branched alkyl alkoxy sulfates as discussed in U.S. Pat. No. 6,008,181 and U.S. Pat. No. 6,020,303; h) modified alkylbenzene sulfonate (MLAS) as discussed in WO 99/05243, WO 99/05242, WO 99/05244, WO 99/05082, WO 99/05084, WO 99/05241, WO 99/07656, WO 00/23549, and WO 00/23548; i) methyl ester sulfonate (MES); and j) alpha-olefin sulfonate (AOS).
[0039] Suitable nonionic surfactants useful herein can comprise any of the conventional nonionic surfactant types typically used in liquid detergent products. These include alkoxylated fatty alcohols and amine oxide surfactants. Preferred for use in the liquid detergent products herein are those nonionic surfactants which are normally liquid.
[0040] Suitable nonionic surfactants for use herein include the alcohol alkoxylate nonionic surfactants. Alcohol alkoxylates are materials which correspond to the general formula: R 1 (C m H 2m O) n OH wherein R 1 is a C 8 -C 16 alkyl group, m is from 2 to 4, and n ranges from about 2 to 12. Preferably R 1 is an alkyl group, which may be primary or secondary, that contains from about 9 to 15 carbon atoms, more preferably from about 10 to 14 carbon atoms. In one embodiment, the alkoxylated fatty alcohols will also be ethoxylated materials that contain from about 2 to 12 ethylene oxide moieties per molecule, more preferably from about 3 to 10 ethylene oxide moieties per molecule.
[0041] The alkoxylated fatty alcohol materials useful in the liquid detergent compositions herein will frequently have a hydrophilic-lipophilic balance (HLB) which ranges from about 3 to 17. More preferably, the HLB of this material will range from about 6 to 15, most preferably from about 8 to 15. Alkoxylated fatty alcohol nonionic surfactants have been marketed under the tradename Neodol® by the Shell Chemical Company.
[0042] Another suitable type of nonionic surfactant useful herein comprises the amine oxide surfactants. Amine oxides are materials which are often referred to in the art as “semi-polar” nonionics. Amine oxides have the formula: R(EO) x (PO) y (BO) z N(O)(CH 2 R′) 2 .qH 2 O. In this formula, R is a relatively long-chain hydrocarbyl moiety which can be saturated or unsaturated, linear or branched, and can contain from 8 to 20, preferably from 10 to 16 carbon atoms, and is more preferably C 12 -C 16 primary alkyl. R′ is a short-chain moiety, preferably selected from hydrogen, methyl and —CH 2 OH. When x+y+z is different from 0, EO is ethyleneoxy, PO is propyleneneoxy and BO is butyleneoxy. Amine oxide surfactants are illustrated by C 12-14 alkyldimethyl amine oxide.
[0043] Non-limiting examples of nonionic surfactants include: a) C 12 -C 18 alkyl ethoxylates, such as, NEODOL® nonionic surfactants from Shell; b) C 6 -C 12 alkyl phenol alkoxylates wherein the alkoxylate units are a mixture of ethyleneoxy and propyleneoxy units; c) C 12 -C 18 alcohol and C 6 -C 12 alkyl phenol condensates with ethylene oxide/propylene oxide block polymers such as Pluronic® from BASF; d) C 14 -C 22 mid-chain branched alcohols, BA, as discussed in U.S. Pat. No. 6,150,322; e) C 14 -C 22 mid-chain branched alkyl alkoxylates, BAE x , wherein x 1-30, as discussed in U.S. Pat. No. 6,153,577, U.S. Pat. No. 6,020,303 and U.S. Pat. No. 6,093,856; f) Alkylpolysaccharides as discussed in U.S. Pat. No. 4,565,647 Llenado, issued Jan. 26, 1986; specifically alkylpolyglycosides as discussed in U.S. Pat. No. 4,483,780 and U.S. Pat. No. 4,483,779; g) Polyhydroxy fatty acid amides as discussed in U.S. Pat. No. 5,332,528, WO 92/06162, WO 93/19146, WO 93/19038, and WO 94/09099; and h) ether capped poly(oxyalkylated) alcohol surfactants as discussed in U.S. Pat. No. 6,482,994 and WO 01/42408.
[0044] In the laundry detergent compositions herein, the detersive surfactant component may comprise combinations of anionic and nonionic surfactant materials. When this is the case, the weight ratio of anionic to nonionic will typically range from 10:90 to 90:10, more typically from 30:70 to 70:30.
[0045] Cationic surfactants are well known in the art and non-limiting examples of these include quaternary ammonium surfactants, which can have up to 26 carbon atoms. Additional examples include a) alkoxylate quaternary ammonium (AQA) surfactants as discussed in U.S. Pat. Nos. 6,136,769; b) dimethyl hydroxyethyl quaternary ammonium as discussed in 6,004,922; c) polyamine cationic surfactants as discussed in WO 98/35002, WO 98/35003, WO 98/35004, WO 98/35005, and WO 98/35006; d) cationic ester surfactants as discussed in U.S. Pat. Nos. 4,228,042, 4,239,660 4,260,529 and U.S. Pat. No. 6,022,844; and e) amino surfactants as discussed in U.S. Pat. No. 6,221,825 and WO 00/47708, specifically amido propyldimethyl amine (APA).
[0046] Non-limiting examples of zwitterionic surfactants include: derivatives of secondary and tertiary amines, derivatives of heterocyclic secondary and tertiary amines, or derivatives of quaternary ammonium, quaternary phosphonium or tertiary sulfonium compounds. See U.S. Pat. No. 3,929,678 to Laughlin et al., issued Dec. 30, 1975 at column 19, line 38 through column 22, line 48, for examples of zwitterionic surfactants; betaine, including alkyl dimethyl betaine and cocodimethyl amidopropyl betaine, C 8 to C 18 (preferably C 12 to C 18 ) amine oxides and sulfo and hydroxy betaines, such as N-alkyl-N,N-dimethylamino-1-propane sulfonate where the alkyl group can be C 8 to C 18 , preferably C 10 to C 14 .
[0047] Non-limiting examples of ampholytic surfactants include: aliphatic derivatives of secondary or tertiary amines, or aliphatic derivatives of heterocyclic secondary and tertiary amines in which the aliphatic radical can be straight- or branched-chain. One of the aliphatic substituents contains at least about 8 carbon atoms, typically from about 8 to about 18 carbon atoms, and at least one contains an anionic water-solubilizing group, e.g. carboxy, sulfonate, sulfate. See U.S. Pat. No. 3,929,678 to Laughlin et al., issued Dec. 30, 1975 at column 19, lines 18-35, for examples of ampholytic surfactants.
Granular Laundry Detergent Compositions
[0048] In one aspect, the laundry care compositions disclosed herein, may take the form of granular, laundry detergent compositions. Such compositions may comprise a sufficient of suitable thiazolium dye that is described under the heading “Suitable Thiazolium Dyes” of the present specification, to provide a tinting effect to fabric washed in a solution containing the detergent, typically by weight of the total composition, from about 0.0001% to about 0.05%, or even from about 0.001% to about 0.01%.
[0049] Granular detergent compositions of the present invention may include any number of conventional detergent ingredients. For example, the surfactant system of the detergent composition may include anionic, nonionic, zwitterionic, ampholytic and cationic classes and compatible mixtures thereof. Detergent surfactants for granular compositions are described in U.S. Pat. No. 3,664,961, Norris, issued May 23, 1972, and in U.S. Pat. No. 3,919,678, Laughlin et al., issued Dec. 30, 1975. Cationic surfactants include those described in U.S. Pat. No. 4,222,905, Cockrell, issued Sep. 16, 1980, and in U.S. Pat. No. 4,239,659, Murphy, issued Dec. 16, 1980.
[0050] Nonlimiting examples of surfactant systems include the conventional C 11 -C 18 alkyl benzene sulfonates (“LAS”) and primary, branched-chain and random C 10 -C 20 alkyl sulfates (“AS”), the C 10 -C 18 secondary (2,3) alkyl sulfates of the formula CH 3 (CH 2 ) x (CHOSO 3 − M + )CH 3 and CH 3 (CH 2 ) y (CHOSO 3 − M + )CH 2 CH 3 where x and (y+1) are integers of at least about 7, preferably at least about 9, and M is a water-solubilizing cation, especially sodium, unsaturated sulfates such as oleyl sulfate, the C 10 -C 18 alkyl alkoxy sulfates (“AE x S”; especially EO 1-7 ethoxy sulfates), C 10 -C 18 alkyl alkoxy carboxylates (especially the EO 1-5 ethoxycarboxylates), the C 10-18 glycerol ethers, the C 10 -C 18 alkyl polyglycosides and their corresponding sulfated polyglycosides, and C 12 -C 18 alpha-sulfonated fatty acid esters. If desired, the conventional nonionic and amphoteric surfactants such as the C 12 -C 18 alkyl ethoxylates (“AE”) including the so-called narrow peaked alkyl ethoxylates and C 6 -C 12 alkyl phenol alkoxylates (especially ethoxylates and mixed ethoxy/propoxy), C 12 -C 18 betaines and sulfobetaines (“sultaines”), C 10 -C 18 amine oxides, and the like, can also be included in the surfactant system. The C 10 -C 18 N-alkyl polyhydroxy fatty acid amides can also be used. See WO 9,206,154. Other sugar-derived surfactants include the N-alkoxy polyhydroxy fatty acid amides, such as C 10 -C 18 N-(3-methoxypropyl)glucamide. The N-propyl through N-hexyl C 12 -C 18 glucamides can be used for low sudsing. C 10 -C 20 conventional soaps may also be used. If high sudsing is desired, the branched-chain C 10 -C 16 soaps may be used. Mixtures of anionic and nonionic surfactants are especially useful. Other conventional useful surfactants are listed in standard texts.
[0051] The detergent composition can, and preferably does, include a detergent builder. Builders are generally selected from the various water-soluble, alkali metal, ammonium or substituted ammonium phosphates, polyphosphates, phosphonates, polyphosphonates, carbonates, silicates, borates, polyhydroxy sulfonates, polyacetates, carboxylates, and polycarboxylates. Preferred are the alkali metal, especially sodium, salts of the above. Preferred for use herein are the phosphates, carbonates, silicates, C 10-18 fatty acids, polycarboxylates, and mixtures thereof. More preferred are sodium tripolyphosphate, tetrasodium pyrophosphate, citrate, tartrate mono- and di-succinates, sodium silicate, and mixtures thereof.
[0052] Specific examples of inorganic phosphate builders are sodium and potassium tripolyphosphate, pyrophosphate, polymeric metaphosphate having a degree of polymerization of from about 6 to 21, and orthophosphates. Examples of polyphosphonate builders are the sodium and potassium salts of ethylene diphosphonic acid, the sodium and potassium salts of ethane 1-hydroxy-1,1-diphosphonic acid and the sodium and potassium salts of ethane, 1,1,2-triphosphonic acid. Other phosphorus builder compounds are disclosed in U.S. Pat. Nos. 3,159,581; 3,213,030; 3,422,021; 3,422,137; 3,400,176 and 3,400,148. Examples of nonphosphorus, inorganic builders are sodium and potassium carbonate, bicarbonate, sesquicarbonate, tetraborate decahydrate, and silicates having a weight ratio of SiO 2 to alkali metal oxide of from about 0.5 to about 4.0, preferably from about 1.0 to about 2.4. Water-soluble, nonphosphorus organic builders useful herein include the various alkali metal, ammonium and substituted ammonium polyacetates, carboxylates, polycarboxylates and polyhydroxy sulfonates. Examples of polyacetate and polycarboxylate builders are the sodium, potassium, lithium, ammonium and substituted ammonium salts of ethylene diamine tetraacetic acid, nitrilotriacetic acid, oxydisuccinic acid, mellitic acid, benzene polycarboxylic acids, and citric acid.
[0053] Polymeric polycarboxylate builders are set forth in U.S. Pat. No. 3,308,067, Diehl, issued Mar. 7, 1967. Such materials include the water-soluble salts of homo- and copolymers of aliphatic carboxylic acids such as maleic acid, itaconic acid, mesaconic acid, fumaric acid, aconitic acid, citraconic acid and methylenemalonic acid. Some of these materials are useful as the water-soluble anionic polymer as hereinafter described, but only if in intimate admixture with the nonsoap anionic surfactant. Other suitable polycarboxylates for use herein are the polyacetal carboxylates described in U.S. Pat. No. 4,144,226, issued Mar. 13, 1979 to Crutchfield et al., and U.S. Pat. No. 4,246,495, issued Mar. 27, 1979 to Crutchfield et al.
[0054] Water-soluble silicate solids represented by the formula SiO 2 .M 2 O, M being an alkali metal, and having a SiO 2 :M 2 O weight ratio of from about 0.5 to about 4.0, are useful salts in the detergent granules of the invention at levels of from about 2% to about 15% on an anhydrous weight basis. Anhydrous or hydrated particulate silicate can be utilized, as well.
[0055] Any number of additional ingredients can also be included as components in the granular detergent composition. These include other detergency builders, bleaches, bleach activators, suds boosters or suds suppressors, anti-tarnish and anti-corrosion agents, soil suspending agents, soil release agents, germicides, pH adjusting agents, nonbuilder alkalinity sources, chelating agents, smectite clays, enzymes, enzyme-stabilizing agents and perfumes. See U.S. Pat. No. 3,936,537, issued Feb. 3, 1976 to Baskerville, Jr. et al.
[0056] Bleaching agents and activators are described in U.S. Pat. No. 4,412,934, Chung et al., issued Nov. 1, 1983, and in U.S. Pat. No. 4,483,781, Hartman, issued Nov. 20, 1984. Chelating agents are also described in U.S. Pat. No. 4,663,071, Bush et al., from Column 17, line 54 through Column 18, line 68. Suds modifiers are also optional ingredients and are described in U.S. Pat. Nos. 3,933,672, issued Jan. 20, 1976 to Bartoletta et al., and 4,136,045, issued Jan. 23, 1979 to Gault et al. Suitable smectite clays for use herein are described in U.S. Pat. No. 4,762,645, Tucker et al., issued Aug. 9, 1988, Column 6, line 3 through Column 7, line 24. Suitable additional detergency builders for use herein are enumerated in the Baskerville patent, Column 13, line 54 through Column 16, line 16, and in U.S. Pat. No. 4,663,071, Bush et al., issued May 5, 1987.
Rinse Added Fabric Conditioning Compositions
[0057] In one aspect, the laundry care compositions disclosed herein, may take the form of rinse added fabric conditioning compositions. Such compositions may comprise a fabric softening active and a sufficient amount of suitable thiazolium dye, that is described under the heading “Suitable Thiazolium Dyes” of the present specification, to provide a tinting effect to fabric treated by the composition, typically from about 0.00001 wt. % (0.1 ppm) to about 1 wt. % (10,000 ppm), or even from about 0.0003 wt. % (3 ppm) to about 0.03 wt. % (300 ppm) based on total rinse added fabric conditioning composition weight. In another specific embodiment, the compositions are rinse added fabric conditioning compositions. Examples of typical rinse added conditioning composition can be found in U.S. Provisional Patent Application Ser. No. 60/687,582 filed on Oct. 8, 2004.
[0058] In one embodiment of the invention, the fabric softening active (hereinafter “FSA”) is a quaternary ammonium compound suitable for softening fabric in a rinse step. In one embodiment, the FSA is formed from a reaction product of a fatty acid and an aminoalcohol obtaining mixtures of mono-, di-, and, in one embodiment, triester compounds. In another embodiment, the FSA comprises one or more softener quaternary ammonium compounds such, but not limited to, as a monoalkyquaternary ammonium compound, a diamido quaternary compound and a diester quaternary ammonium compound, or a combination thereof.
[0059] In one aspect of the invention, the FSA comprises a diester quaternary ammonium (hereinafter “DQA”) compound composition. In certain embodiments of the present invention, the DQA compounds compositions also encompasses a description of diamido FSAs and FSAs with mixed amido and ester linkages as well as the aforementioned diester linkages, all herein referred to as DQA.
[0060] A first type of DQA (“DQA (1)”) suitable as a FSA in the present CFSC includes a compound comprising the formula:
[0000] {R 4-m —N + —[(CH 2 ) n —Y—R 1 ] m }X −
[0000] wherein each R substituent is either hydrogen, a short chain C 1 -C 6 , preferably C 1 -C 3 alkyl or hydroxyalkyl group, e.g., methyl (most preferred), ethyl, propyl, hydroxyethyl, and the like, poly (C 2 -C 3 alkoxy), preferably polyethoxy, group, benzyl, or mixtures thereof; each m is 2 or 3; each n is from 1 to about 4, preferably 2; each Y is —O—(O)C—, —C(O)—O—, —NR—C(O)—, or —C(O)—NR— and it is acceptable for each Y to be the same or different; the sum of carbons in each R 1 , plus one when Y is —O—(O)C— or —NR—C(O)—, is C 12 -C 22 , preferably C 14 -C 20 , with each R 1 being a hydrocarbyl, or substituted hydrocarbyl group; it is acceptable for R 1 to be unsaturated or saturated and branched or linear and preferably it is linear; it is acceptable for each R 1 to be the same or different and preferably these are the same; and X − can be any softener-compatible anion, preferably, chloride, bromide, methylsulfate, ethylsulfate, sulfate, phosphate, and nitrate, more preferably chloride or methyl sulfate. Preferred DQA compounds are typically made by reacting alkanolamines such as MDEA (methyldiethanolamine) and TEA (triethanolamine) with fatty acids. Some materials that typically result from such reactions include N,N-di(acyl-oxyethyl)-N,N-dimethylammonium chloride or N,N-di(acyl-oxyethyl)-N,N-methylhydroxyethylammonium methylsulfate wherein the acyl group is derived from animal fats, unsaturated, and polyunsaturated, fatty acids, e.g., tallow, hardended tallow, oleic acid, and/or partially hydrogenated fatty acids, derived from vegetable oils and/or partially hydrogenated vegetable oils, such as, canola oil, safflower oil, peanut oil, sunflower oil, corn oil, soybean oil, tall oil, rice bran oil, palm oil, etc. Non-limiting examples of suitable fatty acids are listed in U.S. Pat. No. 5,759,990 at column 4, lines 45-66. In one embodiment the FSA comprises other actives in addition to DQA (1) or DQA. In yet another embodiment, the FSA comprises only DQA (1) or DQA and is free or essentially free of any other quaternary ammonium compounds or other actives. In yet another embodiment, the FSA comprises the precursor amine that is used to produce the DQA.
[0061] In another aspect of the invention, the FSA comprises a compound, identified as DTTMAC comprising the formula:
[0000] [R 4-m —N (+) —R 1 m ]A −
[0000] wherein each m is 2 or 3, each R 1 is a C 6 -C 22 , preferably C 14 -C 20 , but no more than one being less than about C 12 and then the other is at least about 16, hydrocarbyl, or substituted hydrocarbyl substituent, preferably C 10 -C 20 alkyl or alkenyl (unsaturated alkyl, including polyunsaturated alkyl, also referred to sometimes as “alkylene”), most preferably C 12 -C 18 alkyl or alkenyl, and branch or unbranched. In one embodiment, the Iodine Value (IV) of the FSA is from about 1 to 70; each R is H or a short chain C 1 -C 6 , preferably C 1 -C 3 alkyl or hydroxyalkyl group, e.g., methyl (most preferred), ethyl, propyl, hydroxyethyl, and the like, benzyl, or (R 2 O) 2-4 H where each R 2 is a C 1 -C 6 alkylene group; and A − is a softener compatible anion, preferably, chloride, bromide, methylsulfate, ethylsulfate, sulfate, phosphate, or nitrate; more preferably chloride or methyl sulfate. Examples of these FSAs include dialkydimethylammonium salts and dialkylenedimethylammonium salts such as ditallowdimethylammonium and ditallowdimethylammonium methylsulfate. Examples of commercially available dialkylenedimethylammonium salts usable in the present invention are di-hydrogenated tallow dimethyl ammonium chloride and ditallowdimethyl ammonium chloride available from Degussa under the trade names Adogen® 442 and Adogen® 470 respectively. In one embodiment the FSA comprises other actives in addition to DTTMAC. In yet another embodiment, the FSA comprises only compounds of the DTTMAC and is free or essentially free of any other quaternary ammonium compounds or other actives.
[0062] In one embodiment, the FSA comprises an FSA described in U.S. Pat. Pub. No. 2004/0204337 A1, published Oct. 14, 2004 to Corona et al., from paragraphs 30-79.
[0063] In another embodiment, the FSA is one described in U.S. Pat. Pub. No. 2004/0229769 A1, published Nov. 18, 2005, to Smith et al., on paragraphs 26-31; or U.S. Pat. No. 6,494,920, at column 1, line 51 et seq. detailing an “esterquat” or a quaternized fatty acid triethanolamine ester salt.
[0064] In one embodiment, the FSA is chosen from at least one of the following: ditallowoyloxyethyl dimethyl ammonium chloride, dihydrogenated-tallowoyloxyethyl dimethyl ammonium chloride, ditallow dimethyl ammonium chloride, ditallowoyloxyethyl dimethyl ammonium methyl sulfate, dihydrogenated-tallowoyloxyethyl dimethyl ammonium chloride, dihydrogenated-tallowoyloxyethyl dimethyl ammonium chloride, or combinations thereof.
[0065] In one embodiment, the FSA may also include amide containing compound compositions. Examples of diamide comprising compounds may include but not limited to methyl-bis(tallowamidoethyl)-2-hydroxyethylammonium methyl sulfate (available from Degussa under the trade names Varisoft 110 and Varisoft 222). An example of an amide-ester containing compound is N-[3-(stearoylamino)propyl]-N-[2-(stearoyloxy)ethoxy)ethyl)]-N-methylamine.
[0066] Another specific embodiment of the invention provides for a rinse added fabric care composition further comprising a cationic starch. Cationic starches are disclosed in US 2004/0204337 A1. In one embodiment, the fabric care composition comprises from about 0.1% to about 7% of cationic starch by weight of the laundry care composition. In one embodiment, the cationic starch is HCP401 from National Starch.
Suitable Thiazolium Dyes
[0067] Suitable thiazolium dyes include azo dyes that may have Formula (I) below:
[0000]
[0068] wherein:
R 3 and R 4 may be identical or different and, independently of one another, are hydrogen, a saturated or unsaturated (C 1 -C 22 )-alkyl group, a (C 1 -C 22 )-alkyl group substituted by a halogen atom, a hydroxy-(C 2 -C 22 )-alkyl group optionally interrupted by oxygen, a polyether group derived from ethylene oxide, propylene oxide or butylene oxide, an amino-(C 1 -C 22 )-alkyl group, a substituted or unsubstituted phenyl group or a benzyl group, a (C 1 -C 22 )-alkyl group terminated in sulfonate, sulfate, or carboxylate, or the radical groups R 3 and R 4 , together with the remaining molecule, can form a heterocyclic or carbocyclic, saturated or unsaturated, substituted or unsubstituted ring system optionally substituted by halogen, sulfate, sulfonate, phosphate, nitrate, and carboxylate; X may be a radical group of the phenol series or a heterocyclic radical group or aniline series or m-toluidine series that may have Formula II below;
[0000]
wherein:
R 5 and R 6 may be identical or different and, independently of one another, are a straight or branched saturated or unsaturated (C 1 -C 22 )-alkyl group, a (C 1 -C 22 )-alkyl ether group, a hydroxy-(C 2 -C 22 )-alkyl group optionally inter-rupted by oxygen, a polyether group derived from ethylene oxide, propylene oxide, butylene oxide, glycidyl or combinations thereof, an amino-(C 1 -C 22 )-alkyl group, a substituted or unsubstituted phenyl group or a benzyl group, a linear or branched (C 1 -C 22 )-alkyl group terminated in a linear or branched (C 1 -C 22 )-alkyl, hydroxyl, acetate, sulfonate, sulfate, or carboxylate, group or R 5 and R 6 or R 5 and R 7 or R 6 and R 7 , together with the nitrogen atom, form a 5-membered to 6-membered ring system, which may comprise a further heteroatom; or R 5 and R 6 or R 5 and R 7 or R 6 and R 7 , form with a carbon atom of the benzene ring an optionally oxygen-containing or nitrogen containing five or six-membered heterocycle which may be substituted with one or more (C 1 -C 22 )-alkyl group; R 7 may be identical or different and, independently of one another, are hydrogen, a halogen atom, a saturated or unsaturated (C 1 -C 22 )-alkyl group, a (C 1 -C 22 )-alkyl ether group, a hydroxyl group, a hydroxy-(C 1 -C 22 )-alkyl group, a (C 1 -C 22 )-alkoxy group, a cyano group, a nitro group, an amino group, a (C 1 -C 22 )-alkylamino group, a (C 1 -C 22 )-dialkylamino group, a carboxylic acid group, a C(O)O—(C 1 -C 22 )-alkyl group, a substituted or unsubstituted C(O)O-phenyl group;
Q − may be an anion that balances the overall charge of the compound of Formula I, and the index q may be either 0 or 1. Suitable anions include chloro, bromo, methosulfate, tetrafluoroborate, and acetate anions.
R 1 may be a (C 1 -C 22 )-alkyl, an alkyl aromatic or an alkyl sulfonate radical having Formula (III) below;
[0000]
wherein
R 2 is hydrogen, methyl, ethyl, propyl, acetate or a hydroxyl group; m and p are integers from 0 to (n−1), n is an integer from 1 to 6 and m+p=(n−1);
with the proviso that the heterocycle of the Formula (I) comprises at least two and at most three heteroatoms, where the heterocycle has at most one sulfur atom;
[0079] In one aspect, a suitable thiazolium dye may have Formula IV below:
[0000]
[0000] wherein R 8 and R 9 may be identical or different and, independently of one another, may be a saturated or unsaturated (C 1 -C 22 )-alkyl group, a (C 1 -C 22 )-alkyl group, a hydroxy-(C 2 -C 22 )-alkyl group optionally interrupted by oxygen, a polyether group derived from ethylene oxide, propylene oxide or butylene oxide, an amino-(C 1 -C 22 )-alkyl group, a substituted or unsubstituted phenyl group or a benzyl group, a (C 1 -C 22 )-alkyl group terminated in sulfonate, sulfate, or carboxylate, or R 8 and R 9 , together with the nitrogen atom, may form a 5-membered to 6-membered ring system, which may comprise a further heteroatom; or R 8 or R 9 may form, with a carbon atom of the benzene ring, an optionally oxygen-containing or nitrogen containing five or six-membered heterocycle which may be substituted with one or more (C 1 -C 22 )-alkyl groups, and mixtures thereof, and R 10 is hydrogen or methyl. For Formula IV, Q − is as described for Formula I above.
[0080] In one aspect, suitable thiazolium dyes may have Formula (V);
[0000]
[0081] wherein:
a.) R 1 may be selected from a branched or unbranched (C 1 -C 22 )-alkyl moiety, an aromatic alkyl moiety, a polyalkylene oxide moiety or a moiety having Formula (VI) below;
[0000]
wherein
(i) R 2 may be selected from hydrogen, methyl, ethyl, propyl, acetate or a hydroxyl moiety; m and p may be, independently, integers from 0 to (n−1), with the proviso that n is an integer from 1 to 6 and m+p=(n−1) (ii) Y may be selected from a hydroxyl, sulfonate, sulfate, carboxylate or acetate moiety;
b.) R 3 and R 4 :
i.) may be independently selected from hydrogen; a saturated or unsaturated (C 1 -C 22 )-alkyl moiety; a hydroxy-(C 2 -C 22 )-alkyl moiety; a hydroxy-(C 2 -C 22 )-alkyl moiety comprising, in addition to the hydroxyl oxygen, an oxygen atom; a polyether moiety; an amino-(C 1 -C 22 )-alkyl moiety; a substituted or unsubstituted phenyl moiety; a substituted or unsubstituted benzyl moiety; a (C 1 -C 22 )-alkyl moiety terminated in sulfonate, sulfate, acetate, or carboxylate; or ii.) when taken together may form a saturated or unsaturated heterocyclic or carbocyclic moiety; or iii.) when taken together may form a saturated or unsaturated heterocyclic or carbocyclic moiety substituted by, sulfate, sulfonate, phosphate, nitrate, and carboxylate;
c.) X may be moiety having Formula VII below;
[0000]
wherein:
i.) R 5 and R 6 :
(a) may be independently selected from hydrogen; a saturated or unsaturated (C 1 -C 22 )-alkyl moiety; a hydroxy-(C 2 -C 22 )-alkyl moiety; a hydroxy-(C 2 -C 22 )-alkyl moiety comprising, in addition to the hydroxyl oxygen, an oxygen atom; a capped or uncapped polyether moiety; an amino-(C 1 -C 22 )-alkyl moiety; a substituted or unsubstituted phenyl moiety; a substituted or unsubstituted benzyl moiety; a (C 1 -C 22 )-alkyl moiety comprising a terminating C 1 -C 4 alkyl ether, sulfonate, sulfate, acetate or carboxylate moiety; a thiazole moiety or (b) when taken together may form a saturated or unsaturated heterocyclic moiety; or (c) when taken together form a saturated or unsaturated heterocyclic moiety substituted by one or more, alkoxylate, sulfate, sulfonate, phosphate, nitrate, and/or carboxylate moieties; (d) when taken together with R 7 , R 8 , or R 7 and R 8 form one or more saturated or unsaturated heterocyclic moieties, optionally substituted by one or more alkoxylate, sulfate, sulfonate, phosphate, nitrate, and/or carboxylate moieties; or (e) when taken together form a thiazole moiety;
ii.) R 7 and R 8 may be independently selected from hydrogen or a saturated or unsaturated alkyl moiety;
d.) Q − may be an anion that balances the overall charge of the compound of Formula I, and the index q is 0 or 1. Suitable anions include chloro, bromo, methosulfate, tetrafluoroborate, and acetate anions.
[0100] In one aspect, for Formula V:
[0101] a.) R 1 may be a methyl moiety;
[0102] b.) R 3 and R 4 may be hydrogen; and
[0103] c.) X may have Formula VIII below:
[0000]
wherein
(i) R 5 and R 6 may be as defined for Formula VII above; (ii) R 7 may be hydrogen or a methyl moiety; and (iii) R 8 may be hydrogen.
[0108] In one aspect, for Formula VII R 5 and R 6 each comprise, independently, from 1 to 20 alkylene oxide units and, independently, a moiety selected from the group consisting of: styrene oxide, glycidyl methyl ether, isobutyl glycidyl ether, isopropylglycidyl ether, t-butyl glycidyl ether, 2-ethylhexylgycidyl ether, or glycidylhexadecyl ether.
[0109] In one aspect, suitable thiazolium dyes are set forth in Table 1 below and are defined as Table 1 Thiazolium Dyes. The chemical names, as determined by ChemFinder software Level:Pro; Version 9.0 available from CambridgeSoft, Cambridge, Mass., U.S.A., for such dyes are respectively provided in Table 2 below. Such dyes are associated, as needed to balance the molecule's charge, with an anion Q − . Such anion is not shown in the structures below but for the purposes of the present specification is assumed to be present as required. Such anion is as described above for Formula (I).
[0000]
TABLE 1
No.
Structure
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
[0000]
TABLE 2
No.
Name
1
(E)-2-((4-(benzyl(methyl)amino)phenyl)diazenyl)-3-methylthiazol-3-ium
2
(E)-2-((4-(dimethylamino)phenyl)diazenyl)-3-methylthiazol-3-ium
3
(E)-2-((4-(bis(2-hydroxyethyl)amino)phenyl)diazenyl)-3-methylthiazol-3-ium
4
(E)-2-((4-(bis(2-(2-(2-hydroxyethoxy)ethoxy)ethyl)amino)phenyl)diazenyl)-
3-methylthiazol-3-ium
5
(E)-2-((4-(bis(2-(2-hydroxyethoxy)ethyl)amino)phenyl)diazenyl)-3-
methylthiazol-3-ium
6
(E)-2-((4-(bis(14-hydroxy-5,8,11-trimethyl-3,6,9,12-
tetraoxapentadecyl)amino)phenyl)diazenyl)-3-methylthiazol-3-ium
7
(E)-2-((4-(bis(2-(2-(2-(2-
hydroxypropoxy)propoxy)propoxy)ethyl)amino)phenyl)diazenyl)-3-
methylthiazol-3-ium
8
(E)-2-((4-(bis(2-(2-(2-
hydroxypropoxy)propoxy)ethyl)amino)phenyl)diazenyl)-3-methylthiazol-3-
ium
9
(E)-2-((4-(bis(35-hydroxy-5,8,11,14,17,20,23-heptamethyl-
3,6,9,12,15,18,21,24,27,30,33-undecaoxapentatriacontyl)amino)-2-
methylphenyl)diazenyl)-3-methylthiazol-3-ium
10
(E)-2-((4-(bis(3-(2,3-dihydroxypropoxy)-2-hydroxypropyl)amino)-2-
methylphenyl)diazenyl)-3-methylthiazol-3-ium
11
(E)-2-((4-(bis(2,3-dihydroxypropyl)amino)-2-methylphenyl)diazenyl)-3-
methylthiazol-3-ium
12
(E)-2-((4-((2-hydroxy-3-(2-(2-(2-hydroxyethoxy)ethoxy)ethoxy)propyl)(2-
hydroxy-3-(2-(2-hydroxyethoxy)ethoxy)propyl)amino)-2-
methylphenyl)diazenyl)-3-methylthiazol-3-ium
13
(E)-2-((4-((2-(2-(2-hydroxyethoxy)ethoxy)ethyl)(2-(2-
hydroxyethoxy)ethyl)amino)-2-methylphenyl)diazenyl)-3-methylthiazol-3-
ium
14
(E)-2-((4-(bis(35-hydroxy-17,20,23,26,29,32-hexamethyl-
3,6,9,12,15,18,21,24,27,30,33-undecaoxahexatriacontyl)amino)-2-
methylphenyl)diazenyl)-3-methylthiazol-3-ium
15
(E)-2-((4-(bis(14-hydroxy-3,6,9,12-tetraoxatetradecyl)amino)-2-
methylphenyl)diazenyl)-3-methylthiazol-3-ium
16
(E)-2-((4-((2-(2-(2-acetoxyethoxy)ethoxy)ethyl)(2-(2-
acetoxyethoxy)ethyl)amino)-2-methylphenyl)diazenyl)-3-methylthiazol-3-
ium
17
(E)-2-((4-(benzyl(2,3-dihydroxypropyl)amino)phenyl)diazenyl)-3-
methylthiazol-3-ium
18
(E)-2-(2-((4-(bis(35-hydroxy-17,20,23,26,29,32-hexamethyl-
3,6,9,12,15,18,21,24,27,30,33-undecaoxahexatriacontyl)amino)-2-
methylphenyl)diazenyl)thiazol-3-ium-3-yl)acetate
19
(E)-2-((4-(benzyl(14-hydroxy-3,6,9,12-tetraoxatetradecyl)amino)-2-
methylphenyl)diazenyl)-3-methylthiazol-3-ium
20
(E)-2-((4-((2-tert-butoxy-15-hydroxy-6,9,12-trimethyl-4,7,10,13-
tetraoxahexadecyl)(2-(tert-butoxymethyl)-17-hydroxy-5,8,11,14-tetramethyl-
3,6,9,12,15-pentaoxaoctadecyl)amino)phenyl)diazenyl)-3-methylthiazol-3-
ium
21
(E)-2-((4-(benzyl(29-hydroxy-3,6,9,12,15,18,21,24,27-
nonaoxanonacosyl)amino)phenyl)diazenyl)-3-methylthiazol-3-ium
22
(E)-2-((4-(bis(14-hydroxy-3,6,9,12-tetraoxatetradecyl)amino)-2-
methylphenyl)diazenyl)-5-methoxy-3-methylbenzo[d]thiazol-3-ium
23
(E)-2-(2-((4-((2-(2-(2-hydroxyethoxy)ethoxy)ethyl)(2-(2-
hydroxyethoxy)ethyl)amino)-2-methylphenyl)diazenyl)thiazol-3-ium-3-
yl)acetate
24
(E)-2-((4-(ethyl(14-hydroxy-3,6,9,12-tetraoxatetradecyl)amino)-2-
methylphenyl)diazenyl)-3-methylthiazol-3-ium
25
(E)-2-((4-(benzyl(1,17-dihydroxy-3,6,9,12,15-pentaoxaoctadecan-18-
yl)amino)-2-methylphenyl)diazenyl)-3-methylthiazol-3-ium
26
(E)-2-((4-((2-(2-(2-(2,3-dihydroxypropoxy)ethoxy)ethoxy)ethyl)(2-(2-(2,3-
dihydroxypropoxy)ethoxy)ethyl)amino)-2-methylphenyl)diazenyl)-3-
methylthiazol-3-ium
27
(E)-2-(2-((4-(bis(14-hydroxy-3,6,9,12-tetraoxatetradecyl)amino)-2-
methylphenyl)diazenyl)-6-methoxybenzo[d]thiazol-3-ium-3-yl)acetate
28
(E)-2-((4-((3-tert-butoxy-2-(2-(2-(2-hydroxyethoxy)ethoxy)ethoxy)propyl)(3-
tert-butoxy-2-(2-(2-hydroxyethoxy)ethoxy)propyl)amino)-2-
methylphenyl)diazenyl)-3-methylthiazol-3-ium
29
(E)-2-((4-((3-butoxy-2-(2-(2-(2-hydroxyethoxy)ethoxy)ethoxy)propyl)(3-
butoxy-2-(2-(2-hydroxyethoxy)ethoxy)propyl)amino)-2-
methylphenyl)diazenyl)-3-methylthiazol-3-ium
30
(E)-2-((4-((2-(2-(2-hydroxyethoxy)ethoxy)-3-isopropoxypropyl)(2-(2-(2-(2-
hydroxyethoxy)ethoxy)ethoxy)-3-isopropoxypropyl)amino)-2-
methylphenyl)diazenyl)-3-methylthiazol-3-ium
31
(E)-2-((4-(benzyl(29-hydroxy-3,6,9,12,15,18,21,24,27-
nonaoxanonacosyl)amino)-2-methylphenyl)diazenyl)-3-methylthiazol-3-ium
32
(E)-2-((4-((2-(2-(2-hydroxyethoxy)ethoxy)-3-(tridecyloxy)propyl)(2-(2-(2-(2-
hydroxyethoxy)ethoxy)ethoxy)-3-(tridecyloxy)propyl)amino)-2-
methylphenyl)diazenyl)-3-methylthiazol-3-ium
33
(E)-3-ethyl-2-((4-(ethyl(23-hydroxy-3,6,9,12,15,18,21-
heptaoxatricosyl)amino)-2-methylphenyl)diazenyl)thiazol-3-ium
34
(E)-2-((4-(bis(2-(2-(2-(2-hydroxyethoxy)ethoxy)ethoxy)ethyl)amino)-2-
methylphenyl)diazenyl)-3-ethylthiazol-3-ium
35
(E)-2-((1-(29-hydroxy-3,6,9,12,15,18,21,24,27-nonaoxanonacosyl)-1,2,3,4-
tetrahydroquinolin-6-yl)diazenyl)-3-methylthiazol-3-ium
36
(E)-2-((4-((2-(2-hydroxypropoxy)ethyl)(2-(2-(2-
hydroxypropoxy)propoxy)ethyl)amino)-2-methylphenyl)diazenyl)-3-
methylthiazol-3-ium
37
(E)-2-((4-(bis(2-(2-(2-(2-hydroxyethoxy)ethoxy)ethoxy)ethyl)amino)-2-
methylphenyl)diazenyl)-3-ethylthiazol-3-ium
38
(E)-2-((4-(ethyl(23-hydroxy-3,6,9,12,15,18,21-heptaoxatricosyl)amino)-2-
methylphenyl)diazenyl)-3-methylthiazol-3-ium
39
(E)-2-((4-(benzyl(14-hydroxy-3,6,9,12-tetraoxatetradecyl)amino)-2-
methylphenyl)diazenyl)-3-ethylthiazol-3-ium
40
(E)-3-ethyl-2-((4-((2-(2-(2-hydroxyethoxy)ethoxy)ethyl)(2-(2-
hydroxyethoxy)ethyl)amino)-2-methylphenyl)diazenyl)thiazol-3-ium
41
(E)-3-(2-((4-(benzyl(29-hydroxy-3,6,9,12,15,18,21,24,27-
nonaoxanonacosyl)amino)-2-methylphenyl)diazenyl)thiazol-3-ium-3-
yl)propane-1-sulfonate
42
(E)-4-(2-((4-(benzyl(29-hydroxy-3,6,9,12,15,18,21,24,27-
nonaoxanonacosyl)amino)-2-methylphenyl)diazenyl)thiazol-3-ium-3-
yl)butane-1-sulfonate
43
(E)-2-((4-(bis(2-(2-(2-(2-hydroxyethoxy)ethoxy)ethoxy)ethyl)amino)-2-
methylphenyl)diazenyl)-3-ethylthiazol-3-ium
44
(E)-3-benzyl-2-((4-((2-(2-(2-hydroxyethoxy)ethoxy)ethyl)(2-(2-
hydroxyethoxy)ethyl)amino)phenyl)diazenyl)thiazol-3-ium
45
(E)-3-ethyl-2-((4-((2-(2-hydroxypropoxy)ethyl)(2-(2-(2-
hydroxypropoxy)propoxy)ethyl)amino)-2-methylphenyl)diazenyl)thiazol-3-
ium
46
(E)-3-benzyl-2-((1-(29-hydroxy-3,6,9,12,15,18,21,24,27-nonaoxanonacosyl)-
1,2,3,4-tetrahydroquinolin-6-yl)diazenyl)thiazol-3-ium
47
(E)-3-benzyl-2-((4-((2-(2-(2-hydroxyethoxy)ethoxy)ethyl)(2-(2-
hydroxyethoxy)ethyl)amino)-2-methylphenyl)diazenyl)thiazol-3-ium
48
(E)-2-((4-((2-(2-(2-hydroxyethoxy)ethoxy)propyl)(2-(2-
hydroxyethoxy)propyl)amino)-2-methylphenyl)diazenyl)-3-methylthiazol-3-
ium
49
(E)-2-((4-(benzyl(29-hydroxy-3,6,9,12,15,18,21,24,27-
nonaoxanonacosyl)amino)-2-methylphenyl)diazenyl)-3-methylthiazol-3-ium
50
(E)-2-((4-(bis(14-hydroxy-3,6,9,12-tetraoxatetradecyl)amino)-2,6-
dimethylphenyl)diazenyl)-3-methylthiazol-3-ium
51
(E)-2-((4-((4-(17-hydroxy-3,6,9,12,15-pentaoxaheptadecyloxy)-3-
methoxybenzyl)(methyl)amino)-2-methylphenyl)diazenyl)-3-methylthiazol-3-
ium
52
(E)-2-((1-(1-hydroxy-2,5,8,11,14,17,20,23,26-nonaoxaoctacosan-28-yl)-
1,2,3,4-tetrahydroquinolin-6-yl)diazenyl)-3-methylthiazol-3-ium
53
(E)-4-(2-((4-(dimethylamino)phenyl)diazenyl)thiazol-3-ium-3-yl)butane-1-
sulfonate
54
(E)-4-(2-((4-(dimethylamino)phenyl)diazenyl)-5-methylthiazol-3-ium-3-
yl)butane-1-sulfonate
55
(E)-2-((4-((2-hydroxyethyl)(methyl)amino)phenyl)diazenyl)-3-methylthiazol-
3-ium
56
(E)-2-(methyl(4-((3-methylthiazol-3-ium-2-yl)diazenyl)phenyl)amino)ethyl
sulfate
57
(E)-2-((4-(butyl(2-(2-hydroxyethoxy)ethyl)amino)phenyl)diazenyl)-3-
methylthiazol-3-ium
58
(E)-2-((4-(bis(2-(2-(2-
hydroxypropoxy)propoxy)ethyl)amino)phenyl)diazenyl)-3-methylthiazol-3-
ium
59
(E)-2-((4-((2-hydroxyethyl)(isopropyl)amino)phenyl)diazenyl)-3-
methylthiazol-3-ium
60
(E)-2-((4-((14-hydroxy-3,6,9,12-tetraoxatetradecyl)(1-hydroxy-3,6,9,13-
tetraoxapentadecan-15-yl)amino)-2-methylphenyl)diazenyl)-6-methoxy-3-
methylbenzo[d]thiazol-3-ium
61
(E)-2-((4-(benzyl(29-hydroxy-3,6,9,12,15,18,21,24,27-
nonaoxanonacosyl)amino)phenyl)diazenyl)-3-methylthiazol-3-ium
62
(E)-2-((4-(benzyl(3-(3-(3-(2,3-dihydroxypropoxy)-2-hydroxypropoxy)-2-
hydroxypropoxy)-2-hydroxypropyl)amino)-2-methylphenyl)diazenyl)-3-
methylthiazol-3-ium
63
(E)-3-(2-((4-(bis(2-(2-(2-(2-hydroxyethoxy)ethoxy)ethoxy)ethyl)amino)-2-
methylphenyl)diazenyl)thiazol-3-ium-3-yl)propane-1-sulfonate
64
(E)-2-((4-(bis(14-hydroxy-3,6,9,12-tetraoxatetradecyl)amino)-2,5-
dimethylphenyl)diazenyl)-6-methoxy-3-methylbenzo[d]thiazol-3-ium
65
(E)-3-ethyl-2-((4-(ethyl(14-hydroxy-3,6,9,12-tetraoxatetradecyl)amino)-2-
methylphenyl)diazenyl)thiazol-3-ium
66
(E)-3-ethyl-2-((1-(29-hydroxy-3,6,9,12,15,18,21,24,27-nonaoxanonacosyl)-
1,2,3,4-tetrahydroquinolin-6-yl)diazenyl)thiazol-3-ium
67
(E)-3-ethyl-2-((1-(29-hydroxy-3,6,9,12,15,18,21,24,27-nonaoxanonacosyl)-
1,2,3,4-tetrahydroquinolin-6-yl)diazenyl)thiazol-3-ium
68
(E)-2-((4-((2-(2-(2-hydroxyethoxy)ethoxy)ethyl)(2-(2-
hydroxyethoxy)ethyl)amino)-2-methylphenyl)diazenyl)-3,5-dimethylthiazol-
3-ium
69
(E)-3-ethyl-2-((4-((2-(2-(2-hydroxyethoxy)ethoxy)ethyl)(2-(2-
hydroxyethoxy)ethyl)amino)-2-methylphenyl)diazenyl)-5-methylthiazol-3-
ium
70
(E)-2-((4-((2-(2-(2-hydroxyethoxy)ethoxy)ethyl)(2-(2-
hydroxyethoxy)ethyl)amino)-2-methylphenyl)diazenyl)-3,5-dimethylthiazol-
3-ium
71
(E)-3-ethyl-2-((4-((2-(2-(2-hydroxyethoxy)ethoxy)ethyl)(2-(2-
hydroxyethoxy)ethyl)amino)-2-methylphenyl)diazenyl)-5-methylthiazol-3-
ium
72
(E)-2-((4-((2-(2-(2-hydroxyethoxy)ethoxy)ethyl)(2-(2-
hydroxyethoxy)ethyl)amino)-2-methylphenyl)diazenyl)-3,5-dimethylthiazol-
3-ium
73
2-((E)-(4-((14-hydroxy-3,6,9,12-tetraoxatetradecyl)(17-hydroxy-3-(4-((E)-
thiazol-2-yldiazenyl)phenyl)-6,9,12,15-tetraoxa-3-
azaheptadecyl)amino)phenyl)diazenyl)-3-methylthiazol-3-ium
74
(E)-2-((4-((2-(2-(2-hydroxyethoxy)ethoxy)ethyl)(2-(2-
hydroxyethoxy)ethyl)amino)-2-methylphenyl)diazenyl)-3-methyl-5-
nitrothiazol-3-ium
75
(E)-2-((4-((2-(2-(2-hydroxyethoxy)ethoxy)ethyl)(2-(2-
hydroxyethoxy)ethyl)amino)-2-methylphenyl)diazenyl)-3-methyl-5-
nitrothiazol-3-ium
76
(E)-2-((4-((2-(2-(2-hydroxyethoxy)ethoxy)ethyl)(2-(2-
hydroxyethoxy)ethyl)amino)-2-methylphenyl)diazenyl)-3-methylthiazol-3-
ium-4-carboxylate
77
(E)-2-((4-((2-(2-(2-hydroxyethoxy)ethoxy)ethyl)(2-(2-
hydroxyethoxy)ethyl)amino)-2-methylphenyl)diazenyl)-3,5-dimethylthiazol-
3-ium-4-carboxylate
78
(E)-2-((4-(benzyl(2-(tert-butoxymethyl)-17-hydroxy-3,6,9,12,15-
pentaoxaheptadecyl)amino)-2-methylphenyl)diazenyl)-3-methylthiazol-3-ium
79
(E)-2-((4-((2-(tert-butoxymethyl)-14-hydroxy-3,6,9,12-
tetraoxatetradecyl)(ethyl)amino)-2-hydroxyphenyl)diazenyl)-3-methylthiazol-
3-ium
80
(E)-2-((4-((13-(sec-butoxymethyl)-1-hydroxy-3,6,9,12-tetraoxapentadecan-
15-yl)(2-(sec-butoxymethyl)-14-hydroxy-3,6,9,12-tetraoxatetradecyl)amino)-
2-methylphenyl)diazenyl)-3-methylthiazol-3-ium
[0110] In one aspect, suitable thiazolium dyes include thiazolium dye molecules numbers 1, 4, 5, 7, 8, 12, 13, 15, 16, 17, 21, 24, 25, 26, 30, 31, 33, 36, 38, 40, 45 and 48 as detailed in Tables 1 and 2 of the present specification.
[0111] In one aspect, suitable thiazolium dyes include thiazolium dye molecules numbers 12, 13, 15, 16, 24, 25, 26, 30, 31, 33, 36, 38, 40, 45 and 48 as detailed in Tables 1 and 2 of the present specification.
[0112] The suitable thiazolium dyes disclosed herein may be made by procedures known in the art and/or in accordance with the examples of the present specification.
Adjunct Materials
[0113] While not essential for the purposes of the present invention, the non-limiting list of adjuncts illustrated hereinafter are suitable for use in the laundry care compositions and may be desirably incorporated in certain embodiments of the invention, for example to assist or enhance performance, for treatment of the substrate to be cleaned, or to modify the aesthetics of the composition as is the case with perfumes, colorants, dyes or the like. It is understood that such adjuncts are in addition to the components that were previously listed for any particular embodiment. The total amount of such adjuncts may range from about 0.1% to about 50%, or even from about 1% to about 30%, by weight of the laundry care composition.
[0114] The precise nature of these additional components, and levels of incorporation thereof, will depend on the physical form of the composition and the nature of the operation for which it is to be used. Suitable adjunct materials include, but are not limited to, polymers, for example cationic polymers, surfactants, builders, chelating agents, dye transfer inhibiting agents, dispersants, enzymes, and enzyme stabilizers, catalytic materials, bleach activators, polymeric dispersing agents, clay soil removal/anti-redeposition agents, brighteners, suds suppressors, dyes, additional perfume and perfume delivery systems, structure elasticizing agents, fabric softeners, carriers, hydrotropes, processing aids and/or pigments. In addition to the disclosure below, suitable examples of such other adjuncts and levels of use are found in U.S. Pat. Nos. 5,576,282, 6,306,812 B1 and 6,326,348 B1 that are incorporated by reference.
[0115] As stated, the adjunct ingredients are not essential to Applicants' cleaning and laundry care compositions. Thus, certain embodiments of Applicants' compositions do not contain one or more of the following adjuncts materials: bleach activators, surfactants, builders, chelating agents, dye transfer inhibiting agents, dispersants, enzymes, and enzyme stabilizers, catalytic metal complexes, polymeric dispersing agents, clay and soil removal/anti-redeposition agents, brighteners, suds suppressors, dyes, additional perfumes and perfume delivery systems, structure elasticizing agents, fabric softeners, carriers, hydrotropes, processing aids and/or pigments. However, when one or more adjuncts are present, such one or more adjuncts may be present as detailed below:
[0116] Surfactants—The compositions according to the present invention can comprise a surfactant or surfactant system wherein the surfactant can be selected from nonionic and/or anionic and/or cationic surfactants and/or ampholytic and/or zwitterionic and/or semi-polar nonionic surfactants. The surfactant is typically present at a level of from about 0.1%, from about 1%, or even from about 5% by weight of the cleaning compositions to about 99.9%, to about 80%, to about 35%, or even to about 30% by weight of the cleaning compositions.
[0117] Builders—The compositions of the present invention can comprise one or more detergent builders or builder systems. When present, the compositions will typically comprise at least about 1% builder, or from about 5% or 10% to about 80%, 50%, or even 30% by weight, of said builder. Builders include, but are not limited to, the alkali metal, ammonium and alkanolammonium salts of polyphosphates, alkali metal silicates, alkaline earth and alkali metal carbonates, aluminosilicate builders polycarboxylate compounds. ether hydroxypolycarboxylates, copolymers of maleic anhydride with ethylene or vinyl methyl ether, 1,3,5-trihydroxybenzene-2,4,6-trisulphonic acid, and carboxymethyl-oxysuccinic acid, the various alkali metal, ammonium and substituted ammonium salts of polyacetic acids such as ethylenediamine tetraacetic acid and nitrilotriacetic acid, as well as polycarboxylates such as mellitic acid, succinic acid, oxydisuccinic acid, polymaleic acid, benzene 1,3,5-tricarboxylic acid, carboxymethyloxysuccinic acid, and soluble salts thereof.
[0118] Chelating Agents—The compositions herein may also optionally contain one or more copper, iron and/or manganese chelating agents. If utilized, chelating agents will generally comprise from about 0.1% by weight of the compositions herein to about 15%, or even from about 3.0% to about 15% by weight of the compositions herein.
[0119] Dye Transfer Inhibiting Agents—The compositions of the present invention may also include one or more dye transfer inhibiting agents. Suitable polymeric dye transfer inhibiting agents include, but are not limited to, polyvinylpyrrolidone polymers, polyamine N-oxide polymers, copolymers of N-vinylpyrrolidone and N-vinylimidazole, polyvinyloxazolidones and polyvinylimidazoles or mixtures thereof. When present in the compositions herein, the dye transfer inhibiting agents are present at levels from about 0.0001%, from about 0.01%, from about 0.05% by weight of the cleaning compositions to about 10%, about 2%, or even about 1% by weight of the cleaning compositions.
[0120] Dispersants—The compositions of the present invention can also contain dispersants. Suitable water-soluble organic materials are the homo- or co-polymeric acids or their salts, in which the polycarboxylic acid may comprise at least two carboxyl radicals separated from each other by not more than two carbon atoms.
[0121] Enzymes—The compositions can comprise one or more detergent enzymes which provide cleaning performance and/or fabric care benefits. Examples of suitable enzymes include, but are not limited to, hemicellulases, peroxidases, proteases, cellulases, xylanases, lipases, phospholipases, esterases, cutinases, pectinases, keratanases, reductases, oxidases, phenoloxidases, lipoxygenases, ligninases, pullulanases, tannases, pentosanases, malanases, β-glucanases, arabinosidases, hyaluronidase, chondroitinase, laccase, and amylases, or mixtures thereof. A typical combination is a cocktail of conventional applicable enzymes like protease, lipase, cutinase and/or cellulase in conjunction with amylase.
[0122] Enzyme Stabilizers—Enzymes for use in compositions, for example, detergents can be stabilized by various techniques. The enzymes employed herein can be stabilized by the presence of water-soluble sources of calcium and/or magnesium ions in the finished compositions that provide such ions to the enzymes.
[0123] Catalytic Metal Complexes—Applicants' compositions may include catalytic metal complexes. One type of metal-containing bleach catalyst is a catalyst system comprising a transition metal cation of defined bleach catalytic activity, such as copper, iron, titanium, ruthenium, tungsten, molybdenum, or manganese cations, an auxiliary metal cation having little or no bleach catalytic activity, such as zinc or aluminum cations, and a sequestrate having defined stability constants for the catalytic and auxiliary metal cations, particularly ethylenediaminetetraacetic acid, ethylenediaminetetra (methyl-enephosphonic acid) and water-soluble salts thereof. Such catalysts are disclosed in U.S. Pat. No. 4,430,243.
[0124] If desired, the compositions herein can be catalyzed by means of a manganese compound. Such compounds and levels of use are well known in the art and include, for example, the manganese-based catalysts disclosed in U.S. Pat. No. 5,576,282.
[0125] Cobalt bleach catalysts useful herein are known, and are described, for example, in U.S. Pat. Nos. 5,597,936 and 5,595,967. Such cobalt catalysts are readily prepared by known procedures, such as taught for example in U.S. Pat. Nos. 5,597,936, and 5,595,967.
[0126] Compositions herein may also suitably include a transition metal complex of a macropolycyclic rigid ligand—abbreviated as “MRL”. As a practical matter, and not by way of limitation, the compositions and cleaning processes herein can be adjusted to provide on the order of at least one part per hundred million of the benefit agent MRL species in the aqueous washing medium, and may provide from about 0.005 ppm to about 25 ppm, from about 0.05 ppm to about 10 ppm, or even from about 0.1 ppm to about 5 ppm, of the MRL in the wash liquor.
[0127] Preferred transition-metals in the instant transition-metal bleach catalyst include manganese, iron and chromium. Preferred MRL's herein are a special type of ultra-rigid ligand that is cross-bridged such as 5,12-diethyl-1,5,8,12-tetraazabicyclo[6.6.2]hexa-decane.
[0128] Suitable transition metal MRLs are readily prepared by known procedures, such as taught for example in WO 00/32601, and U.S. Pat. No. 6,225,464.
Processes of Making Laundry Care Compositions
[0129] The laundry care compositions of the present invention can be formulated into any suitable form and prepared by any process chosen by the formulator, non-limiting examples of which are described in U.S. Pat. No. 5,879,584; U.S. Pat. No. 5,691,297; U.S. Pat. No. 5,574,005; U.S. Pat. No. 5,569,645; U.S. Pat. No. 5,565,422; U.S. Pat. No. 5,516,448; U.S. Pat. No. 5,489,392; and U.S. Pat. No. 5,486,303.
[0130] In one aspect, the liquid detergent compositions disclosed herein may be prepared by combining the components thereof in any convenient order and by mixing, e.g., agitating, the resulting component combination to form a phase stable liquid detergent composition. In one aspect, a liquid matrix is formed containing at least a major proportion, or even substantially all, of the liquid components, e.g., nonionic surfactant, the non-surface active liquid carriers and other optional liquid components, with the liquid components being thoroughly admixed by imparting shear agitation to this liquid combination. For example, rapid stirring with a mechanical stirrer may usefully be employed. While shear agitation is maintained, substantially all of any anionic surfactant and the solid ingredients can be added. Agitation of the mixture is continued, and if necessary, can be increased at this point to form a solution or a uniform dispersion of insoluble solid phase particulates within the liquid phase. After some or all of the solid-form materials have been added to this agitated mixture, particles of any enzyme material to be included, e.g., enzyme prills, are incorporated. As a variation of the composition preparation procedure described above, one or more of the solid components may be added to the agitated mixture as a solution or slurry of particles premixed with a minor portion of one or more of the liquid components. After addition of all of the composition components, agitation of the mixture is continued for a period of time sufficient to form compositions having the requisite viscosity and phase stability characteristics. Frequently this will involve agitation for a period of from about 30 to 60 minutes.
[0131] In another aspect of producing liquid detergents, the thiazolium dye is first combined with one or more liquid components to form a thiazolium dye premix, and this thiazolium dye premix is added to a composition formulation containing a substantial portion, for example more than 50% by weight, more than 70% by weight, or even more than 90% by weight, of the balance of components of the laundry detergent composition. For example, in the methodology described above, both the thiazolium dye premix and the enzyme component are added at a final stage of component additions. In another aspect, the thiazolium dye is encapsulated prior to addition to the detergent composition, the encapsulated dye is suspended in a structured liquid, and the suspension is added to a composition formulation containing a substantial portion of the balance of components of the laundry detergent composition.
[0132] Various techniques for forming detergent compositions in such solid forms are well known in the art and may be used herein. In one aspect, when the laundry care composition is in the form of a granular particle, the thiazolium dye is provided in particulate form, optionally including additional but not all components of the laundry detergent composition. The thiazolium dye particulate is combined with one or more additional particulates containing a balance of components of the laundry detergent composition. Further, the thiazolium dye, optionally including additional but not all components of the laundry detergent composition may be provided in an encapsulated form, and the thiazolium dye encapsulate is combined with particulates containing a substantial balance of components of the laundry detergent composition.
Methods of Using Laundry Care Compositions
[0133] The laundry care compositions disclosed in the present specification may be used to clean or treat a fabric. Typically at least a portion of the fabric is contacted with an embodiment of the aforementioned laundry care compositions, in neat form or diluted in a liquor, for example, a wash liquor and then the fabric may be optionally washed and/or rinsed. In one aspect, a fabric is optionally washed and/or rinsed, contacted with a an embodiment of the aforementioned laundry care compositions and then optionally washed and/or rinsed. For purposes of the present invention, washing includes but is not limited to, scrubbing, and mechanical agitation. The fabric may comprise most any fabric capable of being laundered or treated.
[0134] The laundry care compositions disclosed in the present specification can be used to form aqueous washing solutions for use in the laundering of fabrics. Generally, an effective amount of such compositions is added to water, preferably in a conventional fabric laundering automatic washing machine, to form such aqueous laundering solutions. The aqueous washing solution so formed is then contacted, preferably under agitation, with the fabrics to be laundered therewith. An effective amount of the laundry care composition, such as the liquid detergent compositions disclosed in the present specification, may be added to water to form aqueous laundering solutions that may comprise from about 500 to about 7,000 ppm or even from about 1,000 to about 3,000 pm of laundry care composition.
[0135] In one aspect, one or more of the thiazolium dyes disclosed in the present specification may be provided, for example via a laundry care composition, such that during the wash cycle and or rinse cycle the concentration of such one or more dyes may be from about 0.5 parts per billion (ppb) to about 5 part per million (ppm), from about 1 ppb to about 600 ppb, from about 5 ppb to about 300 ppb, or even from about 10 ppb to about 100 ppb of thiazolium dye. In one aspect such concentrations may be achieved during the washing cycle, and/or rinse cycle, of a 17 gallon automatic laundry washing machine.
[0136] In one aspect, the laundry care compositions may be employed as a laundry additive, a pre-treatment composition and/or a post-treatment composition.
Test Methods
I. Method for Determining of Hueing Efficiency for Detergents
[0000]
a.) Two 25 cm×25 cm fabric swatches of 16 oz white cotton interlock knit fabric (270 g/square meter, brightened with Uvitex BNB fluorescent whitening agent, from Test Fabrics. P.O. Box 26, Weston, Pa., 18643), are obtained.
b.) Prepare two one liter aliquots of tap water containing 1.55 g of AATCC standard heavy duty liquid (HDL) test detergent as set forth in Table 3.
c.) Add a sufficient amount the dye to be tested to one of the aliquots from Step b.) above to produce an aqueous solution absorbance of 1 AU.
d.) Wash one swatch from a.) above in one of the aliquots of water containing 1.55 g of AATCC standard heavy duty liquid (HDL) test detergent and wash the other swatch in the other aliquot. Such washing step should be conducted for 30 minutes at room temperature with agitation. After such washing step separately rinse the swatches and dry the swatches.
e.) After rinsing and drying each swatch, the hueing efficiency, DE* eff , of the dye is assessed by determining the L*, a*, and b* value measurements of each swatch using a Hunter LabScan XE reflectance spectrophotometer with D65 illumination, 10° observer and UV filter excluded. The hueing efficiency of the dye is then calculated using the following equation:
[0000] DE* eff =(( L* c −L* s ) 2 +( a* c a* s ) 2 +( b* c −b* s ) 2 ) 1/2 wherein the subscripts c and s respectively refer to the L*, a*, and b* values measured for the control, i.e., the fabric sample washed in detergent with no dye, and the fabric sample washed in detergent containing the dye to be screened.
II. Method for Determining Wash Removability
[0000]
a.) Prepare two separate 150 ml aliquots of HDL detergent solution set forth in Table 1, according to AATCC Test Method 61-2003, Test 2A and containing 1.55 g/liter of the AATCC HDL formula in distilled water.
b.) A 15 cm×5 cm sample of each fabric swatch from the Method for Determining of Hueing Efficiency For Detergents described above is washed in a Launderometer for 45 minutes at 49° C. in 150 ml of a the HDL detergent solution prepared according to Step II. a.) above.
c.) The samples are rinsed with separate aliquots of rinse water and air dried in the dark, the amount of residual coloration is assessed by measuring the DE* res , of the dye is assessed by determining the L*, a*, and b* value measurements of each swatch using a Hunter LabScan XE reflectance spectrophotometer with D65 illumination, 10° observer and UV filter excluded. The hueing efficiency of the dye is then calculated using the following equation:
[0000] DE* res =(( L* c −L* s ) 2 +( a* c −a* s ) 2 +( b* c −b* s ) 2 ) 1/2 wherein the subscripts c and s respectively refer to the L*, a*, and b* values measured for the control, i.e., the fabric sample initially washed in detergent with no dye, and the fabric sample initially washed in detergent containing the dye to be screened. The wash removal value for the dye is then calculated according to the formula: % removal=100×(1−DE* res /DE* eff ).
[0000]
TABLE 3
Ingredient
weight percent
C11.8 linear alkylbenzene sulfonic acid
12.00
Neodol 23-9
8.00
citric acid
1.20
C12-14 fatty acid
4.00
sodium hydroxide 1
2.65
ethanolamine
0.13
borax
1.00
DTPA 2
0.30
1,2-propanediol
8.00
brightener 15
0.04
water
balance
1 formula pH adjusted to 8.5
2 diethylenetriaminepentaacetic acid, pentasodium salt
EXAMPLES
[0147] The following examples illustrate the compositions of the present invention but are not necessarily meant to limit or otherwise define the scope of the invention herein.
Example 1
[0148] The following liquid formulas are within the scope of the present invention.
[0000]
1a
1b
1c
1d
1e
1f 5
Ingredient
wt %
wt %
wt %
wt %
wt %
wt %
sodium alkyl ether sulfate
14.4%
14.4%
9.2%
5.4%
linear alkylbenzene
4.4%
4.4%
12.2%
5.7%
1.3%
22.0%
sulfonic acid
alkyl ethoxylate
2.2%
2.2%
8.8%
8.1%
3.4%
18.0%
amine oxide
0.7%
0.7%
1.5%
citric acid
2.0%
2.0%
3.4%
1.9%
1.0%
1.6%
fatty acid
3.0%
3.0%
8.3%
16.0%
protease
1.0%
1.0%
0.7%
1.0%
2.5%
amylase
0.2%
0.2%
0.2%
0.3%
lipase
0.2%
borax
1.5%
1.5%
2.4%
2.9%
calcium and sodium
0.2%
0.2%
formate
formic acid
1.1%
amine ethoxylate polymers
1.8%
1.8%
2.1%
3.2%
sodium polyacrylate
0.2%
sodium polyacrylate
0.6%
copolymer
DTPA 1
0.1%
0.1%
0.9%
DTPMP 2
0.3%
EDTA 3
0.1%
fluorescent whitening
0.15%
0.15%
0.2%
0.12%
0.12%
0.2%
agent
ethanol
2.5%
2.5%
1.4%
1.5%
propanediol
6.6%
6.6%
4.9%
4.0%
15.7%
sorbitol
4.0%
ethanolamine
1.5%
1.5%
0.8%
0.1%
11.0%
sodium hydroxide
3.0%
3.0%
4.9%
1.9%
1.0%
sodium cumene sulfonate
2.0%
silicone suds suppressor
0.01%
perfume
0.3%
0.3%
0.7%
0.3%
0.4%
0.6%
Compound 16 of Table 1
0.005%
0.005%
Compound 24 of Table 1
0.005%
Compound 13 of Table 1
0.008%
Compound 36 of Table 1
0.008%
Compound 21 of Table 1
0.015%
Liquitint Aqua AS 4
0.005%
opacifier 6
0.5%
water
balance
balance
balance
balance
balance
balance
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
1 diethylenetriaminepentaacetic acid, sodium salt
2 diethylenetriaminepentakismethylenephosphonic acid, sodium salt
3 ethylenediaminetetraacetic acid, sodium salt
4 a non-tinting dye used to adjust formula color
5 compact formula, packaged as a unitized dose in polyvinyl alcohol film
6 Acusol OP 301
Example 2
[0149] The following granular detergent formulas are within the scope of the present invention.
[0000]
2a
2b
2c
2d
Ingredient
wt %
wt %
wt %
wt %
Na linear alkylbenzene sulfonate
3.4%
3.3%
11.0%
3.4%
Na alkylsulfate
4.0%
4.1%
4.0%
Na alkyl sulfate (branched)
9.4%
9.6%
9.4%
alkyl ethoxylate
3.5%
type A zeolite
37.4%
35.4%
26.8%
37.4%
sodium carbonate
22.3%
22.5%
35.9%
22.3%
sodium sulfate
1.0%
18.8%
1.0%
sodium silicate
2.2%
protease
0.1%
0.2%
0.1%
sodium polyacrylate
1.0%
1.2%
0.7%
1.0%
carboxymethylcellulose
0.1%
PEG 600
0.5%
PEG 4000
2.2%
DTPA
0.7%
0.6%
0.7%
fluorescent whitening agent
0.1%
0.1%
0.1%
0.1%
sodium percarbonate
5.0%
sodium nonanoyloxybenzenesulfonate
5.3%
silicone suds suppressor
0.02%
0.02%
0.02%
perfume
0.3%
0.3%
0.2%
0.3%
Compound 15 of Table 1
0.015% 1
Compound 48 of Table 1
0.017% 2
Compound 38 of Table 1
0.017% 3
Compound 33 of Table 1
0.02% 4
water and miscellaneous
balance
balance
balance
balance
1 formulated as a particle containing 0.5% dye, 99.5% PEG 4000
2 formulated as a layered particle containing 2% dye according to US 2006 252667 A1
3 formulated as a particle containing 0.5% dye according to U.S. Pat. No. 4,990,280
4 formulated as a particle containing 0.5% dye with zeolite
Example 3
[0150] The following rinse added fabric conditioning formulas are within the scope of the present invention.
[0000]
Ingredients
3a
3b
3c
3d
Fabric Softening Active a
13.70%
13.70%
13.70%
13.70%
Ethanol
2.14%
2.14%
2.14%
2.14%
Cationic Starch b
2.17%
2.17%
2.17%
2.17%
Perfume
1.45%
1.45%
1.45%
1.45%
Phase Stabilizing
0.21%
0.21%
0.21%
0.21%
Polymer c
Calcium Chloride
0.147%
0.147%
0.147%
0.147%
DTPA d
0.007%
0.007%
0.007%
0.007%
Preservative e
5 ppm
5 ppm
5 ppm
5 ppm
Antifoam f
0.015%
0.015%
0.015%
0.015%
Compound 45 of Table 1
30 ppm
15 ppm
Compound 25 of Table 1
30 ppm
Compound 30 of Table 1
30 ppm
15 ppm
Tinopal CBS-X g
0.2
0.2
0.2
0.2
Ethoquad C/25 h
0.26
0.26
0.26
0.26
Ammonium Chloride
0.1%
0.1%
0.1%
0.1%
Hydrochloric Acid
0.012%
0.012%
0.012%
0.012%
Deionized Water
Balance
Balance
Balance
Balance
a N,N-di(tallowoyloxyethyl)-N,N-dimethylammonium chloride.
b Cationic starch based on common maize starch or potato starch, containing 25% to 95% amylose and a degree of substitution of from 0.02 to 0.09, and having a viscosity measured as Water Fluidity having a value from 50 to 84.
c Copolymer of ethylene oxide and terephthalate having the formula described in U.S. Pat. No. 5,574,179 at col. 15, lines 1-5, wherein each X is methyl, each n is 40, u is 4, each R 1 is essentially 1,4-phenylene moieties, each R 2 is essentially ethylene, 1,2-propylene moieties, or mixtures thereof.
d Diethylenetriaminepentaacetic acid.
e KATHON ® CG available from Rohm and Haas Co.
f Silicone antifoam agent available from Dow Corning Corp. under the trade name DC2310.
g Disodium 4,4′-bis-(2-sulfostyryl) biphenyl, available from Ciba Specialty Chemicals.
h Cocomethyl ethoxylated [15] ammonium chloride, available from Akzo Nobel
Example 4
Synthesis of mtol-10EO Methylthiazolium
[0151]
[0152] Five hundred and forty-nine grams of 85% phosphoric acid, 75 grams of 98% sulfuric acid and 9 drops of 2-ethyl hexanol defoamer are added to a 100 milliliter three necked flask equipped with a thermometer, cooling bath, and mechanical stirrer. The mixture is cooled and 30.9 grams of 2-aminothiazole is added to the flask. The mixture is further cooled to below 0° C. after which 105 grams of 40% nitrosyl sulfuric acid are added while the temperature is maintained below 5° C. After three hours the mixture gives a positive nitrite test and 25 grams of sulfamic acid are added slowly while the temperature is kept below 5° C. A negative nitrite test is evident after one hour.
[0153] A 2000 milliliter beaker is charged with 190 grams 10 EO m-toluidine intermediate, 200 grams of water, 200 grams of ice and 12 grams of urea. The mixture is cooled to 0° C. The diazo solution is added dropwise to the beaker over about 30 minutes, while maintaining the temperature below 10° C. The resulting mixture is stirred for several hours and allowed to stand overnight, after which 780 grams of 50% sodium hydroxide is added to neutralize excess acid to a pH of about 7 while the temperature is kept below 20° C. The bottom salt layer is removed and the product is washed with 200 milliliters of a 10% sodium sulfate solution. The aqueous layer is removed and the desired product is obtained as an orange liquid (240 grams, 70% actives).
[0154] One hundred grams of the orange liquid from above and 28.40 grams of dimethyl sulfate are placed into a 500 milliliter flask equipped with a reflux condenser, thermometer, heating mantle and mechanical stirrer. The reaction mixture is heated to 70° C. for two hours. The reaction is cooled and the pH is adjusted to 7 with 10 grams of 20% ammonium hydroxide and is used without further purification.
Example 5
[0155] The procedure of Example 4 is used to make N-ethyl-mtol-5EO
[0000]
[0000] with the difference being the use of the following m-toluidine intermediate:
[0000]
Example 6
[0156] The procedure of Example 5, with the noted changes, is used to make:
[0000]
[0157] Twenty grams of the orange liquid per Example 5, as obtained via Example 4, and nine grams of benzyl bromide are placed into a 250 milliliter flask equipped with a reflux condenser, thermometer, heating mantle and mechanical stirrer. The reaction mixture is heated to 70° C. for two hours. The reaction is cooled and the pH is adjusted to 7 with 4 grams of 50% sodium hydroxide and is used without further purification.
[0158] While particular embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this invention.
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The present invention relates to thiazolium dyes, laundry care compositions comprising one or more thiazolium dyes, processes of making such dyes and laundry care compositions and methods of using same. The dyes, compositions and methods of the present invention are advantageous in providing improved hueing of fabric, including whitening of white fabric, while avoiding significant build up of bluing dyes on the fabric.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit pursuant to 35 U.S.C. 119(e) of U.S. Provisional Application No. 61/493,451, filed Jun. 4, 2011, which application is specifically incorporated herein, in its entirety, by reference.
BACKGROUND
[0002] 1. Field
[0003] Embodiments of the invention relate to the field of manipulating data for presentation by a computer prior to use with a specific display system; and more specifically, to using more than one graphics processor to manipulate the data.
[0004] 2. Background
[0005] Electronic devices such as personal computers, digital assistants, media players, wireless communication devices, and the like typically include a visual display unit to provide visual displays to a user. The visual displays are typically generated by application programs being executed by a processing unit included in the electronic device. Several application programs may be executed concurrently and they may share the visual display unit by using only portions of the display unit to present their visual displays and/or by “stacking” their visual displays so that the user can bring the display for any of the applications to the top of the stack to be viewed in its entirety.
[0006] The electronic device will typically include an operating system, which is a program executed by the processing unit, to provide an abstract interface to the hardware of the electronic device for the application programs. This allows specific programming requirements of the hardware to be encapsulated in the operating system and make the application programs independent of the specific hardware implementation. The operating system also manages the sharing of the hardware by the multiple applications.
[0007] The operating system will typically include support for providing visual displays on visual display units. The provided visual display support may include facilities for merging or compositing graphic elements to create a display layer and manipulating one or more display layers to create a visual display using a hierarchical layer abstraction. Supported graphic manipulations may include rotating, moving, and resizing graphic elements. Support may also be provided for adjusting the color and transparency of graphic elements. Animation of any or all of these supported transformations may also be provided.
[0008] It will be appreciated that supporting these graphic manipulations can be computationally intensive, particularly for high resolution displays. The electronic device may support multiple displays, which further increase the computational requirements. For example, an electronic device may include a first display that is included in the electronic device and an interface that allows a second display to be connected to the electronic device to provide additional space for visual displays.
[0009] It would be desirable to provide a computational architecture that supports extensive graphic manipulations for visual displays on multiple visual display units.
SUMMARY
[0010] A graphic display module operating on a first device prepares graphic data to be displayed on a wirelessly connected display adapter that includes graphics processing capability. The display adapter transmits metadata to the graphic display module that includes the graphic processing capabilities of the display adapter. The graphic display module uses the metadata, and possibly the available bandwidth, to selectively delegate graphic processing tasks to the display adapter.
[0011] Other features and advantages of the present invention will be apparent from the accompanying drawings and from the detailed description that follows below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The invention may best be understood by referring to the following description and accompanying drawings that are used to illustrate embodiments of the invention by way of example and not limitation. In the drawings, in which like reference numerals indicate similar elements:
[0013] FIG. 1 is a block diagram of a host device and a slave device that embody the invention.
[0014] FIG. 2 is a visual display that may be produced by an embodiment of the invention.
[0015] FIG. 3 is a conceptual representation of a method for producing the visual display of FIG. 2 .
[0016] FIG. 4 is a flow chart for a method of producing a visual display on a slave device.
[0017] FIG. 5 is a flow chart or in a third of rotating a visual display on a slave device.
[0018] FIG. 6 is an illustration of a rotated visual display on a slave device.
[0019] FIG. 7 is an image frame for producing a rotated visual display on a slave device.
[0020] FIG. 8 is a partial image frame for producing a rotated visual display on a slave device.
[0021] FIG. 9 is another partial image frame for producing a rotated visual display on a slave device.
DETAILED DESCRIPTION
[0022] In the following description, numerous specific details are set forth. However, it is understood that embodiments of the invention may be practiced without these specific details. In other instances, well-known circuits, structures and techniques have not been shown in detail in order not to obscure the understanding of this description.
[0023] FIG. 1 shows a block diagram of a host device 10 and a slave device 20 that embody the invention. An application program 100 is executed by a processing unit on the host device 10 . The application program 100 generates a visual display by communicating graphics commands to a graphic display module of 102 that is also executed by the processing unit on the host device 10 .
[0024] The graphic display module 102 assembles graphic data in buffers 104 , 106 to create a visual display on visual display devices 120 , 134 . In the implementation illustrated, a primary display buffer 104 is used to create a visual display that is local to the host device 10 . The host display driver on 114 communicates the graphic data from the primary display buffer 104 to the host display device 120 .
[0025] A secondary display buffer 106 is used to create a visual display on a slave display device 134 that is driven by a slave device 20 that receives graphic data from the host device 10 over a wireless communications link. On the host device 10 the secondary display buffer 106 may be scaled 108 to produce a display of an appropriate size for the slave display device 134 . The image data may be encoded 112 to compress the data that is transmitted to the slave device 20 . The encoding may require a color space conversion 110 prior to encoding. The graphic data is transmitted by a wireless transmitter 116 on the host device 10 .
[0026] Processes for displaying graphic content are described in pending U.S. Provisional Patent Application No. 61/431,776, which is assigned to the assignee of the present application, and which is incorporated herein, in its entirety by reference.
[0027] The slave device 20 receives the graphic data on a wireless receiver 122 . If the data has been encoded use them decoded 126 by the slave device 20 . A visual display driver 128 receives the graphic data and assembles it in a slave display buffer 130 . A slave display driver 132 communicates the graphic data from the slave display buffer 130 to the slave display device 134 . The slave display device may be a part of the slave device or it may be a separate device that is coupled to a slave device.
[0028] The slave device 20 includes a wireless transmitter 124 . The visual display driver 128 on the slave device 20 transmits metadata to a wireless receiver 118 on the host device 10 . The metadata includes information about the graphic processing capabilities of the slave device 20 . The metadata may also include information about the slave display device 134 including the orientation of the display device. Methods and devices for detecting the orientation of portable electronic devices with displays are described in issued U.S. Pat. No. 7,633,076, which is assigned to the assignee of the present application, and which is incorporated herein, in its entirety by reference.
[0029] The host device 10 includes a wireless receiver 118 that receives the metadata transmitted by the slave device 20 . The graphic display module 102 uses the received metadata to adapt the preparation of the graphic data transmitted to the slave device 20 .
[0030] FIG. 2 shows a visual display 200 that may be created by the graphic display module 102 for display on the slave display device 134 . The visual display 200 illustrated includes several graphic elements including a moving video image 202 , a progress bar 204 , text elements 208 , and a cursor 206 indicating a selection.
[0031] FIG. 3 is a pictorial representation of the hierarchal abstraction that the graphic display module 102 may present to the application program 100 for creating the visual display 200 . The visual display may be created as a number of layers that are superimposed upon one another. In the example illustrated the text elements 208 may be created on a bottom layer 308 . The cursor 206 may be placed on a layer 306 above the text elements. The progress bar 204 may be on a layer 304 above the cursor. The video image 202 may be on a top layer 302 . The graphic display module 102 uses the metadata received from the slave device 20 to create metadata that is associated with the graphic data to delegate some or all of the manipulations of the graphic data to the visual display driver 128 on the slave device 20 .
[0032] FIG. 4 is a flow chart for a process of delegating manipulations of the graphic data to the slave device 20 . The graphics processing capabilities of the slave (second) device are received at the host (first) device 400 . The host device creates data for an image assuming that the slave device will perform some image processing 402 . In some implementations, the data for the image is encoded 404 . The data for the image is wirelessly transmitted from the host device to the second device 406 . The data for the image is wirelessly received at the second device 408 . If the data was encoded, the slave device decodes the image data 410 . The slave device processes the data for the image based on instructions from the host device 412 .
[0033] FIG. 5 is a flow chart for a process of rotating the graphic data in the slave device 20 . The orientation status of the slave display is continuously determined for determining the appropriate orientation of the display on the slave device. The orientation of the slave display and the graphics rotation capabilities of the slave (second) device are received at the host (first) device 500 . The host device creates data for an image assuming that the slave device will perform any necessary rotations 502 . In some implementations, the data for the image is encoded 504 . The data for the image is wirelessly transmitted from the host device to the second device 506 . The data for the image is wirelessly received at the second device 508 . If the data was encoded, the slave device decodes the image data 510 . The slave device rotates the data for the image based on instructions from the host device 512 . The rotated data is provided to the slave display device with an appropriate rotation for the display orientation 514 .
[0034] FIG. 6 shows a host device 10 and a slave device 20 in wireless communication. As suggested by the illustration the host device and a slave device may have identical capabilities. The host device 10 includes a host display device 612 showing a visual display 610 . It will be appreciated that the local visual display 610 is illustrated only to aid in the understanding of the operation of the invention and that it is not necessary that a visual display be displayed on the host device for the purposes of the invention. The slave device 20 new shown with a slave display device 622 showing a visual display 620 . The host display device 612 is shown in a landscape orientation while the slave device 622 is shown in a portrait orientation.
[0035] Display devices typically have a single native orientation. When the display device is viewed in other than its native orientation it is necessary to rotate the visual display so that the display device appears to have an appropriate orientation other than its native orientation. If the native orientation of the slave display 622 is a landscape orientation and the display is viewed with the native top edge to the left as suggested in FIG. 6 , then the visual display 620 will need to be rotated 90° clockwise as shown in FIG. 7 . In one implementation the visual display 620 is fully composited by the host device and tagged with metadata to direct the slave device to rotate the visual display to correspond to the orientation of the slave display device 622 .
[0036] FIGS. 8 and 9 illustrate an implementation where the visual display is provided to the slave device 20 as two image frames. The first image frame 720 shown in FIG. 8 is composited and rotated by the host device 10 . The second image frame 820 shown in FIG. 9 is not rotated. The host device 10 tags each of these image frames with metadata so that the second image frame 820 is rotated by the slave device 20 and then composited with the already rotated first image frame 720 . The host device 10 may tag some image frames as being persistent so that unchanging frames are retained by the slave device for compositing with a stream of changing frames.
[0037] While certain exemplary embodiments have been described and shown in the accompanying drawings, it is to be understood that such embodiments are merely illustrative of and not restrictive on the broad invention, and that this invention is not limited to the specific constructions and arrangements shown and described, since various other modifications may occur to those of ordinary skill in the art. The description is thus to be regarded as illustrative instead of limiting.
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A graphic display module operating on a first device prepares graphic data to be displayed on a wirelessly connected display adapter that includes graphics processing capability. The display adapter transmits metadata to the graphic display module that includes the graphic processing capabilities of the display adapter. The graphic display module uses the metadata, and possibly the available bandwidth, to selectively delegate graphic processing tasks to the display adapter.
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BACKGROUND OF THE DISCLOSURE
[0001] 1. Field of the Disclosure
[0002] The present disclosure relates to apparatuses and methods to lift and install large-diameter tubulars with a drilling rig. More particularly, the present disclosure relates to apparatuses and methods to raise horizontal sections of large-diameter pipe to mount them atop vertical strings of large-diameter pipe. More particularly still, the present disclosure relates to apparatuses and methods to raise horizontal sections of conductor pipe to install them atop vertical strings of conductor pipe extending into a wellbore.
[0003] 2. Description of the Related Art
[0004] Referring to FIG. 11 , a perspective view is shown of a drilling rig 50 used to run tubular members 52 (e.g., casing, drill pipe, etc.) downhole into a wellbore. As shown, drilling rig 50 includes a frame structure known as a “derrick” 54 from which a traveling block 56 and an elevator 58 and/or a top drive (not shown) may be used to manipulate (e.g., raise, lower, rotate, hold, etc.) tubular members 52 . As shown, traveling block 56 is a device that is located at or near the top of derrick 54 , in which traveling block 56 may move up-and-down (i.e., vertically as depicted) to raise or lower tubular members 52 . As shown, traveling block may be a simple “pulley-style” block and may have a hook 60 from which objects below (e.g., elevator 58 ) may be hung. Additionally, elevator 58 may also be coupled below traveling block 56 and/or a top drive (not shown) to selectively grab or release tubular members 52 as they are to be raised or lowered within and from derrick 54 . Typically, elevator 58 includes movable gripping components (e.g., slips) movable between an open position and a closed position (shown in FIG. 11 ). In the closed position, the movable components form a load bearing ring (or shoulder) about or upon which tubular members 52 may bear and be lifted. In the open position, the movable components of elevator 58 may move away from one another to allow the tubular members 52 to be brought within or removed from elevator 58 .
[0005] When assembling a string of tubular members 52 together, the tubular members 52 may be removed from a pipe rack 62 and pulled, or otherwise transported, towards an access opening 64 , for example, a v-door, within the derrick 54 of the drilling rig 50 . The tubular members 52 may be loaded onto a pipe ramp 66 adjacent to the access opening 64 , in which a rigidly mounted end stop 68 may abut the ends of the tubular members 52 to support the tubular members 52 up against access opening 64 .
[0006] Tubular-shaped goods have a variety of uses in oilfield operations including, but not limited to, drill pipe, drill collars, casing, continuous coiled tubing, and the like. One such tubular-shaped good used in exploration and drilling is conductor pipe. Generally, conductor pipe (e.g., drive pipe) is large-diameter pipe (e.g., between about 75 cm to about 100 cm or about 50 cm to about 182 cm in diameter), usually constructed of steel, that extends from the wellhead into the earth or ocean floor. As such, a string of conductor pipe sections (i.e., a conductor string) is typically the first string of “casing” run into the wellbore, and serves to stabilize the sediment surrounding the wellbore to prevent it from caving-in.
[0007] Installation of the conductor string may be performed any number of ways. On land, the conductor string may be driven into the ground from above with an impact loading hammer apparatus. In certain locations, excavation may be necessary prior to driving the conductor string into the uncovered sediment. Offshore, conductor strings may similarly be installed, using impact driving and excavation techniques. In undersea environments, conductor strings may be “jetted in”, for example with a pressurized fluid discharged (e.g., seawater) at a distal end of the conductor string displacing the sediment as the conductor string is advanced into the sea floor. Following such a jetting process, an impact driving process may be performed to force the conductor string further into the sea floor, if desired. Additionally or alternatively, in undersea environments, conductor strings may be “sucked” into the sea floor by filling the string with water, sealing the conductor string, and then pumping, or evacuating, the trapped water from the inner bore of the conductor string. As the water is removed from the sealed bore of the conductor string, the conductor is plunged deeper into the sea floor as the sea floor sediment replaces the evacuated water. Following such a suction process, an impact driving process may be performed to force the conductor string further into the sea floor, if desired. Alternatively, impact driving may be performed simultaneously as the conductor string is jetted or sucked into the sea floor.
[0008] While conductor strings are relatively the largest (diameter) and shortest (length) strings of casing used to case a wellbore, the strings are still long enough to be assembled from several sections, or joints, of conductor pipe. As such, because of their large diameter and desired permanent placement about the wellbore, conductor strings are typically assembled, on site, from several joints of conductor pipe 20-40 feet long, and may be threaded or welded together end-to-end.
[0009] Historically, assembling strings of conductor pipe on the rig floor has been a difficult and time-consuming process. In one example method, to install a new joint of conductor pipe atop a string conductor pipe already engaged into the wellbore, a series of lifting eyes and handling eyes are affixed to the outer periphery of the large diameter and heavy-walled joint of conductor pipe to be added. In particular, a pair of heavy-duty lifting eyes are attached, typically 180° apart near the upper-most end of conductor pipe while it remains horizontal, either in the pipe rack or in another location on or near the drilling rig. Next, at least one pair of handling eyes are added to the joint of conductor pipe to be added, typically at opposite ends of the joint, but at similar radial positions.
[0010] As such, using various rigging and sling mechanisms, a crane may secure the bottom end of the horizontal conductor pipe (from a handling eye) while another crane (or the rig draw works) raises the upper end so that the formerly horizontal joint of conductor pipe may be held in a vertical position. Once moved into place atop the string of conductor pipe already engaged into the wellbore (and held in location by its lifting eyes), the joint of conductor pipe to be added may be threaded together and/or welded in place. With the new joint of conductor pipe attached, the lifting eyes of the former topmost joint may be removed and the entire string of conductor pipe may be supported and lowered by the lifting eyes affixed to the outer profile of the newly-added joint. Once the string of conductor pipe is supported by the lifting eyes of the new joint, the handling eyes of the new joint are removed, e.g., to minimize resistance in running the conductor string into the wellbore.
[0011] However, the installation and removal of the lifting and handling eyes may be problematic in itself. In many cases, bosses, pre-fabricated with the joint of conductor pipe, contain tapped holes to receive the lifting and handling eyes so that high-strength bolts may be used to transfer the load from the eyes to the joint of conductor pipe. Bosses are typically an external protrusion on the outer surface of the conductor pipe. When it comes time to remove the lifting and handling eyes, the bolts may be removed, however the boss remains. As a machining and welding process, the installation and manufacture of the bosses is both time consuming and expensive. Further, as an upset on the outer profile of the joint of conductor pipe, the bosses may add undesired resistance as the conductor string is driven further into the ground about the proposed wellbore and/or may prevent the sediment from re-settling around the conductor string, e.g., not allowing the sediment to sufficiently retain the conductor string in place. As the bosses are typically welded on and bolted to the lifting and handling eyes, they represent possible failure mechanisms that may disrupt operations should a boss, bolt, or lifting eye fail during the installation procedure.
[0012] Alternatively, lifting and handling eyes may be directly welded to the outer profile of the joints of conductor pipe. Following use, the welds may be ground off and the outer profile of the conductor pipe may be ground smoother such that little or no resistance to being driven remains. However, depending on regulations for the particular location, “hot work” such as welding and grinding may not be allowed to be performed at particular times on the rig floor. Additionally, the processes to weld, remove, and grind smooth the outer profiles of the joints of conductor pipe may represent a tremendous amount of time investment. Furthermore, during the removal and grinding process, there is opportunity for the outer profile of the joint of conductor pipe to become damaged to the point where it must be replaced or repaired. Repairing a lower joint of conductor pipe following the installation of an upper joint of conductor pipe would be highly undesirable, and would consume tremendous amounts of time and rig resources.
[0013] Apparatuses and methods to simplify the lifting, assembly, and installation of strings of conductor pipe would be well received in the industry. In particular, apparatuses and methods to assemble and install joints of conductor casing without requiring the installation and removal of lifting and handling eyes would be a significant benefit to the industry.
SUMMARY OF THE CLAIMED SUBJECT MATTER
[0014] In one aspect, the present disclosure relates to a method to add a joint of pipe to a conductor string including securing the conductor string with a spider, grasping an upper end of the joint of pipe with a segmented-ring elevator, engaging a plurality of slips of the elevator with an outer profile of the joint of pipe, raising the grasped joint of pipe from non-vertical to vertical, positioning the vertical joint of pipe atop the secured conductor string, attaching the joint of pipe to the conductor string, releasing the conductor string from the spider, and retaining the joint of pipe and the conductor string with the segmented-ring elevator.
[0015] In another aspect, the present disclosure relates to a lifting elevator including a first elevator segment, a second elevator segment, at least one pivot about which at least one of the elevator segment of the lifting elevator may rotate with respect to each other, a latch connecting the first elevator segment to the second elevator segment, and a plurality of slips to engage a conductor string surrounded by the first and second elevator segments.
[0016] In another aspect, the present disclosure relates to an apparatus to lift non-vertical pipe sections including a first lifting ring connected to a lifting point through a first lifting line, a second lifting ring connected to the lifting point through a second lifting line, and an inner profile of the first and second lifting rings configured to receive and secure a joint of horizontal pipe.
[0017] In another aspect, the present disclosure relates to a method to install a joint of conductor pipe to a conductor string including raising the joint of conductor pipe from a non-vertical position with a lifting apparatus, engaging a segmented ring elevator about the raised non-vertical joint of conductor pipe, closing the segmented ring elevator about the raised non-vertical joint of conductor pipe, activating at least one powered slip of the segmented ring elevator to grip the joint of conductor pipe, raising the segmented ring elevator until the joint of conductor pipe is in a vertical position, positioning the joint of conductor pipe atop the conductor string, and connecting the joint of conductor pipe to the conductor string.
BRIEF DESCRIPTION OF DRAWINGS
[0018] Features of the present disclosure will become more apparent from the following description in conjunction with the accompanying drawings.
[0019] FIG. 1 is a schematic view drawing of a horizontal lifting apparatus in accordance with embodiments of the present disclosure.
[0020] FIG. 2 is a schematic view drawing of a joint of conductor pipe being raised from a horizontal position to a vertical position in accordance with embodiments of the present disclosure.
[0021] FIG. 3 is a schematic view drawing of the joint of conductor pipe of FIG. 2 in the vertical position in accordance with embodiments of the present disclosure.
[0022] FIG. 4 is a schematic view drawing of the joint of conductor pipe of FIGS. 2 and 3 being connected to a string of conductor pipe in accordance with embodiments of the present disclosure.
[0023] FIG. 5 is a schematic view drawing of the joint of conductor pipe of FIGS. 2-4 engaged into the wellbore along with the string of conductor pipe in accordance with embodiments of the present disclosure.
[0024] FIG. 6 is a schematic view drawing of an elevator of FIGS. 2-5 being removed from the string of conductor pipe in accordance with embodiments of the present disclosure.
[0025] FIG. 7 is a detailed perspective view drawing of the elevator of FIGS. 2-6 in accordance with embodiments of the present disclosure.
[0026] FIG. 8 is a schematic view of the elevator of FIG. 7 in an open position about to engage a joint of conductor pipe in accordance with embodiments of the present disclosure.
[0027] FIG. 8A is a schematic view of a first embodiment of an actuated latch mechanism of the elevator of FIG. 8 .
[0028] FIG. 8B is a schematic view of a second embodiment of an actuated latch mechanism of the elevator of FIG. 8 .
[0029] FIG. 9 is a schematic view of the elevator of FIG. 8 in a closed position around the joint of conductor pipe in accordance with embodiments of the present disclosure.
[0030] FIG. 10 is a schematic view of the elevator of FIG. 9 in a closed position with slips engaged into the joint of conductor pipe in accordance with embodiments of the present disclosure.
[0031] FIG. 11 is a prior-art schematic drawing of a typical drilling rig.
DETAILED DESCRIPTION
[0032] Apparatuses and methods disclosed herein relate to the assembly and installation of strings of large-diameter tubulars. While strings of conductor pipe are discussed in conjunction with the embodiments described below, it should be understood that various types (and sizes) of tubular items may be handled, assembled, and installed in accordance with the embodiments described below.
[0033] Referring initially to FIG. 1 , a horizontal lifting apparatus 100 is shown schematically lifting a horizontally-stored joint of conductor pipe 102 . As shown, lifting apparatus 100 includes a pair of lifting rings 104 A and 104 B extending from a pair of lifting lines 106 A and 106 B to a single lifting point 108 . As shown, lifting lines 106 A, 106 B may be of equal length so that when rings 104 A, 104 B are positioned at equal distances from ends of conductor pipe 102 , vertical lifting at point 108 will result in a horizontal lift of joint of conductor pipe 102 . However, in certain circumstances, it may be advantageous to lift joint of conductor pipe 102 at an angle (e.g., when required by available on rig floor, so those having ordinary skill in the art will appreciate that the relative positions of lifting rings 104 A, 104 B and lengths of lifting lines 106 A, 106 B may be varied to achieve the desired angle of joint of conductor pipe 102 as it is lifted.
[0034] Further, it should be understood that lifting rings 104 A, 104 B may be constructed as continuous circular (or other) profiles such that they are simply slid over the ends of conductor pipe 102 and moved into position. Similarly, the internal profiles of lifting rings 104 A, 104 B may comprise friction elements to prevent conductor pipe 102 from sliding out of the grasp of rings 104 A, 104 B during lifting operations. As such, the inner profiles of lifting rings 104 A, 104 B may comprise rubber or hardened metal dies to prevent undesired movement of conductor pipe 102 relative thereto. Furthermore, as shown in FIG. 1 , when lines 106 A, 106 B are pulled at point 108 , lifting rings 104 A, 104 B may be tilted with respect to an axis 110 of the joint of conductor pipe 102 at an angle α. As such, lifting rings 104 A, 104 B may be constructed such that enough diametrical slack exists relative to the outer profile of joint of conductor pipe 102 that lifting rings 104 A, 104 B may “bite” into the conductor pipe 102 to more securely retain it.
[0035] Additionally, lifting rings 104 A, 104 B may be constructed as hinged and segmented rings such that they may be opened and closed laterally around the joint of conductor pipe 102 without needing to be slid over the ends. In particular, in cases where joints of conductor pipe 102 are laying directly on the floor of the rig or in the pipe rack, it may not be possible to slide rings 104 A, 104 B over the ends of layed pipe without lifting the conductor pipe 102 a sufficient amount to allow the thickness of lifting rings 104 A, 104 B thereunder. As such, segmented, openable, and closeable lifting rings 104 A, 104 B may allow the joint of conductor pipe 102 to be “grabbed” from above and lifted. Furthermore, the mechanisms of lifting rings 104 A, 104 B may be such that the segments of each ring 104 A, 104 B are tended to be closed as tension from lines 106 A, 106 B increases. Thus, for a joint of conductor pipe 102 laying on the floor, lifting rings 104 A and 104 B may be hingedly placed around the joint of pipe 102 , but may not be able to fully close with pipe 102 laying on the floor. As lines 106 A, 106 B are pulled from point 108 , rings 104 A, 104 B may be pulled fully closed as pipe 102 is lifted from the floor.
[0036] Finally, while lifting lines 106 A, 106 B and lifting point 108 are shown schematically, it should be understood that various lifting methods and apparatus, for example, but not limited to, lifting slings, chains, and other rigging may be used in place of the simple schematic view shown in FIG. 1 . Furthermore, depending on location and the resources available, the horizontal lifting of joint of conductor pipe 102 from a pipe rack or the rig floor and next to be run may be performed by an auxiliary crane, a separate lifting apparatus, or by the drilling rig's draw works. After a “to be added” joint of conductor pipe 102 is disposed from its position in the pipe rack (or other location on the rig), it must be rotated to vertical before it may be assembled to the remainder of the string of conductor pipe 112 .
[0037] Referring now to FIGS. 2 and 3 , the rotation and assembly of joint of conductor pipe 102 to the remainder of a string of conductor pipe 112 is shown schematically. As depicted, the drilling rig includes a rig floor 114 and a spider 116 holding string of conductor pipe 112 in the well. A segmented elevator 118 grasps a first end of the joint of conductor pipe 102 to be added to string 112 , such that joint of conductor pipe 102 may be tilted from a non-vertical position, e.g., the horizontal position in FIG. 1 , or an intermediate position, e.g., as shown in FIG. 2 , and to a vertical ( FIG. 3 ) position. As will be described below in further detail, elevator 118 includes slips to grip the outer profile of joint of conductor pipe 102 and lifting lugs to allow elevator 118 to be lifted from a horizontal position to a vertical position so that lower end 120 of joint of conductor pipe 102 may be connected (e.g., threaded, welded, etc.) to the upper end 122 of the string of conductor pipe 112 .
[0038] Referring now to FIG. 4 the joint of conductor pipe 102 to be added is shown atop string of conductor pipe 112 where it may be connected in place at 124 . Prior to completion of the welding, spider 116 supports the weight of pipe string 112 and elevator 118 supports the weight of joint of conductor pipe 102 . With joint 102 securely connected to (and now integrally part of) conductor pipe string 112 , the slips of spider 116 may be released so that the entire weight of the conductor pipe string 112 (including add on joint 102 ) may be carried by elevator 118 .
[0039] Referring now to FIG. 5 , conductor pipe string 112 may be engaged into the formation surrounding the wellbore (e.g., through driving, suction, jetting, etc.) from its full height ( FIG. 4 ) to it's new, lowered height such that upper end of joint 102 of conductor string 112 is adjacent and above rig floor 114 . In this new position, the slips of spider 116 may be re-engaged so that spider 116 again holds the entire weight of string of conductor pipe 112 . Referring briefly now to FIG. 6 , the slips of elevator 118 may be de-activated so that elevator 118 may be lifted, e.g., by the rig's draw works, and removed from upper end of added on joint 102 of conductor string 112 so that the process may be repeated with a new joint of conductor pipe to be added.
[0040] Referring now to FIG. 7 , a more detailed view of the elevator 118 depicted in FIGS. 2-6 is shown. Elevator 118 is shown constructed as a segmented ring comprising a first half 126 A, a second half 126 B, a hinge, 128 , and a latch 130 . Latch 130 may be constructed as a pin, a hinge, or any other mechanism through which a connection between half 126 A and half 126 B may be coupled and de-coupled. While elevator 118 is shown segmented into two halves 126 A, 126 B, those having ordinary skill will appreciate that more than two segments may be used. Furthermore, it should be understood that the segments of elevator 118 need not be equal in size or angle swept. For example, in one embodiment, segmented elevator 118 may comprise three segments, two segments having 150° swept angles, and a third (e.g., non-pivoting) segment having an angle of 60°.
[0041] Furthermore, when in the closed position (shown), the inner profile 132 of the halves 126 A, 126 B of the segmented ring is generally circular in shape and includes a plurality of slip assemblies 134 spaced at generally equal radial positions (at a common axial location) thereabout. As shown, each slip assembly 134 includes a die, e.g., gripping surface, 136 configured to “bite” into contact with joints of conductor pipe (e.g., 102 ) and assembled conductor pipe string 112 . Those having ordinary skill in the art will appreciate that slip assemblies 134 may be designed on inclined planes such that the grip diameter (i.e., the average inner diameter among the slip assemblies 134 ) of the slip assemblies 134 decreases as the slip assemblies are thrust downward. In one embodiment, a single “timing ring” axially actuates all slip assemblies 134 simultaneously so that the grip diameter of the elevator 118 is relatively consistent. The timing ring may be thrust hydraulically, pneumatically, mechanically, or through any type of actuator known to those having ordinary skill in the art. Thus, as slip assemblies 134 (and dies 136 ) are activated to engage the outer profile of conductor pipe string 112 , additional downward thrusting of the conductor string 112 (e.g., from the weight of the string 112 ) acts to increase the amount of “bite” dies 136 exhibit into conductor pipe string 112 . Those having ordinary skill in the art will appreciate that slip assemblies 134 of elevator 118 may be activated and actuated using various methods and mechanisms available including, but not limited to, electrical activation, hydraulic activation, pneumatic activation, and mechanical activation.
[0042] Referring now to FIG. 8 , elevator 118 is shown in an open position as it is lowered over a horizontally-laying joint of conductor pipe 102 . A lifting sling (not shown) or an alternative form of rigging may attach to elevator at lifting lugs 138 A and 138 B. Such a lifting apparatus may include swivels or other devices so that elevator 118 may switch from vertical position (e.g., FIGS. 3 and 4 ) to horizontal position ( FIG. 8 ) with relative ease. In certain embodiments, elevator 118 may be suspended directly from the hook (e.g., 60 of FIG. 11 ) of a traveling block (e.g., 56 of FIG. 11 ) of the rig's draw works. As shown, elevator 118 is lowered about horizontal joint of conductor pipe 102 such that a back stop 140 of elevator abuts the top of joint of conductor pipe 102 . Optionally, a pair of cylinders 144 A, 144 B may be used to open and close halves 126 A, 126 B of elevator 118 . Similarly, referring briefly to FIG. 8A , a cylinder 146 may be used to open and close latch 130 between halves 126 B and 126 A. While hydraulic cylinders are depicted in FIGS. 8 and 8A as 144 A, 144 B, and 146 , it should be understood that pneumatic cylinders, mechanical ball screws, or any other type of powered actuator may be used. Alternatively still, referring to FIG. 8B , a torsion spring 148 in conjunction with an upset portion 150 of latch 130 may be used to bias latch 130 in a closed or open direction.
[0043] Referring now to FIG. 9 , the two halves 126 A, 126 B of elevator 118 may rotate about hinge 128 to the closed position and latch 130 may rotate about pin 142 to lockably engage half 126 B with half 126 A. Because joint of conductor pipe 102 is non-vertical and elevated (e.g., with lifting apparatus 100 of FIG. 1 ), two halves 126 A, 126 B of elevator 118 may rotate about hinge 128 to the closed position, e.g., encircling the joint 102 . Depicted latch 130 has sufficient clearance to reach around the bottom of joint of conductor pipe 102 and engage with half 126 A of segmented ring of elevator 118 . With latch 130 secured closed, elevator may be lifted up (in direction Z) without concern that halves 126 A, 126 B will separate and release joint of conductor pipe 102 . As such, slips 134 may be activated to secure (and center) joint of conductor pipe 102 within the inner profile of elevator 118 . In alternative embodiments, latch 130 may function without pivot pin 142 and may have a lower profile. It should be understood that embodiments disclosed herein should not be limited to a particular latch mechanism. Furthermore, it should be understood that latch mechanism (e.g., 130 ) may not be necessary at all, for example, powered actuators used to open and close halves 126 A, 126 B of elevator 118 may be used to keep halves 126 A, 126 B together when lifting joint of conductor pipe 102 .
[0044] Referring now to FIG. 10 , a top-view schematic of elevator 118 is shown with slips 134 activated into the engaged position and securing joint of conductor pipe 102 within the inner profile of segmented ring elevator 118 . As such, elevator may be used to raise and lower the joint of conductor pipe 102 in the vertical position, the horizontal position, and all positions in-between.
[0045] Advantageously, embodiments disclosed herein allow an elevator to engage and lift a (e.g., horizontally laying) joint of conductor pipe without requiring the elevator to be slid over a free end of the joint of conductor pipe. Furthermore, embodiments disclosed herein depict a method by which joints of conductor pipe may be assembled and thrust into the wellbore without the need for welded and/or bolted lifting eyes to be installed and removed from each joint of conductor pipe. Pursuant thereto, embodiments disclosed herein reduce likelihood that individual joints of conductor pipe may become damaged during assembly and installation processes. Advantageously still, embodiments disclosed herein allow cylindrical joints of conductor pipe having no lifting features, e.g., upsets on the outer diameter of the pipe) to be lifted from a non-vertical position in a pipe rack or another rig location, grasped by a lifting elevator, rotated into a vertical position, and installed atop a string of conductor pipe.
[0046] While the disclosure has been presented with respect to a limited number of embodiments, those skilled in the art, having benefit of this disclosure, will appreciate that other embodiments may be devised which do not depart from the scope of the present disclosure. Accordingly, the scope of the invention should be limited only by the attached claims.
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A method to add a joint of pipe to a conductor string includes securing the conductor string with a spider, grasping an upper end of the joint of pipe with a segmented-ring elevator, engaging a plurality of slips of the elevator with an outer profile of the joint of pipe, raising the grasped joint of pipe from non-vertical to vertical, positioning the vertical joint of pipe atop the secured conductor string, attaching the joint of pipe to the conductor string, releasing the conductor string from the spider, and retaining the joint of pipe and the conductor string with the segmented-ring elevator.
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This application is a 371 of PCT/EP2009/004295 filed on 15 Jun. 2009.
BACKGROUND OF THE INVENTION
The present invention relates to an apparatus for wetting fibrous material, in particular wood, woodchips and waste paper.
Woodchips with a size of about 4 cm×2 cm×1 cm are decomposed into their fiber constituents by refiner grinding. This gives rise to the TMP fibrous substance required for papermaking (TMP=thermomechanical pulp). The higher the moisture content of the woodchips is, the more elastic, the softer and the more pliable is the composite fibrous structure within the woodchips and the individual fibers contained in the woodchip. Since, with an increasing length of the fibers, their strength increases, and such fibers are suitable for making high-grade papers, the aim is for the fibers to have as high moisture and elasticity as possible during the refiner grinding.
EP 1 051 551 discloses a method for wetting fibrous material composed of waste paper having a multilayer coating, such as, for example, beverage pasteboard. In beverage pasteboard, as it is known, both sides of the paper are coated with plastic and/or aluminum.
An apparatus and a method for the recovery of cellulose fibers from waste paper are known from U.S. Pat. No. 5,496,439. Here, the waste paper surrounded by a liquid is exposed in succession to underpressure and to overpressure.
SUMMARY OF THE INVENTION
The object on which the invention is based is to provide apparatuses, with the aid of which the wetting of woodchips or waste paper in bale form is possible in a simple and effective way.
In this context, wetting is understood to mean not only the moistening of the woodchips on their surface, but also the introduction of liquid, in particular water, in the overall volume of the woodchips. This means that not only the interspaces between the fibers of the woodchips, but also the interior of the fibers, are filled with a liquid.
This object is achieved, according to the invention, by means of an apparatus having the features of patent claim 1 .
With the aid of the apparatus according to the invention, it is possible to wet fibrous material, whether in the form of woodchips or in the form of waste paper in bales, quickly and effectively with a liquid. In this case, the elasticity of the fibers and the change in volume of the fiber cavities on account of alternating pressures are utilized.
In pulp manufacture, the following principle applies: the moister the woodchips injected into the pulp digester are, the higher are the filling density and therefore the throughput capacity of the pulp digester. Moreover, using the apparatus according to the invention, it is possible to start filling the digester with digesting liquor at a markedly earlier stage, since the woodchips, if their moisture is sufficiently high, do not float when the digesting liquor is pumped in.
If hot digesting liquor is used for wetting the woodchips by the method according to the invention, the digesting time is additionally also shortened markedly, since hot digesting liquor is not only located between the fibers, but also within the fibers (Luumen=fiber cavity).
When round timber (grinding wood) is used for the production of mechanical wood pulp, as high a moisture content of the wood as possible is critical so as to keep the fraction of splinters and fines low. In this method, the wood fragments with a length of up to 2 meters are pressed with high pressure against a large rough grindstone and are thereby defibrated and pulverized. The moister the round timber is during this processing, the more elastic, the softer and the more pliable is the composite fiber structure in the overall wood fragment and each of its individual fibers and the lower is the fraction of splinters and fines. With such wood fragments, too, considerable quantities of energy and time can be saved, using an apparatus according to the invention.
However, it has arisen that dried foodstuffs, such as, for example, mushrooms, beans or apples, can be moistened in dried form quickly, cost-effectively and efficiently.
By means of the ventilation line according to the invention, it is possible to execute the alternation between underpressure and ambient pressure or overpressure more quickly and thereby further increase the effectiveness of moistening.
By means of the at least one closable orifice provided according to the invention, the apparatus can be operated in batch mode or, in the case of two or more orifices, continuously, so that this improved method flow also markedly increases the effectiveness and the throughput rate of the apparatus according to the invention.
In all fiber-containing materials which are to be wetted, according to the present invention the wetting liquid can be used in liquid form (liquid) or gaseous form (vapor) or in a combination of both. The wetting liquid may be water, solvent, an individual chemical or a chemical mixture. The wetting liquids may also be in vaporous form.
Also, all these wetting liquids, when employed and used in the present invention, may have a temperature ranging from very cold to boiling point.
The wetting agents employed may have a coloring, hydrophobic, hydrophilic, bleaching, resin and lignin-decomposing, impregnating, preserving and/or surface tension-lowering or surface tension-increasing character of inorganic or organic type.
It has proved to be especially advantageous if the housing has a closable first orifice for loading the housing and a closable second orifice for unloading the latter, because the effectiveness and throughput of fibrous material to be moistened can thereby be increased even further.
Depending on the preferred intended use and local conditions, the at least one orifice may be closed by means of a door, a flap, a slide, a valve, a plug screw, a sluice and/or a drain trap.
Doors and flaps are suitable especially for the introduction of large fibrous material fragments to be moistened, such as, for example, a bale of pressed waste paper, while a slide or valve is especially suitable when the fibrous material is in small fragments and is to be delivered continuously. The advantage of a door, flap, slide and valve is that the orifice can be closed in a defined way and therefore controlled and reproducible pressure conditions inside the housing always prevail. Closing off the orifice in a pressure-tight or gas-tight manner increases the rate of pressure alternation or the rate of pressure change, this having a positive influence upon the effectiveness of moistening.
The advantage of a plug screw is to be seen in that it can convey fibrous material, which is already wetted with the liquid, such as, for example, water or digesting liquor, into the housing continuously or intermittently and at the same time affords an airtight and vapor tight closure of the housing orifice. The plug screw is therefore suitable especially for continuous or quasi-continuous operation of a plant and may, for example, be coupled to a valve or a slide.
Furthermore, it is possible to close the orifices by means of a drain trap which is filled with a barrier liquid. It is thereby possible, without moved parts, to close off the orifices of the housing in an airtight and vapor tight manner. At the same time, it is possible, by means of this drain trap, to introduce the fibrous material into the housing and also convey it out of the housing. Since this drain trap is a passive closure element, the control of the apparatus according to the invention is also simplified.
So that the liquid quantity absorbed by the fibrous material and transported out of the housing together with the fibrous material can be compensated, in a further advantageous refinement of the invention a supply line for the medium with which the fibrous material is moistened is provided. Further, a regulating valve is provided in this supply line, so that the quantity of medium contained in the housing can be regulated according to a stipulated desired value.
In order further to accelerate moistening and the penetration of the liquid into the woodchips or into the waste paper stacks, a pressure line with a second directional valve may be provided. It is thereby possible not only to carry out a lowering of pressure, but, in alternation with this lowering of pressure, also to carry out a rise in pressure within the housing. By the amplitude of between the pressure maximum and pressure minimum being increased, moistening and the penetration of the liquid into the fibrous material to be moistened are further intensified.
The pressure line is advantageously connected to a compressed air generator and/or to a pressure vessel. It is thereby possible to build up the overpressure quickly, and at the same time, if a pressure vessel is used, the compressed air generator can be of smaller design and run continuously.
The same applies accordingly to the vacuum line which is connected to a vacuum generator and/or to a vacuum vessel.
In order to convey the fibrous material into the apparatus and out of the apparatus fully automatically, a conveying device is provided which is preferably designed as a conveyor worm, transport belt and/or chain conveyor. The conveying device may, however, even be dispensed with if the apparatus is placed sufficiently obliquely.
Depending on the required performance and the space conditions, it is possible to set up one or more housings so as to be connected in parallel and/or in series to one another. On the basis of standard modules, therefore, the performance of the apparatus can be adapted within broad limits to the requirements of an individual case.
BRIEF DESCRIPTION OF THE DRAWINGS
Further advantages and advantageous refinements of the invention may be gathered from the following drawing, its description and the patent claims. All the features disclosed in the drawing, its description and the patent claims may be essential to the invention both individually and in any combination with one another.
In the drawing:
FIG. 1 shows a circuit diagram of the first exemplary embodiment of an apparatus according to the invention,
FIG. 2 shows circuit diagrams of further exemplary embodiments of the apparatus according to the invention with two plug screws and with a conveyor worm,
FIG. 3 shows exemplary embodiments of apparatuses according to the invention with drain traps and with a conveyor belt as a transport device or with a tubular chain conveyor,
FIG. 4 shows an exemplary embodiment of an apparatus according to the invention which combines the functions of a pulper and of an apparatus according to the invention for the moistening of fibrous material.
DETAILED DESCRIPTION
In the exemplary embodiment illustrated in FIG. 1 , the housing is given the reference symbol 1 . The housing 1 illustrated has a parallelepipedal geometry. A sidewall of the housing 1 is designed as a door 2 and can be closed, airtight and vapor tight, with the aid of a closure 3 .
The apparatus according to the invention for wetting is illustrated diagrammatically, and greatly simplified, in FIG. 1 . The structural details are not clear from this illustration, but are within the manual ability of a person skilled in the art.
To load the housing 1 , the door 2 is opened and, for example, woodchips or a bale of waste paper, not illustrated, can be transported into the housing 1 . The door 2 is subsequently closed and locked, so that the housing interior is sealed off, airtight and vapor tight, from the surroundings.
The path along which the paper bale, not illustrated, can be loaded into the apparatus and unloaded from it is indicated by a double arrow 10 .
It is, of course, advantageous if the housing interior can be negotiated by a lift truck or another transport appliance, so that one or more bales of waste paper which are located, for example, on a Europallet can be introduced into the housing interior quickly and simply with the aid of a lift truck.
Various lines, with the aid of which the moistening of the woodchips or of the wastepaper (not illustrated) can take place, issue into the housing 1 .
A supply line is designated by reference symbol 4 . The supply line contains a regulating valve 5 .
The liquid with which the fibrous material is to be moistened can be introduced in liquid and/or vaporous form through the supply line into the interior of the housing 1 according to demand. As a rule, water is used for moistening. However, it is also possible to provide the water with various additives or to employ another liquid, such as, for example, digesting liquor.
It goes without saying that a conveying device, not illustrated, such as, for example, a pump, and/or a storage tank, is located upstream of the regulating valve.
A vacuum line is designated by reference symbol 6 . This vacuum line 6 has a first directional valve 7 which is usually designed as a switchable 2/2-way valve, a vacuum vessel 19 and a vacuum generator 20 . The vacuum vessel 19 is merely optional. If such a vacuum vessel 19 is present, the vacuum generator 20 can have relatively small dimensioning and can suck air or vapor out of the vessel 19 continuously. When the directional valve 7 is opened, a lowering of pressure can be carried out very quickly and effectively in the inner space of the housing 1 , even though the vacuum generator 20 has relatively small dimensioning. It goes without saying that the volume of the vacuum vessel 19 and the volume of the housing 1 and also the power of the vacuum generator 10 must be coordinated with one another.
Reference symbol 8 identifies a pressure line into which a second 2/2-way valve 9 is integrated.
This pressure line 8 is connected to a compressor 15 and to a pressure vessel 16 . Here, too, the pressure vessel 16 serves for increasing the running time of the compressor 15 and at the same time for reducing the required power of the compressor 15 .
The pressure line 8 is necessary only when an overpressure is to be generated after the lowering of the pressure in the inner space of the housing 1 .
Optionally, air, vapor or a liquid can be conducted into the housing 1 via the pressure line 8 .
A ventilation line is designated by reference symbol 11 . A third directional valve 12 is provided in this ventilation line 11 .
The apparatus according to the invention operates as follows:
With a door 2 open, the fibrous material to be moistened is conveyed into the housing 1 . The door 2 is subsequently closed in an airtight and vapor tight manner.
The first directional valve 7 , second directional valve 9 and third directional valve 12 are first closed. With the regulating valve at least partially open, the medium required for moistening the paper (not illustrated) containing the housing 1 is conveyed in a vaporous and/or liquid state through the supply line 4 into the interior of the housing 1 .
The regulating valve 5 is subsequently closed, and the first directional valve 7 is quickly opened. The interior of the housing 1 is thereby connected to the vacuum vessel 19 , and pressure compensation takes place between the two vessels. The pressure inside the housing 1 consequently falls abruptly to values of between 0.9 bar and 0.1 bar, preferably to values of between 0.7 bar and 0.3 bar.
As soon as the desired underpressure has been reached in the housing 1 , the first directional valve 7 is closed and, immediately thereafter, the third directional valve 12 is opened, so that pressure compensation between the surroundings and the inside of the housing can take place. The “abrupt” compensation is in this case especially important. It must take place as quickly as the fibers and cavities, which have collapsed due to the vacuum, also endeavor to recover their original form.
If desired, after a few seconds, the third directional valve 12 can be closed again and the second directional valve 9 opened. A few seconds or even only less than one second may elapse between the closing of the third directional valve 12 and the opening of the second directional valve 9 . Since the pressure line 8 is connected to the pressure vessel 16 , pressure compensation between the pressure vessel 16 and the inside of the housing 1 takes place immediately after the opening of the second directional valve 9 . Consequently, the pressure inside the housing rises to values above the ambient pressure. Overpressures of between 0.1 bar and 1 bar are preferred.
When a desired overpressure inside the housing 1 has been reached, the second directional valve 9 is closed, and this overpressure is maintained for several seconds, for example 5 seconds, but preferably for less than two seconds. The cycle then commences from the outset. So that the overpressure does not have to be broken down by the vacuum generator 20 , the third directional valve 12 can be opened briefly beforehand, so that the overpressure breaks down via the ventilation pressure compensation line 11 .
FIG. 2.1 shows a second exemplary embodiment of an apparatus according to the invention which is preferably operated continuously, but may also be used batchwise.
The housing 1 is designed as a cylindrical tube.
A first orifice 21 is provided at the end, on the left in FIG. 2.1 of the housing 1 . This first orifice 21 is preceded by a first plug screw 23 and a filling funnel 25 . Between the first orifice 21 and the plug screw 23 is arranged a valve 27 which can be actuated via an actuator 29 , for example in the form of a pneumatic cylinder. FIG. 2.1 illustrates the first closing valve 27 in the closed position. The position of the open valve 27 is illustrated by dashes.
As is clear from FIG. 2.1 , the supply line 4 is branched so that one branch of the supply line 4 issues directly in the housing 1 via the regulating valve 5 . 1 , while further branches 4 . 1 and 4 . 2 issue respectively into the filling funnel 25 and into the plug screw 23 .
Upstream of the branches 4 . 1 and 4 . 2 , a second regulating valve 5 . 2 is provided, which likewise serves for controlling the liquid quantity flowing into the apparatus according to the invention.
The plug screw 23 is constructed in a similar way to a conventional conveyor worm. The essential difference is that the pitch of the conveyor worm decreases in the conveying direction, so that, in addition to the conveying movement, compression of the conveyed material is also carried out. However, the plug screw may also additionally taper conically.
The fibrous material to be moistened, preferably in the form of woodchips, together with, for example, water, is administered into the filling funnel 25 and is subsequently conveyed by the first plug screw 23 in the direction of the housing 1 . Simultaneously with a conveying movement, compression of the conveyed woodchips takes place, so that a pressure-tight plug is formed in the first plug screw 23 . Sealing off of the housing interior from the surroundings is thereby achieved. As a rule, it is sufficient to seal off the orifice 21 by means of the plug screw 23 or the woodchips compressed by it. However, as illustrated in FIG. 2.1 , a closing valve 27 may also additionally be provided.
When the first plug screw 23 has conveyed the woodchips and the water through the first orifice 21 into the housing, this mixture of woodchips and water is conveyed slowly through the housing 1 via conveyor worm 31 which is arranged inside the housing 1 . While the material is being conveyed through the housing 1 , the pressure alternation described in connection with the exemplary embodiment according to FIG. 1 takes place. The woodchips are thereby moistened. After the woodchips have been conveyed through the housing 1 by the conveyor worm 31 , they fall through the second orifice 33 into a second plug screw 35 . A closing valve 27 and an actuator 29 actuating the closing valve 27 are likewise arranged at the end of the second plug screw 35 . It is thereby possible also to close off the second orifice 33 of the housing in a pressure tight and vapor tight manner at any time. The conveyor worm 31 may even be dispensed with if the housing 1 is suitably placed obliquely.
When the closing valve 27 at the end of the second plug screw 35 is opened or when the pressure of the plug screw 35 is higher than the pressure of the actuator 29 , the moistened woodchips and any excess water present can fall downward out of the apparatus according to the invention.
The exemplary embodiment of an apparatus according to the invention, as described with reference to FIG. 2 , may selectively be operated continuously or batchwise, since woodchips can be conveyed at any time into the housing 1 by the first plug screw 23 and the moistened woodchips can be conveyed out of the housing 1 with the aid of the second plug screw 35 .
It is also possible to dispense with the second plug screw 35 and to close the second orifice 33 solely by means of the closing valve 27 . Such an embodiment is illustrated in FIG. 2.2 .
In the exemplary embodiment illustrated in FIG. 3.1 , the first orifice 21 and the second orifice 33 of the housing 1 are closed by means of a drain trap 36 . The drain traps 36 contain water or another suitable barrier liquid. The filling level of the barrier liquid is set via the supply lines 37 and the regulating valve 38 such that there is no direct connection between the atmosphere inside the housing 1 and the ambient air. For this purpose, it is advantageous if the first orifice 21 and the second orifice 33 are arranged on a vertical wall of the housing 1 .
A conveyor belt 40 is led through the first orifice 21 and the second orifice 33 and the drain traps 36 and guides the fibrous material (not illustrated) to be moistened into the interior of the housing 1 . The deflecting rollers belonging to the conveyor belt 40 have been given the reference symbol 34 . Teeth 42 are arranged on the conveyor belt 40 and also make it possible to transport the fibrous material in a vertical direction and counter to gravitational force. The supply line 4 , the vacuum line 6 and the pressure line 8 issue into the housing 1 . The inflow and outflow through these lines are controlled with the aid of the valves 5 , 7 and 9 in the way already described above.
FIG. 3.2 shows a further exemplary embodiment of an apparatus according to the invention with a drain trap and a conveyor belt, here a tubular chain conveyor.
FIG. 4 illustrates a further exemplary embodiment of an apparatus according to the invention for wetting fibrous material, which is suitable especially for wetting individual or several waste paper or pulp bales, paper in sheets and split paper rolls.
This apparatus can be produced by converting a conventional pulper is also suitable for retrofitting such pulpers. The pulper, and also the cowl mounted on top, must be adapted to or designed for the pressure conditions prevailing in the invention.
The fibrous material is administered into the housing 1 by means of a conveying device 42 through the open orifice 21 . A slide 48 is subsequently moved down and the orifice 21 is thereby closed.
The regulating valve 5 of the supply line 4 is opened, and wetting liquid, in particular water, is added to the desired level. When the level is reached, the regulating valve 5 is closed again.
A motor 46 is subsequently switched on in that a rotor 44 is set in rotation. Intermixing of the waste paper or pulp bales contained in the housing 1 and of the wetting liquid thereby takes place.
As regards the lines 4 , 6 and 8 , reference is made to what was said regarding these lines in connection with the preceding exemplary embodiments.
After the fibrous material has been moistened, a pump 48 is switched on and the moistened fibrous material is pumped away via a perforated plate 50 . The charging of the pulper and moistening then commence anew.
Since the complete moistening of the fibrous material takes place in a very short time (<2 minutes) and completely moistened fibrous material can immediately be comminuted very effectively at little outlay in terms of energy, it can even be pumped away continuously via the perforated plate 50 . Nonfibrous material (for example, films, wires) can be removed periodically, as already happens now, through a large outward transfer orifice (not illustrated) or by means of grab crane apparatus through orifices, not illustrated, in the pulper cowl.
Owing to the wetting times, which are very short on account of this apparatus, and therefore very short degrading and residence time of the waste paper in the pulper, the paper fibers can be detached very quickly from plastic films or other coatings and pumped away via the perforated plate 50 . These nonfibrous materials can thereby be removed from the pulper housing 1 in markedly larger fragments. Moreover, the currently customary outlay for resorting the fibrous material which has been pumped away via the perforated plate 50 can thereby be reduced very sharply.
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Apparatus for dampening fibrous material using the alternating pressure process with an airtight and vapor-tight housing ( 1 ), with a vacuum line ( 6 ), wherein a first directional valve ( 7 ) is provided in the vacuum line ( 6 ), the housing ( 1 ) has at least one closable opening ( 2, 21, 23 ) for loading and unloading the housing ( 1 ) and a ventilating line ( 11 ), and wherein a third directional valve ( 12 ) is provided in the ventilating line ( 11 ).
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FIELD OF THE INVENTION
[0001] The present invention relates generally to well operations and, more particularly, to a perforating gun.
BACKGROUND OF THE INVENTION
[0002] A perforating gun may be lowered into the well and detonated to pierce a well casing and form fractures in the formation. After the perforating gun detonates, well fluid typically flows into the casing and to the surface of the well via production tubing located inside the well casing.
SUMMARY OF THE INVENTION
[0003] The present invention provides a system and method of generating one or more perforations in a well casing while simultaneously suppressing burr formation. In one embodiment, the present invention provides a perforating gun capable of being lowered into a well casing. The perforating gun provides a gun housing having an outer surface capable of engaging the inner surface of the well casing. In one embodiment, at least a portion of the outer surface of the gun housing has a diameter substantially equal to the diameter of the inner surface of the well casing.
[0004] Through use of an orienting tool, this portion of the gun housing may be positioned to engage the inner surface of the well casing prior to explosive charge detonation. The mass and surface area of the gun housing up against the inner surface of the well casing restricts burr formation both upon the inner surface of the well casing and the outer surface of the gun during explosive charge detonation. In one embodiment, explosive charges are positioned to correspond with the portion of the gun housing designed to engage the inner surface of the well casing.
[0005] In another embodiment, the outer surface of the gun housing may be equipped with one or more bow springs. In one embodiment, the outer surface of each bow spring has a diameter substantially equal to the diameter of the inner surface of the well casing. This feature of the present invention allows the bow spring to engage the inner surface of the well casing prior to and during explosive charge detonation. During detonation, the bow spring acts as a sacrificial target and restricts burr formation upon the inner surface of the well casing.
[0006] In another embodiment, the present invention provides a sleeve designed for attachment to the outer surface of the gun housing. In one embodiment, the sleeve of the present invention is designed to conform to the inner surface of the well casing. In another embodiment, the sleeve is composed of an inflatable material capable of expanding to engage the inner surface of the well casing prior to and during detonation. Further, the sleeve is capable of retracting to facilitate the removal of the gun housing from the well casing after detonation.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] A more complete appreciation of the invention and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings; it being understood that the drawings contained herein are not necessarily drawn to scale; wherein:
[0008] FIGS. 1A-1B are plan views illustrating the perforating gun of a first embodiment of the present invention interacting with the inner surface of a well casing.
[0009] FIGS. 2A-2C are plan views illustrating the perforating gun of a second embodiment of the present invention interacting with the inner surface of a well casing.
[0010] FIGS. 3A-3C are plan views illustrating the perforating gun of a third embodiment of the present invention interacting with the inner surface of a well casing.
[0011] FIGS. 4A-4C are plan views illustrating the perforating gun of a fourth embodiment of the present invention interacting with the inner surface of a well casing.
DETAILED DESCRIPTION OF THE INVENTION
[0012] In the following description, numerous details are set forth to provide an understanding of the present invention. However, it will be understood by those skilled in the art that the present invention may be practiced without these details and that numerous variations or modifications from the described embodiments may be possible.
[0013] In the specification and appended claims: the terms “connect”, “connection”, “connected”, “in connection with”, and “connecting” are used to mean “in direct connection with” or “in connection with via another element”; and the term “set” is used to mean “one element” or “more than one element”. As used herein, the terms “up” and “down”, “upper” and “lower”, “upwardly” and downwardly”, “upstream” and “downstream”; “above” and “below”; and other like terms indicating relative positions above or below a given point or element are used in this description to more clearly describe some embodiments of the invention. However, when applied to equipment and methods for use in wells that are deviated or horizontal, such terms may refer to a left to right, right to left, or other relationship as appropriate.
[0014] The invention is herein described as a perforating gun for generating one or more perforations through a well casing and as a method of suppressing burr formation during well casing perforation.
[0015] Referring to the Figures, the present invention provides a perforating gun ( 10 ) having a gun housing ( 12 ). The gun housing contains one or more explosive charges ( 12 E) for use in perforating the well casing ( 14 ). The gun housing has a generally cylindrical configuration having inner and outer surfaces ( 121 and 120 , respectively).
[0016] Referring to FIGS. 1A-2C , in one embodiment, the outer surface ( 120 ) of the gun housing has a generally cylindrical configuration except in the area where the housing engages the inner surface ( 141 ) of the well casing ( 14 ). This unique portion of the gun housing is designed to have substantially the same shape and/or configuration as the inner surface of the well casing. In one embodiment, the radius of a portion of the outer surface of the gun housing is increased to substantially correspond to the radius of the inner surface of the well casing.
[0017] The unique configuration of the outer surface of the gun housing allows for greater surface contact between the perforating gun ( 10 ) and the inner surface ( 141 ) of the well casing ( 14 ) prior to and during detonation of the explosive charges ( 12 E) held within the gun housing.
[0018] In one embodiment, the perforating gun of the present invention may be positioned within the well casing such that the explosive charges therein are aligned to detonate in the preferential stress direction ( 20 ) for fracturing. The perforating gun may be positioned within the well casing through use of any number of known orienting tools and/or techniques (not shown). Positioning the outer surface of the gun having the unique configuration against the inner surface of the well results in burr suppression during detonation of explosive charges in the preferential stress direction. In short, the mass of the perforating gun and the increased surface contact between the gun and the inner surface of the well casing suppresses burr formation.
[0019] Although FIGS. 1A-2C illustrate 0 degree and 0/180 degree phased arrangements through which charges may be deployed into the well casing, it should be understood that these figures are for example purposes only. Specifically, the unique geometric configuration of the outer surface of the gun housing may be utilized with any number of explosive charge alignments and/or phase arrangements. The unique geometry described above may be applied to multiple locations upon the perforating gun and/or gun housing to allow the invention maximum versatility.
[0020] Referring to FIGS. 3A-3C , the perforating gun of the present invention may utilize one or more bow springs ( 16 ) alone or in conjunction with the unique geometric arrangement described above. In one embodiment, one or more bow springs ( 16 ) may be attached to the outer surface ( 120 ) of the gun housing ( 12 ). In this embodiment, at least a portion of the outer surface ( 160 ) of each bow spring ( 16 ) substantially corresponds to the inner surface ( 141 ) of the well casing ( 14 ). This feature of the present invention allows at least a portion of the outer face of the bow spring to conform to the inner surface of the well casing in order to suppress burrs during explosive detonation.
[0021] The unique configuration of the outer surface of the bow spring allows for greater surface contact between the gun housing ( 10 ) and the inner surface ( 141 ) of the well casing ( 14 ) prior to and during detonation of the explosive charges ( 12 E) held within the gun housing. During detonation, the bow spring acts as a sacrificial target and suppresses burr formation upon the inner surface of the well casing. By suppressing burr formation on the inside of the well casing, the present invention allows other well completion tools, such as packers, to be conveyed past the perforations ( 18 ) in the well casing ( 14 ) without incurring damage.
[0022] In one embodiment, the perforating gun of the present invention may be positioned within the well casing such that the explosive charges therein are aligned to detonate in the preferential stress direction ( 20 ) for fracturing. In one embodiment, one bow spring is provided for each direction of explosive charge detonation. For example, if the perforating gun has a 0/180 degree phased arrangement, two bow springs may be utilized. In the case of spiral phasing, a bow spring having a spiral configuration may be utilized.
[0023] The perforating gun may be positioned within the well casing through use of any number of known orienting tools and/or techniques. Further, the explosive charges may be aligned/phased to enable the explosive charge to proceed from the gun housing, through the bow spring, and into the well casing.
[0024] Although FIGS. 3A-3C illustrate a 0/180 degree phased arrangement through which charges may be deployed into the well casing in opposite directions, it should be understood that the Figures are for example purposes only. Specifically, the unique geometric configuration of the outer surface of the bow springs may be utilized with any number of explosive charge alignments and/or phase arrangements. The unique geometry described above may be applied to multiple locations upon a perforating gun and/or gun housing to allow the invention maximum versatility.
[0025] Referring to FIGS. 4A-4C , the perforating gun ( 10 ) of the present invention may utilize one or more external sleeves ( 22 ) alone or in conjunction with the features of the present invention described above. Such sleeve(s) may be attached to the housing ( 12 ) of the perforating gun ( 10 ) for insertion into the well casing ( 14 ).
[0026] In one embodiment, the purpose of the external sleeve is to centralize the perforating gun so that all explosive detonations are uniform in all directions. Further, the sleeve ( 22 ) is capable of providing a sacrificial target such that when the explosive charge penetrates the sleeve, a burr is created on the inside surface ( 221 ) of the sleeve ( 22 ) instead of upon the inside surface ( 141 ) of the well casing ( 14 ).
[0027] The sleeve of the present invention is capable of expanding and contracting to the inner surface of the well casing. In one embodiment, the outer surface ( 220 ) of the sleeve conforms to the inner surface of the well casing prior to and during explosive charge detonation in order to suppress burr formation on the inner surface of the well casing. In one embodiment, the sleeve of the present invention comprises a radial spring attached to the outer surface of the gun housing and capable of expanding and retracting according to the inner surface of the well casing during gun insertion and retraction. The radial spring may also be configured to provide one or more bypass slots to accommodate fluid flow through the well casing.
[0028] This feature of the present invention allows the perforating gun to be inserted downwardly into the well casing prior to explosive charge detonation, then withdrawn after detonation. By providing a sleeve capable of conforming to the inner surface of the well casing, the goal of suppression burr formation may be achieved.
[0029] As with the embodiments described above, the mass of the sleeve and the increased surface contact with the inside surface of the well casing suppresses formation of burrs during detonation. The sleeve may be composed of any material or combination of materials capable of conforming to the inner surface of the well casing and providing sufficient mass to suppress burr formation upon the inner surface of the well casing. The sleeve may be equipped with one or more bypass slots to allow for fluid bypass within the well casing. In one embodiment, bypass slots may be placed between shot planes.
[0030] In one embodiment, the sleeve may be filled with a fluid, i.e., a liquid or gaseous substance, to allow for controlled expansion and contraction. In one embodiment, the sleeve provides walls defining one or more cavities ( 24 ) capable of receiving fluids. This feature of the present invention allows the sleeve to be smaller than the area provided by the inner surface of the well casing for easy insertion and removal. In one embodiment, the sleeve of the present invention forms an air-tight seal with the outer surface of the gun housing. It being understood that the sleeve may be unsealed as well.
[0031] Upon reaching the desired depth within the well casing, fluids may then be injected into the sleeve, i.e., as a propellant, causing the sleeve to expand and contact the inner surface of the well casing prior to and during explosive charge detonation. Once expanded, the sleeve acts as a burr suppression tool during detonation. In one embodiment, perforation of the sleeve during detonation causes the sleeve to deflate such that the sleeve may be withdrawn from the well casing. In one embodiment, perforating the sleeve results in an equalization of the internal pressure of the sleeve with internal pressure within the well casing. This feature of the present invention allows the perforating gun and the sleeve to be removed from the well casing after explosive charge detonation.
[0032] Although FIGS. 4A-4C illustrate a 0/180 degree phased arrangement though which charges may be deployed into the well casing in opposite directions, it should be understood that the Figures are for example purposes only. Specifically, the external sleeve of the present invention may be utilized with any number of explosive charge alignments and/or phase arrangements. The external sleeve may also be applied to multiple locations upon a perforating gun and/or gun housing to allow the invention maximum versatility.
[0033] Although the invention has been described with reference to specific embodiments, this description is not meant to be construed in a limited sense. Various modifications of the disclosed embodiments, as well as alternative embodiments of the invention, will become apparent to persons skilled in the art upon reference to the description of the invention. It is, therefore, contemplated that the appended claims will cover such modifications that fall within the scope of the invention.
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The present invention provides a system and method of generating one or more perforations in a well casing while simultaneously restricting burr formation. The perforating gun assembly of the present invention includes a gun housing having an outer surface designed to engage the inner surface of the well casing. In one embodiment, at least a portion of the outer surface of the gun housing substantially corresponds to the inner surface of the well casing. The position of the gun housing engaging the inner surface of the well casing restricts burr formation both upon the inner surface of the well casing and the outer surface of the gun during explosive charge detonation.
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PRIORITY AND CROSS REFERENCE TO RELATED APPLICATION
This application claims priority to German Patent Application No. 10 2004 052 218.9, filed Oct. 27, 2004, which is incorporated by reference herein in its entirety.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to memory arrangements such as a read only memory (“ROM”), and in particularly to a memory arrangement having reduced power consumption.
2. Description of the Related Art
FIG. 1 illustrates a prior art read-only memory (ROM) 8 having many 1-bit memory cells, corresponding to the memory capacity of the ROM. These 1-bit memory cells are divided into various sections (also called block columns below) of equal size (equal number of 1-bit memory cells), depending on a word length of an output data item of the ROM. In each section, the 1-bit memory cells are arranged in columns and rows. A word line 3 of the ROM runs along the same row in all sections of the ROM. On the other hand, a virtual supply voltage line 1 and a bit line 2 run along a column in only one section of the ROM. This means that the virtual supply voltage lines 1 run parallel to the bit lines 2 along all memory cells which are arranged in a column.
In the case of traditional ROMs, a 1-bit memory cell which represents a logical “0” is usually constructed out of an NMOS transistor having a gate terminal connected to a word line 3 , one of the source or drain terminals connected to a virtual supply voltage line 1 , and the other terminal being connected to a bit line 2 . There are several possibilities for constructing a 1-bit memory cell 4 that represents a logical “1”. For instance, both the source and the drain terminals can be connected to the same bit line 2 , or to the same virtual supply voltage line 1 , or at least one of the two source and drain terminals hangs in the air, i.e. is connected neither to a bit line 1 nor to a virtual supply voltage line 1 .
In the case of a ROM read operation, in which a data item for an address is read, starting from the address, one word line 3 and n (n corresponds to the word width, or number of bits, of the data item to be read) virtual supply voltage lines 1 are specified, and are then activated in the course of the read operation. The address is divided into a row address part and a column address part, the word line 3 being determined by means of the row address part and the virtual supply voltage lines 1 being determined by means of the column address part.
When a 1-bit memory cell 4 which represents a logical “0” is read, the following occurs: Whereas all bit lines 2 are on a first supply voltage potential before the read operation, the virtual supply voltage line 1 corresponding to the address and a bit position in the data item to be read are put or activated onto a second supply voltage potential only in the course of the read operation, and the word line 3 corresponding to the address is activated. In this way the NMOS transistor which represents the logical “0” becomes conducting, so that the bit line which is connected to the NMOS transistor is charged onto the second supply voltage potential. On the other hand, when a 1-bit memory cell 4 which represents a logical “1” is read, the NMOS transistor (if a transistor is present at all) becomes non-conducting, so that the bit line is not charged onto the second supply voltage potential.
For instance, the first supply voltage potential could be V SS and the second supply voltage potential could be V DD , or conversely the first supply voltage potential could be V DD and the second supply voltage potential could be V SS .
In FIG. 1 , two sections or block columns 12 are shown. Result bit lines 5 of these two block columns 12 represent the least significant and most significant bits of the data item to be read from the ROM 8 . The block columns between these two block columns 12 are only indicated in FIG. 1 . Each result bit line 5 is the output of a multiplexer 11 , in which case, in the context of a read operation, the bit line 2 corresponding to the address or column address part is switched to the output of the multiplexer 11 .
Since, in the case of the ROM 8 according to the prior art, in a column 16 a virtual supply voltage line 1 runs parallel to a bit line 2 over the whole column length, the gap between the virtual supply voltage line 1 and the bit line 2 being extremely small because of the dimensions, which are becoming ever smaller, of the design techniques which are used today, the coupling capacitance or cross-coupling between the virtual supply voltage line 1 and the bit line 2 is great. Because of the coupling capacitance, the bit line 2 is also charged onto the second supply voltage potential if the virtual supply voltage line 1 is charged onto the second supply voltage potential in the course of a read operation. In the case of reading a logical “0”, this is a positive effect, since the bit line 2 is charged onto the second supply voltage potential in the course of an operation to read a logical “0”. On the other hand, in the case of reading a logical “1” it is a counter-productive effect, since the bit line 2 should remain on the first supply voltage potential in the course of an operation to read a logical “1”. Therefore, when reading a logical “1”, it is necessary to wait for a restoration period, until the bit line 2 is again at least near the first supply voltage potential, before the result bit line 5 which corresponds to the bit line 2 is evaluated. Since it is in the nature of the matter that before a read operation it is not known whether a logical “0” or a logical “1” is read, it is always necessary to wait for the restoration period, irrespective of whether a logical “0” or a logical “1” is read. Thus the restoration period decides a clock rate at which the ROM 8 can be read.
In addition to the negative effect on the clock rate of the ROM 8 , the coupling capacitance has a negative effect on the power consumption of the ROM 8 . Additionally, there is a negative effect on the power consumption by the inherent capacitance of each virtual supply voltage line 1 , which must be charged onto the second supply voltage at a read operation. That is, the greater the coupling capacitance and/or the inherent capacitance is, the greater the power consumption that is necessary to charge the corresponding virtual supply voltage lines 1 onto the second supply voltage potential.
In the case of a ROM, in which words with a word width of n bits are stored, in the course of a read operation, n virtual supply voltage lines 1 must be charged onto the second supply voltage potential, and brought back to the first supply voltage potential after the evaluation of the result bit lines 5 . Therefore, specifically in the case of ROMs with a large word width, the inherent capacitance and also the coupling capacitance are decisive for the power consumption and maximum clock frequency of the ROM.
Therefore it is desirable to provide a memory arrangement in which the coupling capacitance and inherent capacitance are as small as possible in the case of a read operation.
SUMMARY OF THE INVENTION
A memory arrangement (particularly a ROM), includes memory cells, supply voltage lines, word lines and result lines, where memory cells of the memory arrangement are connected to a supply voltage line, a result line and a word line. In the memory arrangement, a supply voltage line that is connected to a particular memory cell together with a result line is shorter than the result line, and/or is connected to fewer memory cells than the result line.
Because the supply voltage line is shorter than the result line, a coupling capacitance between the supply voltage line and the result line is less than if the supply voltage line was as long as the result line, as is in the prior art. Additionally, for the same reason, the inherent capacitance of the supply voltage line according to the invention is less than the inherent capacitance according to the prior art would be. By reducing the coupling capacitance, a restoration period, which allows the result line to again accept a different supply voltage potential from the supply voltage line, is also shortened. In this way, a switching time of the memory arrangement is also reduced, and a maximum clock rate of the memory arrangement is increased. Additionally, by reducing the coupling capacitance and inherent capacitance, a power consumption to charge the supply voltage line onto a supply voltage potential is reduced.
According to the invention, the memory cell is also capable of storing multiple bits. The memory cell also or alternatively may be a 1-bit memory cell that stores one bit. In the same way, according to the invention, the result line transports multiple bits. However, within the invention, the result line can also transport only one bit, so that in this case the result line corresponds to a bit line.
In the case of the memory arrangement according to the invention, according to a first embodiment, a 1-bit memory cell can be a transistor, particularly an NMOS transistor. A logical “0” can be implemented or stored by the NMOS transistor in that either the source terminal of the NMOS transistor is connected to one of the bit lines and the drain terminal of the NMOS transistor is connected to one of the supply voltage lines of the memory arrangement, or the source terminal of the NMOS transistor is connected to one of the supply voltage lines and the drain terminal of the NMOS transistor is connected to one of the bit lines of the memory arrangement. A logical “1” can be implemented or stored by the NMOS transistor in that either both the source terminal and the drain terminal of the NMOS transistor are connected to the same bit line or the same supply voltage line, or at least either the source terminal or the drain terminal of the NMOS transistor is connected to neither a bit line nor a supply voltage line.
In another embodiment, a logical “1” may be implemented using an NMOS transistor in that either the source terminal of the NMOS transistor is connected to one of the bit lines and the drain terminal of the NMOS transistor is connected to one of the supply voltage lines of the memory arrangement, or the source terminal of the NMOS transistor is connected to one of the supply voltage lines and the drain terminal of the NMOS transistor is connected to one of the bit lines of the memory arrangement. In this case, a logical “0” is implemented using a memory cell, in such a way that the memory cell never provides a conducting connection between the bit line and supply voltage line which are connected to the memory cell. This corresponds to how a logical “1” is implemented according to the first embodiment.
In the case of both embodiments, the gate terminal of an NMOS transistor is connected to a word line.
Additionally, it is also possible that a memory cell is not implemented using an NMOS transistor, but with a transistor of a different transistor type (e.g. a PMOS transistor or a bipolar transistor).
In particular, the memory arrangement according to the invention can also be in such a form that when a word line and a supply voltage line are activated simultaneously, two bits are read simultaneously. This is possible in that in each case two adjacent memory cells are connected to the appropriate activated word line and the appropriate activated supply voltage line. In each case, one of the two memory cells is connected to one of two bit lines, and the other of the two memory cells is connected to the other of the two bit lines.
Since by activating a word line and a supply voltage line, two bits are read simultaneously, an area of a memory arrangement can be reduced in comparison with an otherwise similar memory arrangement in which when a word line and a supply voltage line are activated only one bit is read.
According to the invention, it is possible that in the case of a first part of the memory arrangement, when a word line and a supply voltage line are activated two bits are read (i.e. two bit lines are evaluated), whereas in a second part of the memory arrangement, when a word line and a supply voltage line are activated only one bit is read (i.e. only one bit line is evaluated).
In particular, in the case of a memory arrangement according to the invention, another supply voltage line, which is connected to one or more supply voltage lines, can be present. In the course of a read operation, depending on an address for which a data item of the memory arrangement is to be read, a specified further supply voltage line, which is connected to a supply voltage line which is connected to a memory cell which is addressed by the address, is specified.
In particular, the supply voltage lines run parallel to the bit lines, and the further supply voltage lines run parallel to the word lines in the memory arrangement according to the invention. In particular, the supply voltage lines and bit lines run perpendicularly to the further supply voltage lines and word lines.
For a read operation, starting from the address, a word line, a further supply voltage line and, per bit of the data item to be read, a bit line, are determined or decoded.
This is a simplification, since in the case of prior ROM's one virtual supply voltage line per bit of the data item to be read is charged or activated, whereas according to the invention only one further supply voltage line in total is activated.
This invention is preferably suitable for use for programmable ROM arrangements. However, of course the invention is not restricted to this preferred application field, but can also be used for mask ROMs, erasable ROMs (EPROMs, EEPROMs) and RAMs.
DESCRIPTION OF THE DRAWINGS
This invention is explained in more detail below, with reference to the attached drawings and on the basis of preferred embodiments.
FIG. 1 shows schematically a ROM according to the prior art.
FIG. 2 shows schematically a ROM according to the invention, wherein when a word line and a supply voltage line are activated, two adjacent memory cells are activated.
FIG. 3 shows schematically another ROM according to the invention, wherein a coupling according to the invention of supply voltage lines and further supply voltage lines is shown.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Identical or functionally identical elements and signals are referred to with the same reference symbols in the figures of the drawing unless stated otherwise.
In FIG. 2 , a ROM 8 according to the invention, consisting of multiple blocks 14 , is shown. A specified number of blocks 14 forms a block column 12 , two of which are shown. Similarly, n/2 blocks form a block row 13 , three of which are shown. The reference n stands for a word width of a data item which is read out of the ROM 8 in a read operation. Each word line 3 and also each further supply voltage line or global virtual supply voltage line 6 runs through the whole width of the ROM 8 or each double column 15 of the ROM 8 . Each bit line 2 of the ROM 8 runs through the whole length of the ROM 8 or each row 17 of the ROM 8 . On the other hand, each supply voltage line or local virtual supply voltage line 7 runs through only the length of a block 14 of the ROM 8 . Each global virtual supply voltage line 6 is connected in each block column 12 , e.g. via a via, to a local virtual supply voltage line 7 . Conversely, each local virtual supply voltage line 7 is connected to a global virtual supply voltage line 6 . Since each local virtual supply voltage line 7 is connected in each row to two memory cells 4 , each block column 12 has two result bit lines 5 as output. On the output side, for each block column 12 a multiplexer 11 , which switches two adjacent bit lines 2 onto the two result bit lines 5 depending on an address of the data item of the ROM 8 to be read, is arranged.
A result of the structure of the ROM 8 includes that for each block 14 a number of word lines 3 which run through the block is equal to a number of global virtual supply voltage lines 6 which also run through this block, equal to half a number of bit lines 2 which also run through this block, equal to a number of local virtual supply voltage lines 7 which also run through this block. In other words, a number of memory cells 4 per row 17 of a block 14 equals double a number of memory cells per double column 15 of a block 14 .
To clarify how the ROM 8 functions, a read operation of the ROM 8 is described below. In the read operation, the data item, which consists of n bits, is read out depending on a specified address. Let it be assumed that at the start of the read operation all bit lines 2 are charged onto V SS . Starting from the address, in a first step, the ROM 8 decodes a word line 3 *, a global virtual supply voltage line 6 * and, for each block column 12 , two bit lines 2 * or a double column 15 *, this double column 15 * (and thus the two bit lines 2 *) being arranged equally relative to the relevant block column 12 (e.g., the last double column on the right in each block column 12 ). Via the decoded word line 3 * and the decoded double column 15 * or decoded bit lines 2 *, in each block column 12 two 1-bit memory cells 4 * are addressed. Additionally, in each decoded double column 15 *, a local virtual supply voltage line 7 * is connected to the decoded global virtual supply voltage line 6 *, and is in turn connected to the appropriate two addressed 1-bit memory cells 4 *.
To decode the word line 3 *, the global virtual supply voltage line 6 * and the two bit lines 2 * or double column 15 * per block column 12 , as is usual according to the prior art, the address is divided into a column address part and a row address part. As in the case of the prior art, the word line 3 * is determined by means of the row address part, and the two bit lines 2 * or double column 15 * per block column 12 are determined by means of the column address part. To decode the global virtual supply voltage line 6 *, both the row address part and the column address part are used, so that via the decoded global virtual supply voltage line 6 *, in each case, that local virtual supply voltage line 7 * which is in the desired block row 13 * and the appropriate double column 15 * is addressed. It should be noted that in the chosen example, the decoded global virtual supply voltage line 6 * is not directly next to the decoded word line 3 *.
In a second step of the read operation, the decoded word line 3 * is activated, and the decoded global virtual supply voltage line 6 * is charged onto the supply voltage potential V DD . In this way, also in each block column 12 , the local virtual supply voltage line 7 * in the block row 13 * (corresponding to the address) of the decoded double column 15 * is charged onto the supply voltage potential V DD . If a logical “0” is stored in a memory cell which is addressed in the read operation, i.e. an NMOS transistor which is switched to conducting via the decoded word line 3 * couples the corresponding local virtual supply voltage line 7 * to the corresponding bit line 2 *, the bit line 2 *, which is connected to the memory cell 4 *, is recharged onto the supply voltage potential VDD. On the other hand, if a logical “1” is stored in a memory cell 4 * which is addressed in the read operation, the bit line 2 *, which is connected to the memory cell 4 *, is not recharged onto the supply voltage potential VDD via an NMOS transistor. However, each decoded bit line 2 *, because of a coupling capacitance between the local virtual supply voltage line 7 * and the decoded bit line 2 * when the local virtual supply voltage line 7 * is charged onto the supply voltage potential V DD , is also pulled in the direction of V DD . It is therefore necessary to wait for a restoration period until the decoded bit line 2 * falls back to V SS before the corresponding result bit line 5 is evaluated.
However, since the local virtual supply voltage line 7 is significantly shorter than a virtual supply voltage line 1 (see FIG. 1 ) according to the prior art, the coupling capacitance between the local virtual supply voltage line 7 and the bit line 2 is significantly less than the coupling capacitance according to the prior art. The restoration period is therefore shorter, which results in advantages regarding the read time and clock frequency of the ROM 8 according to the invention. Thus, in the case of a ROM as described in FIG. 2 , a total switching capacitance and with it also a dynamic power consumption of the ROM are significantly less than in the case of a ROM according to the prior art.
Finally in the read operation, the result bit lines 5 , which are connected via the appropriate multiplexers 11 to the decoded bit lines 2 *, are evaluated, to determine the data item which corresponds to the specified address. After this evaluation, the ROM 8 returns to a standby mode, in which all word lines 3 , all bit lines 2 and all global virtual supply voltage lines 6 , and thus all local virtual supply voltage lines 7 , are charged onto V SS . A new read operation then begins at the previously described first step.
Obviously, the distinguishing feature of standby mode could also be that all word lines 3 , all bit lines 2 and all global virtual supply voltage lines 6 , and thus all local virtual supply voltage lines 7 , are charged onto V DD , in which case PMOS transistors are usually used instead of NMOS transistors. In the case of a read operation, the decoded word line 3 * and the decoded global virtual supply voltage line 6 *, and thus the local virtual supply voltage lines 7 * which are connected to it, would then be charged onto V SS .
FIG. 3 illustrates a schematic diagram of an embodiment of a ROM 8 according to the invention. Compared with FIG. 2 , fewer details are shown in FIG. 3 . The difference between the ROMs shown in FIGS. 2 and 3 is that in the case of the ROM shown in FIG. 3 , only one result bit line (not shown) exists for each block column 12 . The ROM 8 shown in FIG. 3 consists of multiple blocks 14 , each block 14 having a number of columns 21 (number of columns per block) and a number of rows 22 (number of rows per block). In other words, each block has a number of columns, and each column has a number of memory cells which is equal to the number of rows 22 . That is, each block has a number of rows, and each row has a number of memory cells which is equal to the number of columns 21 . The number of columns 21 equals the number of rows 22 , which means that each block 14 has a number of memory cells which equals a product of the number of columns 21 and the number of rows 22 or equal to a square of the number of columns 21 or number of rows 22 (since number of columns=number of rows).
The blocks 14 are in turn arranged in block rows 13 and block columns 12 . Each block column 12 has a result bit line (not shown), so that a number of block columns 12 equals the word width of a data item which can be read out of the ROM 8 shown in FIG. 3 . Thus, a difference between the ROMs of FIGS. 2 and 3 is that in the ROM of FIG. 3 , only one bit per block column 12 may be read out, whereas in the ROM shown of FIG. 2 two bits per block column 12 may be read out.
The connection between the global virtual supply voltage lines 6 and the local virtual supply voltage lines 7 is also illustrated in FIG. 3 , where each global virtual supply voltage line 6 , in each block 14 through which the global virtual supply voltage line 6 runs, is connected to the local virtual supply voltage line 7 which is arranged equally relative to this block 14 . For instance, in each block row 13 , the second global virtual supply voltage line 6 from the bottom is connected to the second local virtual supply voltage line 7 from the left in each block of this block row 13 . Since each local virtual supply voltage line 7 supplies a column of a block 14 or memory cells that are arranged in a column of a block 14 , for instance the second global virtual supply voltage line 6 from the bottom in the second block row 13 from the bottom (in FIG. 3 ) must be charged onto V DD , if the result of decoding the address to be read is that a word line 3 in the second block row 13 from the bottom is to be activated, and in each block column 12 the second bit line from the left (not shown in FIG. 3 ) is to be evaluated.
By comparing the ROM 8 of FIG. 3 with the ROM 8 of FIG. 1 , a further advantage of this invention can be explained. During a read operation, in the case of the ROM 8 shown in FIG. 1 according to the prior art, n (number of bits in the data item read from the ROM or number of block columns 12 ) virtual supply voltage lines 1 must be charged onto V DD . On the other hand, in the case of the ROM of FIG. 3 , only one global virtual supply voltage line 6 and n local virtual supply voltage lines 7 that are connected to it must be charged onto V DD . Since the local virtual supply voltage lines 7 in FIG. 3 are significantly shorter than the virtual supply voltage lines 1 in the case of the ROM shown in FIG. 1 according to the prior art, a total length consisting of a global virtual supply voltage line 6 and the local virtual supply voltage lines 7 that are connected to it is shorter than a total length of n virtual supply voltage lines 1 in the case of a ROM shown in FIG. 1 according to the prior art. Therefore, the inherent capacitance in the case of the memory arrangement according to the invention, with reference to the global virtual supply voltage line 6 and the local virtual supply voltage lines 7 which are connected to it, is less than the inherent capacitance of the n virtual supply voltage lines 1 in the case of a ROM according to the prior art. The more block rows the corresponding ROM has, the greater is the difference between the inherent capacitances, or the advantage according to the invention.
Also, since the number of memory cells which are connected to local virtual supply voltage lines 7 which are connected to the same global virtual supply voltage line 6 is less than the number of memory cells which are connected to n virtual supply voltage lines 1 in the case of a ROM according to the prior art (see FIG. 1 ), in the case of a ROM according to the invention the load because of diffusion charging processes is less than in the case of a ROM according to the prior art. This pays for itself in a lower power consumption, and also offers the advantage of operating the ROM according to the invention with a higher clock frequency than a comparable ROM according to the prior art.
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A memory arrangement, particularly a ROM, having memory cells, local virtual supply voltage lines, word lines and result lines may also include global virtual supply voltage lines that run along the width of the memory arrangement parallel to the word lines. The local virtual supply voltage lines run parallel to the result lines, and perpendicularly to the word lines where the each local virtual supply voltage line runs only within a block of the memory arrangement. Each global virtual supply voltage line, in each block through which it runs, is connected to one local virtual supply voltage line. The coupling capacitance between the supply voltage lines and the result lines, and the inherent capacitance of the supply voltage lines are reduced, reducing the power consumption and increasing the clock frequency of the memory arrangement.
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TECHNICAL FIELD
[0001] This invention relates generally to a method for making retreaded tires and particularly to a method for making retreaded tires that eliminates the need for spray cement normally applied to the tire casing.
BACKGROUND OF THE INVENTION
[0002] Retreaded tires have been available for many years and provide an economical way to gain additional use out of a tire casing after the original tread has become worn. According to one conventional method of retreading, sometimes referred to as cold process retreading, the remaining tread on the used tire is removed by a special buffing machine that grinds away the old tread and leaves a buffed surface to which a new layer of tread may be bonded.
[0003] Removal of the old tread from the tire casing provides a generally smooth treadless surface about the circumference of the tire casing. The tire casing may then be examined for injuries, often called skives, which are filled with a repair gum. After completion of the skiving process, the buffed surface is sprayed with a tire cement that provides a tacky surface for application of bonding material and new tread. Then a layer of cushion gum is applied to the back, i.e., the inside surface, of a new layer of tread. The cushion gum and tread are applied in combination about the circumference of the tire casing to create a retreaded tire assembly ready for curing. The cushion gum forms the bonds between the tread and the tire casing during curing.
[0004] Following assembly of the tire casing, cement, cushion gum and tread, the overall retreaded tire assembly is placed within a flexible rubber envelope. An airtight seal is created between the envelope and the bead of the tire. The entire enveloped tire assembly is placed within a curing chamber, and subjected to pressure and a raised temperature for a specific period of time. The combination of pressure, temperature and time chemically bonds the layer of cushion gum to both the tire casing and the new tire tread.
[0005] The above-described method of cold process retreading works well and provides high quality, retreaded tires. However, in certain applications it would be advantageous to eliminate the spray cement. This is particularly true in geographical areas where there is increased regulation of the use of chemicals within spray cement. Generally, available spray cements include either heptane solvent or methyl chloroform. The heptane solvent has been found to contribute to smog formation, and methyl chloroform, although it does not cause smog, has tended to be substantially more expensive than heptane solvent.
[0006] Use of spray cement can also add to the cost of producing retreaded tires due to the product cost and equipment cost. For example, because cementing of the tire casing should only be done in a well ventilated spray booth, retreading shops must purchase appropriate ventilation equipment. Elimination of the spray cement thus eliminates the need to purchase ventilated spray booths.
[0007] A potential solution to smog problems associated with using heptane solvent is the installation of solvent capture equipment at each retreading shop. However, this solution is disadvantageous due to the cost of the equipment and the operational and maintenance costs. The present invention addresses the drawbacks associated with using spray cement during retreading of tires.
SUMMARY OF THE INVENTION
[0008] The present invention includes a method for retreading a tire that comprises the steps of removing the tire tread from a tire casing to present a buffed surface. Then, a layer of cushion gum is applied directly to the buffed surface without spraying cement over the buffed surface. A tread layer is wrapped about the layer of cushion gum, and finally, the tire is treated to form bonds between the casing and the layer of cushion gum and between the tread layer and the layer of cushion gum.
[0009] Another unique aspect of the invention is a retreaded tire assembly prepared for insertion into a pressurized heating chamber. The tire assembly includes a tire casing having a pair of side walls and a radially outer wall spanning the pair of side walls. The radially outer wall has a buffed surface disposed about the outer circumference of the tire casing. A layer of cushion gum is disposed directly against the buffed surface, and a tread layer is disposed against the cushion gum about the outside circumference of the cushion gum. After appropriate heat and pressure treatment, the tire casing, cushion gum and tread layer become bonded into an integral retreaded tire that may be used on an appropriate over-the-road vehicle.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The invention will hereafter be described with reference to the accompanying drawings, wherein like reference numerals denote like elements, and:
[0011] [0011]FIG. 1 is a cross-sectional view of an exemplary original tire;
[0012] [0012]FIG. 2 is a cross-sectional view of the tire of FIG. 1 after the tread layer has been removed from the tire casing;
[0013] [0013]FIG. 3 is a schematic representation of the layer of cushion gum and the new tread layer being applied to a tire casing;
[0014] [0014]FIG. 4 is a cross-sectional view of the tire casing illustrated in FIG. 2 with the addition of the layer of cushion gum and the new tread layer; and
[0015] [0015]FIG. 5 is a perspective cross-sectional view of an alternate embodiment of a retreaded tire according to the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0016] Referring generally to FIG. 1, an original tire is shown as having a tire casing 12 from which extends a tire tread 14 . The illustrated tire 10 is a radial tire; however, the invention applies equally to other types of tires, such as bias ply tires.
[0017] More particularly, tire 10 includes a pair of side walls 16 bounded by a generally radially outward wall 18 that spans side walls 16 . Each side wall 16 extends radially inward from outer wall 18 and terminates in a bead area 20 designed for mounting on the tire rim (not shown). Bead area 20 may be designed in a variety of configurations depending on, for example, tire type, tire size or rim configuration. In the illustrated embodiment, each bead area 20 includes a bead heel 22 , a bead toe 24 , and a bead sole 26 . Each bead area 20 may also include a bead bundle 28 and a chafer ply 30 . Both bead bundle 28 and chafer ply 30 may include, for example, metal strands or wires to improve the strength of bead area 20 .
[0018] Side walls 16 may also include multiple layers, such as a rubber layer 32 , a radial ply 34 and an inner liner 36 which cooperate to provide a strong but flexible side wall. Side walls 16 are joined to radially outward wall 18 and tread 14 through a pair of shoulder areas 38 . Shoulder areas 38 extend towards tire tread 14 which, in turn, is disposed radially outwardly from wall 18 of tire casing 12 . Tire tread 14 may include a plurality of grooves 40 designed to channel water and provide added traction during certain road conditions. Additionally, outer wall 18 may be strengthened by a plurality of belts or cords 42 extending circumferentially about tire 10 within wall 18 (see FIGS. 2 and 5).
[0019] After tire tread 14 wears beyond a certain limit, tire 10 must either be discarded or retreaded before it should be used on the vehicle for which it was designed. In cold process retreading, the remaining tire tread 14 is removed from tire casing 12 by a buffing machine, such as the Model 8110 buffing machine manufactured by Bandag, Incorporated of Muscatine, Iowa. During the buffing operation, the original tire tread 14 is ground away from tire casing 12 , leaving a buffed surface 44 as illustrated in FIG. 2. Buffed surface 44 extends circumferentially about tire casing 12 and also extends transversely across the outside of outer radial wall 18 until it terminates at buffed shoulder areas 46 .
[0020] Following removal of the used tread layer, a process called skiving and filling is performed on tire casing 12 . Skiving is the removal of damaged material from a tire prior to making a repair. Often, the tire casing 12 accumulates holes, nicks or tears due to stones or other sharp objects the tire comes in contact with during use. The injured or damaged area is first ground smooth by an appropriate grinding tool and then filled with repair gum, such as Bandag extruder repair rope or repair gum or some other suitable material. It is necessary to fill the injured areas to the level of buffed surface 44 to avoid air pockets between buffed surface 44 and the later applied tread layer. Trapped air can have negative effects on the longevity of a typical retreaded tire. Following the skiving and filling operation, a building step occurs in which a layer of cushion gum and a new tread layer are wrapped about the circumference of tire casing 12 along buffed surface 44 .
[0021] As illustrated best in FIG. 3, a building machine 48 (shown schematically), such as the Bandag 5110 semiautomatic builder manufactured by Bandag, Incorporated, may be used to apply a layer of cushion gum 50 , such as HD30 cushion gum manufactured by Bandag, Incorporated. Although the layer of cushion gum 50 could be applied to tire casing 12 in a variety of ways, the schematic representation of FIG. 3 shows a roll of the cushion gum 52 rotatably mounted on building machine 48 . The layer of cushion gum 50 moves about a tensioning roller 54 prior to being wrapped circumferentially around buffed surface 44 .
[0022] Preferably, cushion gum layer 50 is covered by a bottom plastic sheet 56 , e.g. a poly sheet, and a similar top plastic sheet 58 . As illustrated, bottom sheet 56 is peeled away from cushion gum layer 50 shortly before the cushion gum is wrapped about tire casing 12 along buffed surface 44 . Bottom plastic sheet 56 may then be wrapped about tensioning roller 54 as shown in FIG. 3.
[0023] Cushion gum layer 50 is preferably applied to buffed surface 44 within eight hours of buffing. Additionally, the application has been found to work best when the layer of cushion gum 50 is applied under tension in the circumferential direction. Depending on the application, it may be desirable to slightly stretch the cushion gum layer 50 to achieve better adherence to buffed surface 44 . Cushion gum layer 50 is cut transversely and the cut edge is spliced with the leading edge so there is no gap between the beginning and the end of cushion gum layer 50 . Any, overlap between the leading edge and the trailing cut edge is preferably limited to one-eighth inch or less.
[0024] After cushion gum layer 50 is applied to tire casing 12 , layer 50 is stitched, or in other words pressed, against buffed surface 44 to drive out any air trapped between the cushion layer and buffed surface 44 . Following stitching, the top layer of plastic 58 is removed from cushion gum layer 50 to permit a new tread layer 60 to be applied over the cushion gum. The stitching step also helps prevent the cushion from lifting away from buffed surface 44 when plastic layer 58 is removed and tread layer 60 is applied.
[0025] Preferably, tread layer 60 is also applied with the assistance of building machine 48 , although there are a variety of ways to wrap tread layer 60 about the circumference of tire casing 12 . When using building machine 48 , a tread roll 62 is rotatably mounted thereon, and tread layer 60 is guided onto tire casing 12 against cushion gum layer 50 by guide rollers 64 .
[0026] Tire casing 12 is rotated an building machine 48 until a sufficient length of tread layer 60 is unraveled from tread roll 62 to extend about the circumference of tire casing 12 . Tread layer 60 is then cut generally transversely to the circumferential direction, and the cut end is butted up against the leading edge of tread layer 60 to form a splice. The tread layer splice is often held together by a plurality of staples (not shown). It is also preferred that the spliced area of cushion gum layer 50 and the spliced area of tread layer 60 be disposed at different points along buffed surface 44 .
[0027] Although the application of cushion gum layer 50 and tread layer 60 to a tire casing 12 by building machine 48 has been generally known in the industry for many years, the unique aspects of this inventive method of retreading allows the omission of a previous step, namely the application of spray cement to buffed surface 44 . Previously, spray cement would be initially applied to buffed surface 44 . Then, cushion gum layer 50 would be applied to the inside or lower surface of tread layer 60 . The combination of cushion gum layer 50 and tread layer 60 would be wrapped about cement covered buffed surface 44 and spliced together.
[0028] The present method permits the elimination of the spray cement which overcomes certain disadvantages described in the background of the invention section above. By first stretching the layer of cushion gum about the circumference of tire casing 12 , stitching the cushion gum and then applying tread layer 60 over the combined tire casing 12 and cushion gum layer 50 , the necessity of using spray cement has been eliminated. It has been found that retreaded tires made according to the new method have very desirable characteristics without requiring an extra cementing step.
[0029] After application of cushion gum layer 50 and tread layer 60 , a retreaded tire assembly 66 is created and ready for curing under appropriate heat and pressure conditions. A cross section of the retreaded tire assembly 66 is illustrated best in FIG. 4. After assembly, the overall tire assembly is inserted into a rubberized curing envelop, such as the appropriate Bandag, Incorporated curing envelope designed for the particular tire type and size being retreaded.
[0030] The retreaded tire assembly 66 is sealed within the curing envelope and placed within a curing chamber, such as the Model 4130 or 4120 curing chamber sold by Bandag, Incorporated. Pressure and heat are applied to the retreaded tire assembly 66 within the curing chamber. The amount of time necessary to cure a given retreaded tire may vary depending on the size of the tire and the materials used. However, the time must be long enough to create sufficient bonding between the tire casing 12 and cushion gum layer 50 and between the tread layer 60 and cushion gum layer 50 . Generally, the bonding results from vulcanization between the tire casing, cushion gum layer and tread layer. The times, pressures and temperatures within the curing chamber would be known by one of ordinary skill in the art. However, exemplary parameters during curing within the curing chamber are temperature: approximately 210° F.; pressure: approximately 85 psi; and time: approximately three and one half hours. The above listed temperature, pressure and time parameters are only provided as examples, and are not meant to limit the scope of the invention. As stated previously, the time within the curing chamber may vary depending on the tire size and tire materials. Additionally, other combinations of temperature and pressure can potentially provide satisfactory results. After curing, the retreaded tire may undergo certain minor trimming operations, but otherwise is ready for use on a vehicle.
[0031] Another embodiment of retreaded tire assembly 66 is illustrated in FIG. 5. The process used for this type of retreaded tire is the same as that described above, except for the addition of a pair of shoulder strips 68 of cushion gum that are added to accommodate arched outer flanges 70 of a slightly different tread layer 72 . In this embodiment, tread layer 72 extends about the circumference of tire casing 12 as described above, but the arched outer flanges 70 curve in the transverse direction generally about shoulder areas 46 of tire casing 12 . Accordingly, additional cushion gum must be added in the form of shoulder strips that run generally along each shoulder area 46 of tire casing 12 and beneath flanges 70 .
[0032] Thus, after cushion gum layer 50 is applied to buffed surface 44 , and stitched thereto, the top layer of plastic 58 is removed and shoulder strips 68 are applied along shoulder areas 46 . The tread layer 72 including its arched outer flanges 70 is applied over cushion gum layer 50 and shoulder strips 68 , measured, cut, and spliced similarly to that described above.
[0033] The various parameters involved in cementless retreading of tires may vary depending on the overall design of the tire being retreaded and the composition of the retreading materials. However, in general, it is preferred that the temperature of both tire casing 12 and cushion gum layer 50 be at least 65 degrees Fahrenheit when the cushion gum layer is applied to buffed surface 44 . Additionally, the cushion should be applied to the uncemented casing within eight hours of buffing or, if the buffed casing is covered with poly, the cushion application should be within 72 hours of buffing. Furthermore, to ensure a high quality retreaded tire, it is preferred that the centerline of cushion layer 50 be aligned with the center line of the buffed casing within plus or minus one eighth inch. When applying the flat style tread illustrated in FIG. 4, there should be at least one eighth inch of cushion layer 50 extending transversely past the base of the tread on each side of tread layer 60 . Similarly, cushion layer 50 should be applied with enough tension to facilitate conformation to the buffed surface 44 , but the tension should not cause the width of cushion layer 50 to be reduced by more than one eighth inch. Generally, the length of cushion layer 50 is approximately 2-8 inches shorter than the circumference of buffed surface 44 .
[0034] It will be understood that the foregoing description is of the preferred exemplary embodiment of this invention and that the invention is not limited to the specific form shown. For example, the invention is directed to a tire assembly and a method for retreading tires that does not require the use of spray cement, and therefore a wide variety of equipment may be used to apply the layers of cushion gum and tread to the tire casing. Additionally, the invention encompasses a broad variety of tires, materials, and tread designs that may be assembled according to the invention. The methods of preparing the tire casing and curing the retreaded tire assembly may vary substantially due to differences in materials, equipment and techniques for creating retreaded tires. These and other modifications may be made in the design and arrangement of the elements without departing from the scope of the invention as expressed in the appended claims.
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A retreaded tire assembly and method for making the same is disclosed. The method and assembly provide for the application of new tread to a buffed tire casing with only a layer of cushion gum disposed therebetween. The cushion gum is applied directly to the buffed circumference of a tire casing without the use of conventional spray cement normally applied to the buffed surface of the entire casing.
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BACKGROUND OF THE INVENTION
This invention relates to an improved apparatus for electrically heating pipes and particularly thawing frozen pipes, hydrants, electric cable ducts and the like.
Such apparatus is known which comprises a movable trailer incorporating a generator, a step-down transformer and two bus bars to which electric cables can be connected. Each bus bar is arranged to accept several cables, one or more cables of one bus bar being connected to one end of a pipe (or pipe system) to be thawed and one or more cables of the other bus bar being connected to the other end of the pipe to be thawed.
One problem with the known apparatus is due to the fact that the operators generally have little knowledge of electrical theory. They connect up one pair of cables and run the machine at a current output of around 200 amps. If, after 10 minutes or so there is no evidence of thawing they simply increase the current as it seems logical that will bring about the desired result. They do not think it necessary to add more cables, which is time-consuming, when one pair of cables evidently can carry easily the increased current. This is because they do not appreciate that the resistance of the cables themselves is an important factor especially where the pipe is copper which has a very low resistance. In this case the I 2 R heat generated in the cables will increase at a greater rate than the I 2 R heat generated in the pipe and what is required is a reduction in the cable resistance which can only be accomplished by adding cables in parallel.
The effect of this misuse of the thawing apparatus is that the cables become excessively hot giving rise to a tendency for the cable connections to melt and the connections to come off. Moreover, since this increased heat is at the expense of the heat applied to the pipe it can take an unacceptably long time to thaw out a pipe and, in fact, where the cables are long or the pipe diameter is large, the pipe may never thaw. Further, because of the proportion of the I 2 R heat lost in the cables, a very high capacity generator is required. Additionally, because of the length of time of application of heat there is a danger of melting the lead in the joints in the pipe and of burning valve gaskets and packings.
Another effect of excessive current in the cables is a large variation in the voltage applied at the pipe between load and no-load. The result is that should the pipe circuit become open the voltage immediately rises substantially, thereby forcing an excessive current over the neutral of the electrical distribution system, which system is parallel with the water system and is not designed or intended to carry excessive current. This excessive current heats up the ground wires to the point where they can ignite combustible materials or even to the point where they fuse and create an arc.
It is an object of the present invention to obviate or mitigate the above defects.
SUMMARY OF THE INVENTION
According to the present invention there is provided apparatus for heating electrically conductive pipes electrically, comprising, a first pair of terminals connectible to a source of power, at least one other pair of terminals connectible to the source of power in parallel with first pair of terminals, current sensing means connected to sense the current flowing in at least one of the terminals of the first pair of terminals, and warning means operated by the current sensing means when the current sensing means senses a current in excess of a predetermined value.
Preferably, there is also provided further current sensing means connected to sense the current flowing in the other terminal of the first pair of terminals and further warning means operated by the further current sensing means when the current to the other terminal exceeds the predetermined value.
The operator is thus given a warning when an excess current condition exists and his standing instructions will be to add a further pair of cables between the pipe and the other pair of terminals when there is such a condition. In a preferred embodiment, not only is he provided with a warning, which may be audio or visual, but he is prevented from increasing the current through the first cable pair by means of an automatic circuit breaker which trips when the maximum permitted current is exceeded.
Each pair of terminals should be numbered consecutively to remove any doubt as to the sequence in which cable pairs have to be attached. To further reduce the risk of improper operation a current sensing means may be provided to sense the current at each terminal and provide a warning and/or operate the circuit breaker when current to any terminal exceeds the predetermined limit.
The effect of doubling the number of parallel connected cables is to half the resistance and the voltage drop along the cables. Thus, the effective voltage applied to the pipe is increased considerably which causes a consequent increase in the heating current in the pipe.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described in greater detail with reference to the accompanying drawings the single FIGURE of which is a diagrammatic view of a pipe thawing machine embodying the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The apparatus includes a step-down transformer 1 having a primary coil 2 and a secondary coil 3. The primary coil 2 is wound to accept the H.V. output of a diesel generator (not shown), and is tapped so that the voltage derived on the secondary coil 3 may be varied up to a maximum of 45 volts, the current in the coil 3 being up to 1500 amperes.
Each end of secondary coil 3 is connected to a terminal 4 and 5, respectively, which are each formed with a projecting stud or socket receiving a connector 6 and 7, respectively connected to an end of a flexible cable 8 and a flexible cable 9.
The other end of cable 8 is provided with a suitable connector, such as a screw-clamp connector 12 for connecting the cable to a water tap 13 defining one end of the pipe system 14 to be thawed. The other end of cable 9 is also provided with a screw-clamp 15 for connecting the cable 9 to a hydrant 16 defining the other end of the pipe system to be thawed.
Each end of secondary coil 3 is also connected to a respective bus 18 or 19. Each bus 18 or 19 is formed with one or more, four in this embodiment, studs 20 identical to the studs of terminals 4 and 5. It should be clear that up to four more flexible cables similar to the cables 8 and 9 may be connected from each bus 18 or 19 to the tap 13 and the hydrant 16, respectively, in the same way that the cables 8 and 9 are connected. As an example, the first stud of bus 18 is shown connected to the tap 13 by a dotted line 22 representing a flexible cable connection and the first stud of bus 19 is shown connected to the hydrant 16 by a dotted line 23 also representing a flexible cable.
It can be seen that each end of the secondary 3 is branched forming two branches 24 and 25 (and 24' and 25') at each end, these branches forming the connection between the secondary and the terminal 4 and bus 18 (and terminal 5 and bus 19).
A current transformer 26 (26') is received on each branch 24 (24') and the output of the current transformer is connected as the input of a relay 27 (27') arranged to operate at a voltage corresponding to a current of 250 amps in the branch 24 (24'). Actuation of the relay 27 (27') causes energisation of a warning light or flasher 28 (28') and/or an audible signal.
The apparatus described above is preferably incorporated in a self-contained unit which may be towed to the site at which pipe thawing is to be carried out. The unit houses the diesel electric generator, step-down transformer, current transformers and relays. The terminals 4 and 5 and the busses 18 and 19 are mounted on end of the housing in the configuration shown and the flashers 28 and 28' are mounted adjacent the respective terminals 4 and 5.
In operation, with the unit as the location of the frozen pipe, the operator attaches cables 8 and 9 as shown and runs the generator with the primary tap adjusted to give a current output of less than 250 amps. This current flows through the circuit comprising the secondary 3, cable 8, connector 17, tap 13, pipe 14, hydrant 16, connector 15 and cable 9. The I 2 R heat losses in the tap 13, pipe 14 and hydrant 16 tend to thaw the tap, pipe or hydrant as the case may be. If after some 10 minutes or so there is no evidence that the thawing is effective it is obvious that the I 2 R loss is insufficient and greater current flow is necessary. If the operator simply increases the current output the flashers 28 and 28' will operate at the 250 amp level warning him that at least one more pair of cables is needed. The operator will, therefore, add the cables indicated by the dotted lines and crank up the generator until the current output in the secondary is considerably above 250 amps, possibly as high as 1500 amps.
It may be found necessary to increase the current still further to effect thawing and this may be done providing that sufficient cables are added to ensure that the flashers 29 and 28' are extinguished.
It is envisaged that the invention need not incorporate a generator as the necessary power may be drawn directly from the electrical power company supply.
The apparatus according to the invention may also be provided with an additional warning light or buzzer on the actual control panel which is remote from the bus bars.
The apparatus of the invention may additionally be provided with automatic tripping means in the form of a circuit breaker energised by the current transformer 26, for example, to break the supply from the secondary winding 3 if the current exceeds a predetermined value--350 amps for example.
In practice, the pairs of terminals might be formed in the side of the housing of the pipe thawing machine somewhat as shown or they might be formed in two vertical columns rather than horizontal rows. In either case, the bus bars would not be visible and to differentiate clearly the pairs of terminals and indicate clearly the intended order of connection, the housing could be provided with consecutive numbering adjacent the terminal pairs as shown in numerals 1 to 5.
As a modification, a current transformer, relay and flasher could be provided for each terminal, the flasher being disposed adjacent the appropriate terminal.
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Apparatus for heating pipes and particularly for thawing frozen pipes is disclosed. The apparatus may be a self contained trailer having a generator and step-down transformer. One pair of terminals is connected to the secondary of the transformer and a pair of bus bars is also connected across the secondary. A current transformer operates a warning system indicating that the current to the first terminals is above a maximum value. This warns the operator that another pair of cables is necessary to heat effectively the pipe.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a moving picture communication system, and more particularly, to a moving picture communication system for transmitting and receiving a color moving picture between devices connected to a network.
[0003] 2. Description of the Related Art
[0004] In the related art, Japanese Patent Application Publication No. 2002-247383 proposes a data transmission and reception method which enables color moving pictures to be transmitted at high speed between devices having low communication capability.
[0005] On the transmission side of this data transmission and reception method, a color moving picture inputted from a video camera is converted into still pictures at certain time points, and the still pictures are compressed. Moreover, the color moving picture is converted into a black and white moving picture having a reduced number of pixels. The compressed color still pictures and the black and white moving picture are then transmitted.
[0006] On the receiving side, on the other hand, the received color still pictures are analyzed into color pixels to obtain color information, and the color moving picture is restored on the basis of this color information and the received black and white moving picture.
[0007] Furthermore, it is known that, when the moving picture stream is encoded, the frame rate can be varied and the image size can be changed, in accordance with the transmission bandwidth.
[0008] However, in such a data transmission and reception method which colorizes a black and white moving picture on the basis of a black and white moving picture and color still pictures at some time points, if there is large movement of the subject of the pictures, then it is difficult to obtain a satisfactory color moving picture unless the frequency of sending the color still pictures is set to be very high, and consequently, it can be difficult to reduce the data volume. Furthermore, since the number of pixels is reduced in the black and white moving picture, then it is difficult to achieve a moving picture of high resolution even if a color moving picture can be obtained.
[0009] Moreover, if the frame rate of the moving picture stream is reduced in accordance with the bandwidth of the communication path, then when the subject moves, it may be difficult to see the details of the movement of the subject on the restored moving picture.
SUMMARY OF THE INVENTION
[0010] The present invention has been contrived in view of the foregoing circumstances, an object thereof being to provide a moving picture communication system whereby a moving picture having smooth movement and a high resolution can be transmitted and received, even if there is variation in the transmission bandwidth of the communication path.
[0011] In order to attain the aforementioned object, the present invention is directed to a moving picture communication system, comprising communication terminals configured to mutually send and receive a color moving picture including luminance information and color information through a network to which the communication terminals are connected, wherein each of the communication terminals comprises: a transfer bandwidth information acquisition device which acquires transfer bandwidth information representing a bandwidth of a communication path through which the color moving picture is sent and received; a color information compression device which compresses the color information of the color moving picture in accordance with the transfer bandwidth information acquired by the transfer bandwidth information acquisition device; an encoding device which encodes the color moving picture outputted from the color information compression device; a transmission device which transmits the color moving picture encoded by the encoding device; a reception device which receives the encoded color moving picture transmitted from another of the communication terminals; a decoding device which decodes the encoded color moving picture received by the reception device; and a color moving picture output device which outputs the color moving picture decoded by the decoding device.
[0012] According to this aspect of the present invention, the transfer bandwidth of the communication path is monitored by the transfer bandwidth information acquisition device, and if the transfer bandwidth narrows and it becomes difficult to adequately send and receive a color moving picture including the color information and the luminance information, then the color information of the color moving picture is compressed (reduced) in accordance with the bandwidth, thereby gradually changing the images into black and white images. Accordingly, it is possible to send and receive a moving picture of high resolution, while preventing feelings of incongruity.
[0013] Preferably, the color information is saturation information; and the color information compression device reduces an amount of the saturation information as the bandwidth narrows, in accordance with the acquired transfer bandwidth information.
[0014] Regarding the method for reducing the volume of saturation information, a bit shift operation which removes bit information, starting from the low bit, in order to reduce the bit depth, may be used.
[0015] Preferably, the transfer bandwidth information acquisition device acquires the transfer bandwidth information in accordance with delay information of the color moving picture received from the other communication terminal performing two-way communication of the color moving picture.
[0016] Preferably, if the color information is compressed by the color information compression device, the encoding device adds compression information relating to this compression to the encoded color moving picture; and if the reception device receives the compression information in addition to the color moving picture, the decoding device decodes the received color moving picture in accordance with this compression information.
[0017] According to this aspect of the present invention, on the transferring side, compression information which indicates what type of compression has been carried out with respect to the color information is added to the color moving picture. On the receiving side, the color moving picture is restored on the basis of the compression information which is received along with the color moving picture.
[0018] According to the present invention, when a color moving picture is sent and received through a network, the transfer bandwidth of the communication path is monitored, and if the transfer bandwidth changes and it becomes difficult to send or receive a color moving picture adequately, then the color information, of the luminance information and color information constituting the color moving picture, is reduced in accordance with the bandwidth, thereby gradually changing the image into a black and white image. Therefore, it is possible to send and receive a smooth moving picture at high resolution, in comparison with a case where the number of pixels or the frame rate is reduced, and furthermore, it is also possible to send and receive a color moving picture which does not create a feeling in incongruity, by making the image become a black and white image in a gradual fashion.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] The nature of this invention, as well as other objects and benefits thereof, will be explained in the following with reference to the accompanying drawings, wherein:
[0020] FIG. 1 is a block diagram showing a moving picture communication system according to an embodiment of the present invention;
[0021] FIG. 2 is a block diagram showing an example of the internal composition of a communication terminal which is a component of the moving picture communication system;
[0022] FIG. 3 is an oblique front diagram of the communication terminal;
[0023] FIG. 4 is a schematic diagram of an encoding unit which encodes a moving picture stream;
[0024] FIGS. 5A to 5 C are diagrams used to describe a macro-block forming a minimum encoding unit;
[0025] FIG. 6 is a schematic diagram of a decoding unit which decodes the encoded data; and
[0026] FIG. 7 is a diagram used to describe a method of reducing the number of bits in accordance with the transfer bandwidth.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0027] FIG. 1 is a block diagram showing a moving picture communication system according to an embodiment of the present invention.
[0028] In this system, a communication terminal 1 a and a communication terminal 1 b having the same composition (hereinafter also referred to jointly as “communication terminal 1 ”), are connected to each other via a network 10 , such as the Internet, so that video data (representing color moving pictures) and audio data are transmitted between these terminals.
[0029] The connection path between the communication terminal 1 a and the communication terminal 1 b is specified by an exchange server 6 constituted by a SIP (Session Initiation Protocol) server, using a network address (global IP (Internet Protocol) address, and the like), a port and an identifier (MAC (Media Access Control) address, or the like). Information relating the user of the communication terminal 1 , such as the name and email address, and information relating to the connection of the communication terminal 1 (account information) are stored in an account database (DB) 8 a , and are managed by an account management server 8 . The account information can be updated, modified or deleted through a communication terminal 1 connected to the account management server 8 via a Web server 7 . The Web server 7 also serves as a mail server for sending mails (e-mails) and a file server for downloading files.
[0030] The communication terminal 1 a is connected to a microphone 3 a , a camera 4 a , a speaker 2 a and a monitor 5 a . Video data captured through the camera 4 a , and audio data gathered through the microphone 3 a , are transmitted to the communication terminal 1 b via the network 10 . The communication terminal 1 b is also connected to a microphone 3 b , a camera 4 b , a speaker 2 b and a monitor 5 b , and is able to transmit the video data and the audio data to the communication terminal 1 a in a similar fashion.
[0031] The video data and the audio data received by the communication terminal 1 b are reproduced through the monitor 5 b and the speaker 2 b , and the video data and the audio data received by the communication terminal 1 a are reproduced through the monitor 5 a and the speaker 2 a.
[0032] FIG. 2 is a block diagram showing an example of the internal composition of the communication terminal 1 .
[0033] An audio input connector 31 , a video input connector 32 , an audio output connector 33 , and a video output connector 34 are provided on the outer surface of the main body of the communication terminal 1 , and are connected respectively to the microphone 3 , the camera 4 , the speaker 2 and the monitor 5 . The microphone 3 and the speaker 2 may be integrated into a headset.
[0034] An audio signal inputted to an audio input unit 14 from the microphone 3 connected to the audio input connector 31 , and a video signal inputted to a video input unit 15 from the camera 4 connected to the video input connector 32 , are digitized, compressed, encoded, and converted into stream data (content data in a format compatible with real-time distribution), by an encoding unit 11 a constituted by an encoder compatible with high image quality, such as an MPEG-2 encoder or an MPEG-4 encoder (MPEG stands for Moving Picture Experts Group).
[0035] The stream data is converted into packets by a packeting unit 25 , and then stored temporarily in a transmission buffer 26 . The transmission buffer 26 sends the packets to the network 10 at regular intervals, via a communication interface 13 . The transmission buffer 26 has a capacity for storing and sending one frame of data in one packet, when a moving image having 30 frames per second is read in, for example.
[0036] A bandwidth estimation unit 11 c estimates the bandwidth of the transfer path on the network 10 through which the packets are to be transferred, on the basis of the jitter (fluctuation) of the network 10 , and the like, and then the bandwidth estimation unit 11 c adjusts the data volume encoded by the encoding unit 11 a in accordance with the transfer bandwidth thus estimated. The details of the processing of the encoding unit 11 a on the basis of the estimated transfer bandwidth are described later.
[0037] On the other hand, the packets of the stream data received from the other communication terminal 1 via the communication interface 13 are stored temporarily in a reception buffer 21 , and are then outputted to a streaming unit 22 at regular intervals. The streaming unit 22 reassembles content data from the received packets. The content data is then decoded by a decoding unit 11 b constituted by an MPEG-2 decoder or an MPEG-4 decoder, or the like. The video data included in the content data is converted into an NTSC (National Television Standards Committee) signal by a video output unit 17 , and the NTSC signal is outputted to the monitor 5 . The audio data included in the content data is converted into an analog audio signal by an audio output unit 16 , and the analog audio signal is outputted to the speaker 2 .
[0038] The communication interface 13 is provided with a network connector 61 , which is connected to a broadband router, ADSL (Asymmetric Digital Subscriber Line) modem, or the like, by various cables, so as to be connected to the network 10 .
[0039] It is recognized by persons skilled in the art that if the communication interface 13 is connected to a router having firewall or NAT functions (NAT stands for Network Address Translation, which can achieve interconversion between a global IP address and a private IP address), then it is difficult to make the direct connection between the communication terminals 1 according to SIP (known as “NAT problem”). It is possible to provide a relay server compatible with a NAT traversal function, such as a STUN (Simple Traversal of UDP (User Datagram Protocol) through NATs) server 30 or a UPNP (Universal Plug and Play) server, with the purpose of relaying the connection between the communication terminals 1 . In order to prevent the occurrence of delay in the transmission and reception of the video and audio data, it is preferable that various types of NAT traversal functions which do not operate via a relay server are incorporated into the communication terminals 1 (see, for example, Japanese Patent Application Publication No. 2003-352950).
[0040] The control unit 11 controls the units in the communication terminal 1 , on the basis of operational inputs from an operating unit 18 , which is constituted by various types of buttons, keys, and the like. The control unit 11 includes a calculation device, such as a CPU (central processing unit), which achieves the functions of the encoding unit 11 a , the decoding unit 11 b , the bandwidth estimation unit 11 c , a display control unit 11 d , and a timer recording management unit 11 e , by means of programs stored on a storage medium 23 .
[0041] The display control unit 11 d controls the output of video signals to the monitor 5 . Hereinafter, for the purpose of simplicity, it is supposed that all of the video signals outputted to the monitor 5 are controlled by the display control unit 11 d . However, it is also possible to change the video signal outputted from the communication terminal 1 to the monitor 5 , to a standard television broadcast signal.
[0042] The address for uniquely identifying each communication terminal 1 (which is not necessarily synonymous with the global IP address), a password required by the account management server 8 in order to authenticate the communication terminal 1 , and a startup program for the communication terminal 1 , are all stored in a ROM 35 , which is capable of holding data even if the power supply is switched off. The ROM 35 is constituted by a flash ROM, or the like, and the programs stored thereon can be updated to the latest version by means of an updating program supplied by the account management server 8 .
[0043] The data required for the various processes carried out in the control unit 11 is stored in a main memory 36 constituted by a RAM, which temporarily stores data.
[0044] The storage medium 23 is a removable medium, such as a compact flash card, and it is used principally for reading and writing the video data and audio data. The storage medium 23 is also capable of storing the application program of the control unit 11 , and the application program can be updated to the latest version by means of an updating program supplied by the account management server 8 .
[0045] The communication terminal 1 is provided with a remote control signal input unit 63 , which is connected to a remote control light reception unit 64 . The remote control light reception unit 64 converts an infrared light signal received from a remote controller 60 into an analog electric signal, and the remote control signal input unit 63 converts the analog electric signal inputted from the remote control light reception unit 64 into a digital signal, which is sent to the control unit 11 . The control unit 11 controls the various operations in accordance with the digitized remote control signal inputted from the remote control signal input unit 63 .
[0046] The control unit 11 controls a light control circuit 24 for blinking or lighting on and off of light-emitting diodes (LEDs) 65 arranged on the outer face of the communication terminal 1 . It is possible that the light control circuit 24 is connected to a flash lamp 67 through a connector 66 , and controls blinking or flashing on and off of the flash lamp 67 . The control unit 11 uses a real time clock (RTC) unit 20 as an internal clock.
[0047] FIG. 3 is an oblique front side diagram showing an external appearance of the communication terminal 1 . The communication terminal 1 is a set top box (STB) comprising an erect-type frame body. In the front area of the frame body, the remote control light reception unit 64 , the operating unit 18 including a power button and the like, the LEDs 65 including a “data reception” light, a “timer set” light and the like, the video input connector 32 , the video output connector 34 , and the like, are arranged. Although not shown in FIG. 3 , the network connector 61 , the audio input connector 31 , the audio output connector 33 , and the like, are arranged on the rear area of the frame body.
[0048] Next, the encoding unit 11 a shown in FIG. 2 is described below.
[0049] FIG. 4 is a schematic diagram of the encoding unit 11 a , and it shows the portions about encoding color moving pictures, in particular.
[0050] This encoding unit 11 a comprises an adder 102 , a motion-compensated interframe prediction unit 104 , a DCT (discrete cosine transformation) unit 106 , a quantization unit 108 , and a VLC (variable length coding) unit 110 .
[0051] The encoding unit 11 a creates an I-picture (intra-coded), a P-picture (predictive-coded) and a B-picture (bidirectionally predictive-coded), from the inputted picture. The I-picture is encoded using solely the information in that frame, the P-picture is encoded as a differential image by using information from the frame being coded and from a previous frame, and the B-picture is encoded as a differential image by using information from the frame being coded and from a previous or future frame.
[0052] The image (color moving picture) inputted through the video input unit 15 is supplied to the adder 102 and the motion-compensated interframe prediction unit 104 .
[0053] The motion-compensated interframe prediction unit 104 performs an inverse quantization, an inverse DCT, and the like, of the previously quantized image inputted from the quantization unit 108 , and thereby creates a previous image. Then, the motion-compensated interframe prediction unit 104 determines motion vectors on the basis of the current input image and the previous image, and compensates (corrects) the previous image for movement according to the motion vectors, and then outputs the compensated image to the adder 102 .
[0054] When the P-picture or the B-picture is encoded, the adder 102 subtracts the previous image that has been compensated for movement by the motion-compensated interframe prediction unit 104 , from the currently inputted image, thereby finds a differential image, and outputs this differential image to the DCT unit 106 . When the I-picture is encoded, the adder 102 outputs the input image without alteration, to the DCT unit 106 .
[0055] As shown in FIGS. 5A and 5B , the DCT unit 106 uses macro blocks MB of 16×16 pixels extracted from one frame, as minimum encoding units, and the size of the DCT is 8×8. As shown in FIG. 5C , the DCT unit 106 allocates the luminance signal Y to four blocks Y 1 , Y 2 , Y 3 and Y 4 , allocates each of the color differential signals Cr and Cb to two blocks, Cr 1 and Cr 2 , and Cb 1 and Cb 2 , and carries out an 8×8 two-dimensional DCT for each block. The DCT operation has the function of concentrating the image signal into a smaller number of low-frequency coefficients, and hence makes it possible to reduce the amount of information about a spatial direction of the image. Furthermore, the DCT unit 106 also includes a color compression unit 106 a . This color compression unit 106 a compresses the data volume of the blocks Cr 1 and Cr 2 , and Cb 1 and Cb 2 , on the basis of the bandwidth information inputted from the bandwidth estimation unit 11 c . The details of the color compression unit 106 a are described later.
[0056] In the image format shown in FIG. 5C , the data volume of each of the color differential signals Cr and Cb constituting pixels is reduced by one half, in the horizontal direction, and the ratio of Y, Cr and Cb is 4:2:2, where Y=4, Cr=2, and Cb=2. Since the human eye is less perceptive for color than for luminance, then even if the color information is reduced, no substantial decline in image quality is appreciated.
[0057] The quantization unit 108 quantizes the DCT coefficients created by the DCT unit 106 , by means of a quantization table, and carries out processing for reducing the code volume by representing all of the DCT coefficients by a set of low-value numbers. The VLC unit 110 encodes the quantized data by means of a Huffman table (it carries out the allocation of codes, in accordance with the probabilities of appearance of codes).
[0058] The stream data thus encoded by the encoding unit 11 a is converted into packets by the packeting apparatus 25 , and the packets are stored temporarily in the transmission buffer 26 , and then sent to the network 10 at regular intervals.
[0059] Next, the decoding unit 11 b shown in FIG. 2 is described below.
[0060] FIG. 6 is a schematic diagram of the decoding unit 11 b , and it shows the portions about decoding color moving pictures, in particular.
[0061] This decoding unit 11 b comprises a VLC decoder 120 , an inverse quantization unit 122 , an inverse DCT unit 124 , an adder 126 , and a motion-compensated interframe prediction unit 128 .
[0062] The decoding unit 11 b restores a moving picture by means of an expansion process which is inverse to the compression process carried out by the encoding unit 11 a.
[0063] The VLC decoder 120 generates quantized DCT coefficients by Huffman decoding of the encoded data inputted from the streaming unit 22 , and outputs the DCT coefficients thereby generated to the inverse quantization unit 122 . The inverse quantization unit 122 generates DCT coefficients by inverse quantization of the quantized DCT coefficients inputted from the VLC decoder 120 , and outputs the DCT coefficients thereby generated to the inverse DCT unit 124 .
[0064] The inverse DCT unit 124 generates a digital image signal by inverse DCT processing of the input DCT coefficients, and outputs the digital image signal thereby generated to the adder 126 . As the other input of the adder 126 , the previous image for which the interframe prediction has been performed is supplied from the motion-compensated interframe prediction unit 128 . When the I-picture is inputted from the inverse DCT unit 124 , then the adder 126 outputs the input image without alteration, whereas when the P-picture or the B-picture is inputted from the inverse DCT unit 124 , then the adder 126 adds the predicted image supplied from the motion-compensated interframe prediction unit 128 to the input image, and outputs the sum image.
[0065] The video data thus decoded by the decoding unit 11 b is converted into an NTSC signal by the video output unit 17 and then outputted to the monitor 5 .
[0066] Next, a method of varying the volume of the data that is encoded by the encoding unit 11 a is described below.
[0067] The bandwidth estimation unit 11 c shown in FIG. 2 estimates the transfer bandwidth of the communication path between the communication terminals 1 a and 1 b , and sends transfer bandwidth information representing the estimated transfer bandwidth to the encoding unit 11 a.
[0068] This transfer bandwidth information is supplied to the color compression unit 106 a of the DCT unit 106 , as shown in FIG. 4 . The color compression unit 106 a compresses the data of the four blocks Cr 1 , Cr 2 , Cb 1 and Cb 2 of the color differential signals Cr and Cb, in the macro-block MB comprising 8 blocks shown in FIG. 5C , in accordance with the transfer bandwidth information, and outputs a macro-block MB' including the four blocks of the luminance signal Y and the four blocks of the compressed color differential signals Cr and Cb. The encoding of each of the blocks constituting the macro-block MB' is performed by means of the process as described above.
[0069] Next, the method of compressing the color differential signals Cr and Cb in the color compression unit 106 a is described below.
[0070] The color differential signals Cr and Cb each have 8 bits describing 256 possible shades. If the color compression unit 106 a estimates, on the basis of the input transfer bandwidth information, that sufficient bandwidth for transmitting a color moving picture in full is available, then the color compression unit 106 a outputs the color differential signals Cr and Cb directly in the form of 8-bit data without compression.
[0071] On the other hand, if the color compression unit 106 a estimates, on the basis of the input transfer bandwidth information, that sufficient bandwidth for transmitting a color moving picture in full is not available, then the color compression unit 106 a reduces the number of bits of the color differential signals Cr and Cb, as the transfer bandwidth becomes narrower, as shown in FIG. 7 .
[0072] In this case, the number of bits is reduced by removing a bit(s), starting from the low bit of the 8 bits, by means of a bit shift operation. Thereby, as the transfer bandwidth narrows, the image gradually approaches a black-and-white image. In the case of the 4:2:2 format shown in FIG. 5C , if the image completely becomes a black-and-white image (if there are no longer any blocks of the color differential signals Cr and Cb), then the number of blocks constituting the macro-block MB' is reduced to one half of that of the macro-block MB, and the data volume can be reduced to one half.
[0073] The encoding unit 11 a adds compression information indicating how the color differential signals Cr and Cb have been compressed, to the encoded data. The information relating to the compression of the color information may be shared previously between the communication terminals. The encoding unit 11 b on the receiving side decodes the encoded data on the basis of the information about the compression that has been sent (or previously shared).
[0074] The moving picture communication system according to the present invention is particularly valuable as a communication system between persons having hearing difficulties. More specifically, persons having hearing difficulties communicate with each other by exchanging sign language and gestures, and in this case, it needs to accurately recognize the person's manual gestures in detail. In the moving picture communication system according to the present invention, the color information is reduced in accordance with the transmission bandwidth, but the frame rate and resolution of the moving picture are not reduced. Therefore, even if detailed manual gestures are performed rapidly, these gestures can be reproduced smoothly and with good resolution.
[0075] In the present embodiment, the bandwidth estimation unit estimates the transfer bandwidth of the communication path, on the basis of the jitter, but the invention is not limited to this, and it is also possible to monitor the transferred packets of a color moving picture and to estimate the transfer bandwidth on the basis of the related delay information (time stamp differential), by means of the bandwidth estimation units that are synchronized in terms of time between the communication terminals.
[0076] Moreover, in this embodiment, a 4:2:2 format is described as an example of an image format including luminance information and two types of color information, but the invention is not limited to this, and a 4:2:0 (4:1:1) or 4:4:4 (1:1:1) format may also be used.
[0077] Further, the color differential signals are described as an example of color information, but the invention is not limited to this. In the color space represented by the luminance, the saturation and the hue, it is possible to reduce the color information including the saturation or the hue, or the color information including both the saturation and the hue.
[0078] Furthermore, the method of encoding the color moving picture is not limited to the above embodiment.
[0079] It should be understood that there is no intention to limit the invention to the specific forms disclosed, but on the contrary, the invention is to cover all modifications, alternate constructions and equivalents falling within the spirit and scope of the invention as expressed in the appended claims.
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The moving picture communication system comprises communication terminals configured to mutually send and receive a color moving picture including luminance information and color information through a network to which the communication terminals are connected. Each of the communication terminals comprises: a transfer bandwidth information acquisition device which acquires transfer bandwidth information representing a bandwidth of a communication path through which the color moving picture is sent and received; a color information compression device which compresses the color information of the color moving picture in accordance with the transfer bandwidth information acquired by the transfer bandwidth information acquisition device; an encoding device which encodes the color moving picture outputted from the color information compression device; a transmission device which transmits the color moving picture encoded by the encoding device; a reception device which receives the encoded color moving picture transmitted from another of the communication terminals; a decoding device which decodes the encoded color moving picture received by the reception device; and a color moving picture output device which outputs the color moving picture decoded by the decoding device.
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TECHNICAL FIELD
This invention relates to the art of implements, which may be attached to a vehicle, for moving an object.
BACKGROUND ART
A commonly used vehicle for moving earth is a bulldozer. A bulldozer is usually fitted with a blade which is attached to the bulldozer by a pair of arms. Each of the arms is pivotally attached to the bulldozer at one end, and the blade may be raised or lowered relative to the bulldozer.
A known device for digging-out rocks is a ripper which attaches to the rear of a vehicle, such as a bulldozer. In order to remove a boulder, the bulldozer straddles the buried boulder, allowing the tooth of the ripper to engage the boulder as the bulldozer passes over it.
Devices are also known which extend outwardly from the blade of a bulldozer for shaping a slope.
U.S. Pat. No. 3,429,381 shows a slope blade (for a bulldozer) which comprises a blade pivotally mounted to a hinge, which is pivotally mounted for rotation about a vertical axis. A hydraulic cylinder extends from the hinge to the blade to pivot the blade about a horizontal axis, and an adjustable arm extends from another arm (attached to the bulldozer) to the blade for adjustment of the blade about a vertical axis.
U.S. Pat. No. 3,430,706l shows an attachment which is pivotally mounted to a bulldozer blade. The attachment rotates about a vertical axis in response to the extension of a hydraulic cylinder.
U.S. Pat. No. 3,464,499 shows a blade for shaping a slope. The blade is attached to a bulldozer arm and is rotatable about a horizontal axis which is generally parallel to the direction of the arm.
U.S. Pat. No. 4,079,791 shows an adjustable blade for attachment to a bulldozer. The blade is pivotally mounted for rotation about a horizontal axis in response to action of a hydraulic cylinder.
STATEMENT OF THE INVENTION
When moving earth to provide a slope, the slope is typically cut in a stairstep manner also known as a serration cut. Thus, earth is moved out of horizontal volumes the height of one step, and each succeeding horizontal volume is horizontally displaced the width of the step. This technique leaves a triangular-shaped step which can be graded later to produce a smooth slope.
It is common to have boulders embedded in the earth being moved, and these boulders are typically moved by the use of a ripper which descends from the rear of a bulldozer. The bulldozer must drive over the boulder so that the ripper can engage the boulder, to break the boulders up.
In some instances, a boulder or other objects is embedded in the triangular-shaped stairstep volume after the horizontal volume of dirt has been removed. In this instance, the removal of a boulder is quite difficult, since it would require to bulldozer to back up the slope to engage the conventional ripper with the boulder. Slopes are typically too steep for this to be convenient and thus the operator of the bulldozer must rearrange the earth to allow the bulldozer to approach the boulder properly. This process usually involves pushing earth back into the area which had previously been excavated to provide a ramp upon which the bulldozer can approach the boulder. This process takes time and resources, and hence is expensive.
The invention is a device which attaches to the side of a bulldozer, preferably to an arm which supports a blade. The apparatus of the invention has a ripper which extends from a first arm of the apparatus, for engaging the boulder or other objects to be removed. The first arm supporting the ripper is pivotally attached to a second arm which is in turn pivotally attached to a main support bracket which is fixed to the bulldozer arm. The second arm is rotated with respect to the main support bracket by means of a hydraulic cylinder, and the first arm is rotated with respect to the second arm by means of another hydraulic cylinder. The ripper is secured in the first arm by means of a pin which may be retracted so that the extent to which the ripper extends from the arm may be adjusted.
It is an object of this invention to provide a ripper for engaging objects to be removed from soil and which extends from the side of an earth-moving vehicle.
It is an object of this invention to provide an apparatus for removing objects from the earth and employing a ripper which is pivotally attached to a vehicle.
It is a further object of this invention to provide a method for removing objects from the earth with a vehicle moving in a direction along a contour of a slope.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top view of a bulldozer showing the invention attached thereto.
FIG. 2 is a perspective view of the apparatus of the invention.
FIG. 3 is an end elevation view of the apparatus of the invention.
FIG. 4 is a perspective view of an arm of the invention.
FIG. 5 is a cross-section of an arm of the invention taken through line 5--5 of FIG. 4.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows how the apparatus of the invention may be employed to remove an object, such as rock 5, which is embedded in a slope adjacent a bulldozer 1. The apparatus of the invention allows the bulldozer to approach the object to be removed by driving along, or parallel to, the contour of the slope.
FIG. 2 shows a perspective view of the apparatus of the invention. A main support bracket 2, shown attached to an arm 3, includes a rectangular portion 4 and main support arms 8 and 10. The rectangular portion 4 is adapted to be fixed to the side of a piece of heavy equipment, for example the arm of a bulldozer. The rectangular portion may be attached by any known method, for example by bolting or by welding.
The main support arms 8 and 10 are shown tilted at an angle of about 60°, but may be at other angles, depending on the particular circumstances. A first hydraulic cylinder 12 is pivotally mounted between the main support arms 8 and 10. The main support bracket 2 also includes a plurality of bosses 14 which provide a hinge. Pivotally attached to the main support bracket 2 is a first arm 16. This first arm is pivotally attached at one end to the main support bracket 2 by a hinge pin 18 which passes through the bosses 14 and holes in one end of the first arm 16. The first arm 16 may comprise a plurality of elements extending parallel to each other, as shown in FIG. 1, or may be of other suitable construction.
The first hydraulic cylinder 12 is attached to the main support bracket 2 at one end, and to the first arm 16 at its other end. As shown in FIG. 2, the cylinder is attached between main support arms 8 and 10 by a pin 11, and is attached to arm 16 by a pin 13 extending through mounting blocks 15 which are fixed to arm 16.
A second arm 20 is pivotally attached to the other end of the first arm 16. A hinge pin 22 passes through holes in the first and second arms to provide the pivotal connection. Second and third hydraulic cylinders 24 extend between the first arm 16 and the second arm 20 for controlling the angular relationship between these arms. The respective ends of the hydraulic cylinders are pivotally mounted on blocks 26 on arm 16 and on brackets 28 on arm 20.
Ripper 30 is mounted on arm 20. Ripper 30 projects from the arm 20 in a direction which is generally perpendicular to the plane of arm 20. The ripper 30 is curved at one end, to produce a J-shaped claw section, so that the ripper is useful for removing objects from the earth. The ripper includes a removable tooth 32 and a replaceable wear plate 34 on the shank, which provides for easy repair of the ripper.
The hydraulic cylinders 12 and 24 are controlled by a mechanism, which has not been illustrated, and which is usually located adjacent the operator in the cab of the vehicle carrying the inventive apparatus. The operating mechanism may, for example, be a joy stick wherein movement in one direction activates hydraulic cylinder 12 and movement in a transverse direction activates the hydraulic cylinders 24.
FIG. 3 shows the apparatus of the invention wherein the first arm 16 is generally horizontal and the second arm 20 is generally vertical, having been rotated to this position by the retraction of hydraulic cylinders 24. The ripper 30 is then generally horizontal and is in position for engaging an object embedded in a vertical portion of the earth.
As seen in FIGS. 2 and 3, the apparatus of the invention allows the ripper 30 to be oriented at a number of angles. The ripper is oriented in FIG. 2 for grasping objects located under a horizontal surface, whereas the ripper in FIG. 3 is oriented to remove an object from a vertical surface. Clearly, the ripper may be oriented to grasp an object in orientations other than these two specific ones, depending only upon the design parameters of the hydraulic cylinders.
FIG. 4 shows a perspective view of the second arm of the invention illustrating how the ripper 30 is retained in the support plate 36. The ripper is shown in phantom lines inserted in the support plate, and one of the elements of arm 20 is shown in vertically position. The shank of the ripper 30 has a hole 40 for receiving a pin 42. The pin 42 is connected to a lever 44 which is pivotally attached to the arm 20 by a hinge pin 46. The opposite end of the lever 44 is connected to a fourth hydraulic cylinder 48, which is mounted by bracket 50. Activation of the hydraulic cylinder 48 moves pin 42 to either engage or disengage the hole 40 in the shank of the ripper 30. When the pin 42 engages the hole 40 in the shank of the ripper, the ripper is held secure in the arm 20. On the other hand, when the pin is withdrawn from the hole 40, the ripper may be moved with respect to the arm 20. The weight of the ripper will move it downward whereas upward movement is accomplished by operating the hydraulic cylinders to push the ripper against the ground. Thus, the extent to which the ripper projects from arm 20 may be adjustable by providing a plurality of holes for engaging with the pin 42. The ripper 30 may also be removed from the arm 20 by withdrawing the pin 42.
FIG. 5 shows a cross-sectional view of the second arm 20. This arm includes a support plate 36 which forms a hole 38 for receiving the shank of the ripper 30. The support plate is attached to the arm 20 by brackets 37 or other suitable means, or may be integrally formed therewith. The plate 36 has a thickness adequate to support the ripper 30, and the plate 36 may also include an extension (not shown) which extends above the second arm 20 to give additional support to the shank of the ripper 30.
The hydraulic cylinders 12 and 24 may be controlled by a known automatic levelling system which operates to maintain a given position of the ripper for various attitudes of the vehicle.
It is clear that a bulldozer, or other vehicle may have an apparatus of the invention on each side of the bulldozer, and may have more than one on each side.
As will be appreciated by those of skill in the art, the apparatus of the invention represents a significant improvement over the prior art. Instead of having to build a ramp to facilitate the bulldozer's approach to the object for use of the conventional implement, the bulldozer need only approach the object to be removed by driving along, or parallel to, the slope. The ripper may then be oriented to grasp the object, and the force of the ripper on the object will remove it, whether the object is on a slope or conventionally rough or smooth terrain at ground level and/or below ground.
While a particular embodiment of the invention has been shown and described, it should be understood that other embodiments covered by the claims will be apparent to those of skill in the art.
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Apparatus is provided for moving objects which may be partially buried. The apparatus comprises a hook-like element which may be attached to the side of a vehicle, such as a bulldozer. The hook-like element is pivotally attached so that its orientation is adjustable.
A method of moving objects is disclosed where a hook-like element extending from the side of a vehicle engages the objects to be moved.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional Application No. 62/286,424, filed Jan. 24, 2016.
FIELD OF THE INVENTION
[0002] The invention relates generally to communication systems, and specifically to messaging platforms for commerce.
BACKGROUND
[0003] Consumer interest in interacting with commercial entities over non-traditional mediums has increased dramatically in recent years. Although telephone communication remains the primary method by which consumers interact with physical and non-physical (e.g. online) merchants, inherent limitations in the technology prevent novel, impactful functionality from being introduced over the same medium. Additionally, the rapid growth of smartphone usage means that many customers have access to internet-enabled smartphones and increasingly prefer to use these devices to interact not only with friends but also with merchant entities.
[0004] Text-based communication, otherwise known as messaging, has long been popular with smartphone users as a means of communicating with friends and relatives. Consumers now increasingly prefer to use this same medium to interact with merchant entities. Consumers further desire this messaging medium to incorporate multimedia such as images, video, audio, and maps, as well as button-based transactional capability, to augment and improve the user experience.
SUMMARY
[0005] Consumers communicate with vendors and conduct transactions over a commerce-messaging medium. The messaging medium is enabled by a platform that includes a back-end system, mobile applications, and browser-based or desktop applications. Consumers can engage directly with vendor owners, employees, or representatives to conduct transactions. Consumers can engage with intermediary vendors who facilitate transactions with peer vendors or external vendors. The platform provides a programmatic interface for vendors to integrate automated business operations, such as customer outreach, marketing, and sales operations, into the commerce-messaging medium.
DESCRIPTION OF DRAWINGS
[0006] FIG. 1 is a diagram of a commerce messaging platform, according to one embodiment.
[0007] FIG. 2 is a diagram of a vendor services API layer, according to one embodiment.
[0008] FIG. 3 is a diagram of a registered vendor, according to one embodiment.
[0009] FIG. 4 is a diagram of a transaction process involving a user and a registered vendor, according to one embodiment.
[0010] FIG. 5 is a diagram of a transaction process involving a user and a non-registered vendor, according to one embodiment.
DETAILED DESCRIPTION
[0011] FIG. 1 depicts the environment of a commerce-messaging platform 100 (or “platform”). The platform 100 enables users 130 to interact with registered vendors 140 via a commerce-messaging medium (or “messaging medium” or simply “medium”). A registered vendor 140 represents a real business with a physical and/or online presence. For example, the registered vendor 140 could be (a) purely physical, like a neighborhood dry cleaner, (b) purely online, like a web hosting company, (c) or physical and online, such as a retailer with both a physical store location and a virtual online store. A user 130 creates a registered vendor 140 , as will be described in detail later.
[0012] In order to enable communication between users 130 over the messaging medium as described previously, the platform 100 includes a back-end system 102 , a client mobile application 104 , and a client terminal 106 . The back-end system 102 , client mobile application 104 , and client terminal 106 are developed, maintained, and/or administered by a single enterprise. The client mobile application 104 executes on a mobile device, smartphone, or other Internet-enabled device. Users 130 utilize the client mobile application 104 to enter and send messages, view received messages, and view previously sent messages. Users 130 also utilize the client mobile application 104 to search for and select registered vendors 140 . In one embodiment, the client mobile application 104 allows the user 130 to send the same message to multiple registered vendors 140 at the same time. Users 130 can also create a new registered vendor 140 using the client mobile application 104 . The client terminal 106 is a desktop, mobile, or browser-based application that is operated by a user 130 and executes on a computing device associated with a registered vendor 140 . In one embodiment, a user 130 associated with a registered vendor 140 uses the client terminal 106 to view and respond to messages received by the registered vendor 140 . In the example of FIG. 1 , user 130 b associated with registered vendor 140 uses the client terminal 106 to view and respond to messages sent to registered vendor 140 by user 130 a. Additionally, multiple instances of the client terminal 106 may execute concurrently, allowing multiple users 130 , each associated with the same registered vendor 140 , to receive and respond to messages simultaneously.
[0013] In order to enable users 130 to interact with registered vendors 140 via the messaging medium of the platform 100 , the back-end system 102 includes a user database 108 , a vendor database 110 , a transaction database 112 , a messaging server 114 , a mobile client API layer 116 , a vendor services API layer 118 , a rules engine 120 , and a transaction server 122 .
[0014] The user database 108 stores personal information and account information for each user 130 , such as name, location, email, and so on. The vendor database 110 stores information describing each registered vendor 140 in the platform 100 , including the vendor's name, category, location, hours, and associated users 130 . The transaction database 112 stores information describing each transaction conducted between users 130 and registered vendors 140 , including the amount of the transaction, the product or service which was purchased, the time and date of the transaction, and an identification of all of the users 130 involved in the transaction (including those associated with the registered vendor 140 ).
[0015] The messaging server 114 may be implemented according to one of a number of protocols. Some examples include but are not limited to XMPP and Web Sockets. The messaging server 114 is configured to organize, archive, and route messages sent between users 130 of the platform 100 . The messaging server 114 may be configured to support multimedia messaging which includes text, images, video, and other forms of multimedia content such as emojis, GIFs, and so on.
[0016] The mobile client API layer 116 is configured to provide a standardized interface through which the client mobile application 104 and client terminal 106 can interact with the back-end system 102 . The client mobile application 104 and client terminal 106 may be configured to use the mobile client API layer 116 to (among other functions) search for registered vendors 140 , retrieve and edit user and vendor information, and initiate and process transactions.
[0017] The vendor services API layer 118 is configured to provide a standardized interface through which registered vendors 140 can consume additional services provided by the back-end system 102 . These services, which will be described in detail later, may be used to augment, enhance, or complement the messaging functionality provided to registered vendors 140 .
[0018] The rules engine 120 is configured to control the operations of and interactions between each of the components of the back-end system 102 . In a typical embodiment, the rules engine 120 contains business logic that governs how users 130 and registered vendors 140 may interact with one another. The rules engine 120 also controls data transfer and organization within the user database 108 , vendor database 110 , and transaction database 112 . The rules engine 120 additionally facilitates the execution of payment transactions involving the transaction server 122 . Finally, the rules engine 120 manages requests for data or operations received from client applications (such as the client mobile application 104 and client terminal 106 ) via the mobile client API layer 116 and vendor services API layer 118 .
[0019] The transaction server 122 is configured to control, monitor, and facilitate payment transactions between users 130 and registered vendors 140 . The transaction server 122 is configured to interact with the transaction database 112 , for purposes of carrying out transactions as well as storing and editing transaction records. The transaction server 122 is also configured to interact with external payment gateways or other payment processing services to facilitate payment transactions.
[0020] In a typical embodiment, a user 130 sends a request in the form of a message (or “query”) to one or more registered vendors 140 . The message describes a request for a product or service (or information about the registered vendor 140 ). The message is received by the user(s) 130 who are associated with each recipient registered vendor 140 . In the example depicted in FIG. 1 , a message sent by user 130 a to registered vendor 140 is received by user 130 b. User 130 b may be an owner or employee of the registered vendor 140 . User 130 a may be a customer inquiring about a product or service offered by the registered vendor 140 . Users 130 a and 130 b may subsequently communicate via the messaging medium.
[0021] It should be noted that in the example embodiment of FIG. 1 , User 130 a may or may not be associated with another registered vendor 140 . Additionally, multiple users 130 may be associated with registered vendor 140 .
[0022] All entities and components described with reference to FIG. 1 , including those contained within the back-end system 102 , are configured to communicate and/or interact with one another. For the sake of simplicity, communication connections between each of these components are not depicted.
[0023] The vendor services API layer 118 , described with reference to FIG. 1 , is an interface through which registered vendors 140 can utilize the platform 100 (more specifically, the messaging medium that it enables) as a customer-engagement channel for a multitude of automated or system-driven processes. In a typical embodiment, a registered vendor's business activities include system-driven processes such as customer outreach and feedback, marketing efforts, sales operations, account management, and so on. Traditionally, these and other business activities are entirely automated, operating without direct human involvement, and rely on email as a medium for engaging users. The vendor services API layer 118 allows registered vendors 140 to use the messaging medium enabled by the platform 100 as a primary means for engaging users 130 .
[0024] In one embodiment, the vendor services API layer 118 includes a message automation portal 202 , a transaction portal 204 , and an input request portal 206 . Each portal serves as an interface for a class or category of system-driven processes belonging to a registered vendor 140 . In a typical embodiment, the registered vendor 140 submits content, such as an account management message or promotional advertisement, to the portal. It is then received and processed by the rules engine 120 . The rules engine 120 may interact with the messaging server 114 , transaction server 122 , and databases ( 108 , 110 , 112 ) to relay the content to one or more users 130 . Specifically, the content is transmitted to and displayed within the client mobile application 104 . The content may be displayed as part of a persisted “conversation”. The conversation includes a user 130 and the registered vendor 140 which originated the content, and displays all communication between the two parties from some time in the past to the current time. Some of this communication may include text-based “human-to-human” communication between the user 130 and an owner, employee, or representative of the registered vendor 140 .
[0025] The message automation portal 202 allows a registered vendor 140 to transmit automated messages to a user 130 over the messaging medium. These messages can be periodic or repetitive. Some examples of automated messages that could be transmitted through the message automation portal 202 include monthly statements, order confirmations, tickets and boarding passes, and general marketing/outreach content.
[0026] The transaction portal 204 allows a registered vendor 140 to initiate and execute a transaction involving a user 130 via the messaging medium. In one embodiment, if a user 130 wishes to purchase a product or service from a registered vendor 140 , the registered vendor 140 may initiate a transaction via the transaction portal 204 . The user 130 receives, on his/her client mobile application 104 , details describing the intended transaction as well as a request to approve the transaction.
[0027] The input request portal 206 allows a registered vendor 140 to transmit requests for user input via the messaging medium. Requests for user input may include requests for account verification, other account management requests, and requests for customer feedback (e.g., surveys and questionnaires).
[0028] Registered vendors 140 , as described previously with reference to FIGS. 1 and 2 , receive messages sent by users 130 of the platform 100 . In a typical embodiment, other users 130 associated with a registered vendor 140 receive and respond to these messages.
[0029] In one embodiment, a registered vendor 140 receives a high volume of messages from users 130 and must service them at an elevated rate (known as a “high throughput” situation). In this instance, a registered vendor 140 may maintain a customer service organization consisting of one or more representatives. These representatives collaborate to service each request received by the registered vendor 140 .
[0030] FIG. 3 . includes a user 130 a engaged in communication with a registered vendor 140 a. The user 130 a, via the client mobile application 104 executing on his/her smartphone or mobile device, sends a request to the registered vendor 140 a. As described previously, the registered vendor 140 a is configured to service a high volume of requests from other users 130 . The request sent by user 130 a is first received by a connection manager 304 .
[0031] The connection manager 304 may be implemented by a combination of software and/or hardware, and is configured to route the request to one of multiple representatives associated with the registered vendor 140 a. In the example of FIG. 3 , registered vendor 140 a includes a representative pool 302 . The representative pool 302 further includes three representatives 306 a, 306 b, and 306 c, each operating an instance of the client terminal 106 (a registered vendor 140 can contain hundreds or even thousands of representatives). In the example of FIG. 3 , representative 306 a uses client terminal 106 a, representative 306 b uses client terminal 106 b, and representative 306 c uses client terminal 106 c. It should be noted that representative pool 302 can be a virtual or physical entity. In one embodiment, representative pool 302 is simply a physical space shared by the representatives 306 . In another embodiment, representative pool 302 is a virtual space that each representative 306 accesses remotely.
[0032] The request sent by user 130 a is routed by the connection manager 304 to one of the available representatives 306 . In the example of FIG. 3 , the request is routed to representative 306 a. Representative 306 a can service the request in multiple ways. In one embodiment, representative 306 a services the request by referencing an internal information source specific to the registered vendor 140 a. For example, if the user 130 a is inquiring about the delivery status of a recent order, the representative 306 a may consult an internal order tracking system. Or, if the user 130 a requests specific information regarding customization options for one of the products offered by the registered vendor 140 a, the representative 306 a may consult another employee who is knowledgeable on the subject.
[0033] Representatives 306 may also contact other registered vendors 140 in order to service a request. As shown in FIG. 3 , representative 306 a contacts registered vendor 140 b. This contact may occur in multiple channels, including over the phone, via a website published by registered vendor 140 b, or by sending a message within the platform 100 to the registered vendor 140 b. If representative 306 a sends a request via messaging, then a user 130 or representative 306 a associated with vendor 140 b can receive and respond to the request.
[0034] Representatives 306 may also contact non-registered vendors 140 in order to service a request. Non-registered vendors 340 are considered “external” or “unaffiliated”, and as such, cannot be contacted via the platform 100 . As shown in FIG. 3 , representative 306 a contacts a non-registered vendor 340 . This contact occurs according to traditional channels, including over the phone or via a website published by non-registered vendor 340 .
[0035] In some embodiments, a registered vendor 140 is staffed, maintained, and operated by the same enterprise that develops and maintains the back-end system 102 , client mobile application 104 , and client terminal 106 . This registered vendor 140 is identified as a “concierge” service or “concierge vendor”. The concierge vendor may field general or non-specific requests from users 130 and representatives of the concierge vendor may fulfill these requests by contacting other registered vendors 140 or non-registered vendors 340 . The concierge vendor facilitates transactions between users 130 and non-registered vendors 340 (as will be described in detail later).
[0036] As described previously, users 130 can purchase products or services from registered vendors 140 over the messaging medium enabled by the platform 100 .
[0037] FIG. 4 depicts an example embodiment of a transaction conducted between a user 130 and a registered vendor 140 via the back-end system 102 of the platform 100 . Using the client mobile application 104 on his/her smartphone device, a user 130 sends 402 a request for a product or service to a registered vendor 140 . The registered vendor 140 services 404 the request. As described previously, the actual servicing may be carried out by a user 130 or representative 306 associated with the registered vendor 140 . If the request concerns a product or service that is available from the registered vendor 140 , the registered vendor 140 then generates 406 a transaction.
[0038] Generation of a transaction may be accomplished in one of multiple ways. In one embodiment, a representative 306 directs a computer server of the registered vendor 140 to generate a transaction via the transaction portal 204 within the vendor services API layer 118 of the back-end system 102 (first described with reference to FIG. 2 ). Or, in another embodiment, the representative 306 utilizes his/her client terminal 106 to generate the transaction via the transaction portal 204 . As part of generating a transaction, the representative 306 enters specific details describing the transaction, such as the product or service being purchased, the amount and currency of the transaction, and an identification of the buyer and the representative 306 .
[0039] The back-end system 102 receives the transaction via the transaction portal 204 of the vendor services API layer 118 . The transaction server 122 of the back-end system 102 may perform verification, risk analysis, or other pre-processing steps to determine the legitimacy of the intended transaction. The back-end system 102 subsequently transmits 408 the transaction details as well as an approval request to the user 130 . As described with reference to previous figures, the transaction details and approval request are displayed within a messaging interface in the client mobile application 104 of the user 130 . In one embodiment, the transaction details and approval request are displayed in the same messaging interface containing the current conversation between the user 130 and the representative 306 . The user 130 reviews and approves 410 the transaction by tapping a button or typing a message. The approval is transmitted 412 from the user 130 to the back-end system 102 .
[0040] The transaction server 122 of the back-end system 102 processes 414 the transaction. In one embodiment, the transaction server 122 charges a payment instrument belonging to the user 130 for the amount of the product or service being purchased and credits an account of the registered vendor 140 with an equal amount. The transaction server 122 may retrieve and edit payment instrument information stored in the transaction database 112 in order to process the transaction. The transaction server 122 also stores a record of the transaction in the transaction database 112 .
[0041] Subsequent to successful completion of the transaction, the back-end system 102 transmits 416 a confirmation message to the registered vendor 140 . The confirmation message may be displayed to the representative 306 in his/her client terminal 106 ; it may also be stored in a computer server of the registered vendor 140 as part of regular transactional recordkeeping. The back-end system 102 then transmits 418 a confirmation message to the user 130 . The confirmation message is displayed in the client mobile application 104 of the user 130 . The confirmation message may be displayed in the same messaging interface containing the conversation between the user 130 and the representative 306 .
[0042] Asynchronously, the registered vendor 140 delivers 420 the product or service to the user 130 . Delivery of the product or service can be carried out according to existing order fulfillment processes.
[0043] As described previously, registered vendors 140 can facilitate transactions involving users 130 and non-registered vendors 340 .
[0044] FIG. 5 depicts an example embodiment of a transaction involving a user 130 and a non-registered vendor 340 , and facilitated by a registered vendor 140 via the back-end system 102 . Using the client mobile application 104 on his/her smartphone device, a user 130 sends 502 a request for a product or service to a registered vendor 140 . The registered vendor 140 services 504 the request. As described previously, the actual servicing may be carried out by another user 130 or representative 306 associated with the registered vendor 140 . The nature of the request may require it to be fulfilled by a non-registered vendor 340 .
[0045] Accordingly, the registered vendor 140 identifies 506 one or more non-registered vendors 340 to which to forward the request. The registered vendor 140 forwards 508 the service request to these non-registered vendors 340 via existing channels (phone and/or web). Forwarding of the request can be accomplished in one of multiple ways. In one embodiment, a representative 306 contacts each non-registered vendor 340 by telephone and negotiates directly with a representative of the non-registered vendor 340 . In another embodiment, the representative 306 accesses a website of the non-registered vendor 340 and determines if the non-registered vendor 340 is capable of fulfilling the request. If one of the non-registered vendors 340 indicates that it is able to fulfill the request, or if the representative 306 of the registered vendor 140 determines that a non-registered vendor 340 is able to fulfill the request, then the registered vendor 140 proceeds to generate 512 a transaction.
[0046] As described with reference to FIG. 4 , generation of a transaction may be accomplished in one of multiple ways. In one embodiment, a representative 306 directs a computer server of the registered vendor 140 to generate a transaction via the transaction portal 204 within the vendor services API layer 118 of the back-end system 102 (first described with reference to FIG. 2 ). In another embodiment, the representative 306 generates the transaction via his/her client terminal 106 , which transmits the transaction to the back-end system 102 via the transaction portal 204 of the vendor service API layer 118 . The generated transaction indicates that the service request is being fulfilled by a non-registered vendor 340 and facilitated by the registered vendor 140 . The generated transaction also includes details describing the transaction, such as the product or service being purchased, the amount and currency of the transaction, an identification of the buyer, an identification of the non-registered vendor 340 , and if applicable, an identification of the representative 306 responsible for facilitating the transaction.
[0047] The back-end system 102 receives the generated transaction via the transaction portal 204 of the vendor services API layer 118 . The transaction server 122 of the back-end system 102 may perform verification, risk-based analysis, or other pre-processing steps to determine the legitimacy of the intended transaction. The back-end system 102 subsequently transmits 514 the transaction details as well as an approval request to the user 130 . As described with reference to previous figures, the transaction details and approval request are displayed within a messaging interface in the client mobile application 104 of the user 130 . In one embodiment (as described with reference to FIG. 4 ), the transaction details and approval request are displayed in the same messaging interface containing the current conversation between the user 130 and the representative 306 . The user 130 reviews and approves 516 the transaction by tapping a button or typing a message. The approval is transmitted 518 from the user 130 to the back-end system 102 .
[0048] The transaction server 122 of the back-end system 102 processes 520 the transaction. In one embodiment, the transaction server 122 charges a payment instrument belonging to the user 130 in the amount of the product or service being purchased and credits an account of the registered vendor 140 with an equal amount. The transaction server 122 may retrieve and edit payment instrument information stored in the transaction database 112 in order to process the transaction. The transaction server 122 also stores a record of the transaction in the transaction database 112 .
[0049] Subsequent to successful completion of the transaction, the back-end system 102 transmits 522 a confirmation message to the registered vendor 140 . The confirmation message may be displayed to the representative 306 in his/her client terminal 106 ; it may also be stored in a computer server of the registered vendor 140 as part of regular transactional recordkeeping. Subsequently, the registered vendor 140 transmits 524 a purchase order to the non-registered vendor 340 indicating the product or service to be purchased. Transmission of the purchase order can be accomplished in multiple ways: for example, by describing a purchase order to the non-registered vendor 340 over the phone, or by placing a purchase order via an online checkout page of the non-registered vendor 340 .
[0050] Subsequently, the non-registered vendor 340 processes 526 the order. At this time, the non-registered vendor 340 may also collect payment from the registered vendor 140 . In one embodiment, the registered vendor 140 acts as a proxy agent for the purchase; in other words, the non-registered vendor 340 treats the registered vendor 140 as the purchaser of the product or service. Accordingly, the non-registered vendor 340 charges a payment instrument associated with the registered vendor 140 . This payment instrument may be stored in perpetuity by the non-registered vendor 340 or it may be provided to the non-registered vendor 340 at the time of purchase. The non-registered vendor 340 returns 528 an order confirmation to the registered vendor 140 .
[0051] The registered vendor 140 transmits 530 an order summary to the back-end system 102 . The order summary includes information such as a description of the product or service, the amount and currency, and the time and date of the purchase. The transaction server 122 of the back-end system 102 records 532 the order summary by creating a new record in the transaction database 112 . The transaction server 122 also verifies that the amount, product description, and other details of the order summary match the transaction conducted previously between the user 130 and the registered vendor 140
[0052] Subsequently, the back-end system 102 transmits 534 an order confirmation message to the user 130 . The order confirmation is displayed in the client mobile application 104 of the user 130 , and indicates what product or service was purchased by the registered vendor 140 on behalf of the user 130 as well as other relevant order details. As described earlier, the order confirmation may be displayed in the same messaging interface containing the conversation between the user 130 and the representative 306 of the registered vendor 140 .
[0053] Asynchronously, the non-registered vendor 340 delivers 536 the product or service to the user 130 . Delivery of the product or service can be carried out according to existing order fulfillment processes.
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A commerce-messaging medium over which consumers interact and transact with vendors is disclosed. The messaging medium is enabled by a platform that includes a back-end system, mobile applications, and browser-based or desktop applications. Consumers engage directly with vendor owners, employees, or representatives to communicate and conduct transactions. Consumers further engage with intermediary vendors who facilitate transactions with peer vendors or external vendors. The platform provides programmatic interfaces for vendors to integrate automated business operations, such as customer outreach, marketing, and sales operations, into the commerce-messaging medium. Messaging associated with automated business operations is transmitted over the medium to consumers.
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TECHNICAL FIELD
[0001] This invention relates to a dispenser for food seasonings that include but which are not limited to salt, pepper, grated onion and grated cheeses, garlic and others. More particularly, this invention relates to dispensing and dispensers for granular seasonings.
BACKGROUND
[0002] It is well known that most restaurants and food services strive to maintain product consistency, reduce preparation time and control production costs. It is also well known that many of the products produced in restaurants and food services are prepared using various types of seasonings.
[0003] Some seasonings are applied simply by tossing them onto the food product. Other seasonings are applied using hand-held shakers. In either case, the amount of the seasoning applied is inconsistent and the seasoning distribution across a food product is not uniform. Stated another way, seasoning application is highly operator-dependant. Product consistency inevitably varies depending on who prepares a seasoned food product.
[0004] Varying and/or uncontrollable food quality is anathema to most restaurants, but especially so to restaurant chains, which strive for consistent product characteristics and quality from outlet to outlet. A seasoning dispenser able to provide consistent and controllable seasoning applications would be an improvement over the prior art.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] FIG. 1 is a perspective view of a preferred embodiment of a seasoning dispenser;
[0006] FIG. 2 is a perspective view of the bottom of the seasoning dispenser shown in FIG. 1 ;
[0007] FIG. 3 is a bottom view of the seasoning dispenser shown in FIG. 1 , looking into the top of the hopper;
[0008] FIG. 4 is an exploded view of the seasoning dispenser shown in FIG. 1 ;
[0009] FIG. 5 is a second exploded view of the seasoning dispenser shown in FIG. 1 viewed from below the bottom of the dispenser;
[0010] FIG. 6 is a perspective view of one embodiment of a rotatable measuring disc used in the seasoning dispenser depicted in FIGS. 1-5 ;
[0011] FIG. 7 is a bottom view of the disc shown in FIG. 6 ;
[0012] FIG. 8 is a bottom view of an alternate embodiment of a disc for use in the seasoning dispenser depicted in FIGS. 1-6 .
DETAILED DESCRIPTION
[0013] FIG. 1 is a perspective view of a preferred embodiment of a seasoning dispenser 10 . The dispenser 10 is comprised of a hopper 12 which preferably has an open top covered by a removable lid 14 . The hopper 12 is removably attached to a dispenser body or base, identified by reference numeral 15 . The attachment of the hopper 12 to the base 15 is best seen in the exploded views, which are described below.
[0014] The lid 14 is preferably attached to the hopper 12 through a hinge, not shown in FIG. 1 because of the angle from which the dispenser 10 is viewed in the figure. The lid hinge allows the lid 14 to be opened and closed in order to permit the hopper 12 to be re-filled with seasoning. In alternate embodiments, the lid 14 is snapped into place over a lip formed into or along the top edge (not shown) of the hopper 12 . In yet another embodiment, the lid 14 is hingedly attached to the dispenser handle 16 . In yet another embodiment, a single-use hopper 12 is filled once and the top is sealed. When seasoning in the single-use hopper 12 is consumed or if it loses flavor, a new single-use sealed hopper 12 or a re-usable hopper 12 can be installed into the base 15 and the single-use hopper discarded.
[0015] Seasonings are dispensed from the dispenser 10 by a user operating an L-shaped actuator 20 , best seen in FIG. 2 . The vertex 19 of the actuator 20 is provided with a pair of hinge pins 29 (See FIG. 4 .) that extend outwardly from the body of the actuator and which ride in actuator hinge pin receptacles 28 . Neither the L-shape of the actuator 20 , the hinge pins 29 nor the receptacles 28 are visible in FIG. 1 but can be seen in the other figures described below.
[0016] The actuator 20 is preferably molded plastic. The hinge pins 29 , which extend outwardly from the sides of the actuator 20 and which allow the actuator to rotate are preferably formed during the same molding process and in a sense, become part of the actuator 20 .
[0017] The handle 16 and the dispenser base 15 , which are also best seen in the exploded figures are also preferably molded plastic. The aforementioned actuator hinge receptacles are therefore also preferably formed during the same molding process. In a sense, the receptacles become part of the molded handle/base structure.
[0018] FIG. 2 is a perspective view of the seasoning dispenser 10 looking upward toward the bottom of the dispenser 10 including a granular dispensing screen 22 through which dispensed seasonings pass. The terms, granular dispensing screen, dispensing screen and screen are used interchangeably.
[0019] FIG. 2 shows that the overall shape of the actuator 20 can be seen to resemble the upper case letter L, the long arm of which is beneath the handle 16 , the short arm of which extends downward. In addition to showing the granule dispensing screen 22 , FIG. 2 also shows an actuator return spring 30 , and a torque arm 36 coupled to the bottom end 31 through a connecting rod 33 .
[0020] The torque arm 36 is connected to the spindle, which is also referred to interchangeably herein as an axis or central axis 34 , of a rotatable, seasoning-measuring disc, not seen in FIG. 1 or FIG. 2 because it is above the screen 22 . The axis 34 extends downwardly from the seasoning measuring disc and through the screen 22 as shown. Rotation of the torque arm thus effectuates a corresponding rotation of the seasoning measuring disc.
[0021] The dispensing screen 22 is preferably formed as part of the base 15 and handle 16 , to reduce manufacturing costs, simplify assembly of the dispenser 10 and improve reliability. In an alternate embodiment the dispensing screen 22 can be formed as a separate part that fits inside the dispenser base 15 .
[0022] The dispensing screen 22 has several round seasoning-dispensing through-holes 24 . The terms seasoning-dispensing through-holes, dispensing through-holes and holes are used interchangeably.
[0023] Seasoning dispensing through-holes 24 are grouped or clustered together between un-perforated areas referred to herein as “lands” that are identified in the FIGS. by reference numeral 26 . Granules from the seasoning measuring disc fall through the seasoning dispensing through-holes 24 and onto a food product. The lands 26 are preferably solid to strengthen the screen 22 but more importantly to stop granules from flowing out of the dispenser 10 when the actuator 20 is “down,” at its initial or starting position.
[0024] Some granules from the seasoning-measuring disc can migrate to the disc's perimeter and cause the disc to bind. The screen 22 is therefore also provided with additional by-pass dispensing holes 25 that are formed into the screen 22 and located just inside the perimeter 27 of the screen 22 . In the preferred embodiment, the by-pass holes 25 are the same size and shape as the seasoning dispensing through-holes 24 . As described below, the screen perimeter-located by-pass holes 25 provide an exit pathway for granules that miss one of the seasoning dispensing through-holes 24 . The bypass holes thus reduce the likelihood that granules will accumulate above the screen 22 and jam the rotating dispensing disc. In an alternate embodiment, the bypass holes 25 are larger than the seasoning-dispensing through-holes 24 . In yet another embodiment, the by-pass holes 25 are not holes per se but are formed as open slots, not shown, or sections of an arc that are open and which follow the curvature of the inside of the body 15 , also not shown. The width of the slots or of the open arc sections, are selected to allow granules to fall through them. For purposes of claim construction, by-pass holes should be considered to include at least holes of all cross sectional shapes and diameters as well as straight slots and arcuate-shaped slots.
[0025] It can be seen from FIG. 2 that when the long arm of the L-shaped handle actuator 20 is pulled upwardly, the actuator 20 pivots on the hinge pins 29 located at the vertex 19 . Translation of the bottom end 31 of the short arm of the actuator 20 away from the base 15 and the screen 22 causes the connecting rod 33 to pull the torque arm 36 . Rotation of the torque arm 36 around the axis 34 rotates a seasoning-measuring disc, described below and depicted in FIGS. 4 , 5 and 6 . Squeezing the handle actuator 20 upwardly thus causes the seasonings to be dispensed by causing the aforementioned disc to rotate from a starting position, through an angle to a second position. The return spring 30 in the handle 16 causes the actuator 20 to move back, downwardly from the handle 16 , causing the bottom end 31 of the short end of the actuator 20 to move back toward the base 15 and toward the screen 22 and axis 34 . The force provided by an operator and the return force provided by the return spring 30 thus enable the actuator to oscillate up and down, which causes the torque arm 36 to oscillate back and forth between a starting and ending position, which causes the disc, not shown in FIG. 2 to rotate between a starting and an ending position.
[0026] Controlled measurement and distribution of seasonings from the dispenser 10 can be better understood by starting the description of the dispenser's operation with an inspection of FIG. 3 , which is a bottom view of the hopper 12 showing several elongated openings 38 formed into the bottom of the hopper 12 . The elongated openings 38 shown in FIG. 3 are substantially “pie-shaped” and the dimensions and shapes of them are empirically determined to allow granules stored in the hopper 12 to freely pass through the elongated openings 38 of the hopper 12 .
[0027] FIG. 4 is an exploded view of the seasoning dispenser 10 shown in FIG. 1 , taken from above the hopper and looking downward toward the screen 22 . The lands 26 between the groups of holes 24 can be seen in FIG. 4 .
[0028] In FIG. 4 , the hopper 12 is shown with the lid 14 in place. FIG. 4 also shows one of at least two engagement tabs 13 that are formed as part of the hopper 12 and which are sized and arranged to lockingly engage mating slots 9 formed into the interior of the base 15 and handle 16 . One of the slots 9 in the base 15 that mate with a tab 13 , is visible in FIG. 4 .
[0029] The dispenser bottom or base 15 and the handle 16 are preferably molded at the same time to form a single unitary structure. The two actuator hinge pin receptacles 28 that receive the hinge pins 29 are also formed at the same time such that they are part of the body/handle structure. In an alternate embodiment, the base 15 and the handle 16 are formed separately and fastened together by an adhesive or other fastening mechanism, many of which are known to those of ordinary skill in the art.
[0030] FIG. 5 is another exploded view of the seasoning dispenser 10 albeit looking up toward the bottom of the body and the lower side of the screen 22 and lands 26 . The elongated openings 38 in the bottom of the hopper 12 allow granules to pass from the hopper 12 and fall into voids 46 formed in the disc 40 . FIG. 5 also shows the torque arm 36 depicted in FIG. 2 and which is attached to the axis 34 of the disc 40 . In one embodiment, a U-shaped hook at the distal end of the connecting rod 33 engages a pivot hole 47 in the torque arm 36 . Other embodiments use a threaded rod, one or more clevis pins and/or cotter pins, to attach the connecting rod 33 to appropriate holes formed into the torque arm 36 . Oscillating angular movement of the torque arm 36 caused by the oscillating translation of the actuator bottom end 31 of the actuator 20 , causes the seasoning-measuring disc 40 to oscillate around the axis 34 .
[0031] It is important to note that the actuator 20 is depicted in FIG. 4 and FIG. 5 as being above the handle 16 and above the base 15 whereas in FIG. 1 and 2 , the actuator 20 is below the handle 16 and the short arm of the actuator 20 is outside the base 15 . When the seasoning dispenser 10 is assembled, as it is in FIG. 1 and FIG. 2 , the hinge pins 29 are in the receptacles 28 but the long part of the actuator 20 is below the handle 16 ; the short arm of the actuator 20 and its bottom end 31 is outside the base 15 as shown in FIG. 2 .
[0032] FIG. 4 and FIG. 5 both show that seasoning measurement and seasoning dispensing is effectuated by the rotatable seasoning measuring member, preferably embodied as the disc 40 shown in the figures. The disc 40 shown in the figures is provided with several voids 46 that extend between the disc's top and bottom opposing surfaces. A filler portion or gasket 39 is attached to the top or upper surface of the disc 40 . The gasket 39 is formed to have its own holes or voids 46 A, which are aligned with the voids 46 in the disc 40 when the gasket 39 is installed in and affixed to the top surface 41 of the disc 40 . As described below, the voids 46 in the disc 40 and the matching voids 46 A in the gasket 39 effectively determine how much of a seasoning in the hopper 12 will be dispensed with each operation of the actuator 20 .
[0033] When the dispenser 10 is assembled, the disc 40 with the gasket 39 attached thereto, are in the base 15 above the screen 22 but beneath the hopper 12 . When the hopper 12 is in place in the base 15 and the disc 40 is at its starting, initial position, voids 46 A in the gasket 39 and voids 46 in the disc 40 should be directly below the elongated openings 38 in the hopper 12 but also directly above the lands 26 . Granules in the hopper 12 will thus fall through the elongated openings 38 in the bottom of the hopper 12 and fill voids 46 in the disc 40 and the voids 46 A in the gasket 39 . Since the bottom of the voids 46 and 46 A are above the lands 26 when they are below the elongated openings 38 , the voids 46 and 46 A fill with granules, which are prevented from falling out of the voids 46 and 46 A by the lands 26 .
[0034] Pulling the actuator 20 upward causes the disc 40 and the granule-filled voids 46 and 46 A therein to rotate away from the elongated openings 38 in the hopper 12 and away from the lands 26 . As the disc 40 rotates away from its starting position, granules in the voids 46 and 46 A fall through the holes 24 in the screen 22 . Rotation of the disc 40 back and forth around its axis exerts centrifugal force on granules in the voids 46 and 46 A. Centrifugal force on granules urges them outward. Granules that miss one of the holes 24 in the screen fall out one of the by-pass holes 25 .
[0035] The top surface of the gasket 39 abuts extrusions that surround the elongated openings 38 in the hopper 12 . The gasket 39 thus prevents granules from leaking out of the hopper 12 when the disc 40 is rotated away from its starting position. Granules are thus permitted to fall out of the hopper 12 only when the voids 46 are below the elongated openings 38 .
[0036] Repeated actuation of the actuator 20 causes the disc 40 to rotate back and forth around axis 34 . As voids 46 in the disc 40 pass underneath the elongated openings 38 , they fill with granules, which then fall from the voids as the disc is rotated away from the disc's starting location. Repeated actuation of the actuator 20 will thus dispense the same or substantially the same amount of seasoning each time the disc 40 rotates.
[0037] FIG. 6 is a perspective view of the rotatable disc 40 . It shows that the disc has a first, top surface 41 and a second, bottom surface 43 , which is not visible in FIG. 6 . The disc 40 has a rim 48 at the perimeter, which extends upwardly from the top surface 41 of the disc 40 . The rim 48 provides a relatively wide surface for the disc 40 to engage the interior of the base 15 . The rim 48 also provides a structure that retains in place, the aforementioned pliable gasket 39 .
[0038] The disc 40 can be seen to have a thickness, defined as the distance between the top surface 41 and the bottom surface 43 . The thickness of the disc 40 and the area of a void 46 in the disc 40 determine the volume of seasoning that a void 46 can hold. Similarly, the thickness of the gasket 39 and the area of each void 46 A in the gasket determine the volume of seasoning that a void 46 A in the gasket 39 can hold. Thickness of the disc 40 , thickness of the gasket 39 , area of the disc void 46 and area of the gasket void 46 A thus determine the volume of the granulated seasoning dispensed with each actuation of the actuator 20 .
[0039] The gasket 39 is preferably formed from a soft or pliable material, such as neoprene rubber. The gasket 39 is also provided with holes that align with the voids 46 in the disc 40 to determine dispense volume. The gasket 39 is sized, shaped and arranged such that its top surface just meets the bottoms of the elongated openings 38 in the hopper 12 in order to close off the elongated openings 38 when the disc 40 rotates the voids 46 and 46 A away from the openings 38 .
[0040] FIG. 7 is a bottom view of the disc 40 shown in FIG. 6 . This view shows the bottom or second side of the disc 40 as well as the bottom or opposing side of the voids 46 . FIG. 7 also shows the axis 34 and the torque arm 36 , depicted in FIG. 5 . The pivot hole 47 in the torque arm 36 , which receives the connecting rod 33 , is also clearly shown.
[0041] FIG. 8 shows an alternate embodiment of the disc 40 that is identical to the disc shown in FIG. 6 and FIG. 7 except that the voids 46 shown in the disc 40 of FIG. 8 are of circular cross section. Voids 46 in the disc 40 and voids 46 A in the gasket 39 can also be shaped as ovals, squares, triangles or other regular or irregular polygons.
[0042] For purposes of claim construction, the term rotatable seasoning measuring member includes the disc 40 depicted in the figures, however, the term should also be considered to include square, rectangular, elliptical or other planar bodies formed to have at least one void that can be filled with granules as described above. The rotatable seasoning member whether it is a disc, wheel, or other planar body, has an outer edge corresponding to a “circumference.”
[0043] The hopper 12 is depicted in the figures as having substantially oval or “pie-shaped” elongated openings that are identified by reference numeral 38 . Alternate equivalent embodiments include a hopper having only a single elongated opening as well as one or more round, oval, rectangular or other shaped holes. For claim construction purposes, terms that identify hopper openings that allow granules to pass through should be construed to include all of the above.
[0044] The screen 22 is depicted in the figures as having a hole pattern that is essentially the same. Alternate embodiments of the invention include screens having varying hole patterns as well as screens having different hole sizes. The dispensing holes 24 can also have more than one diameter. Different hole locations can also effectuate different granule distribution patterns, e.g., square, rectangular or circular granule distribution patterns. The term, “screen” should be construed to include at least all of the above alternate embodiments.
[0045] The lands 26 depicted in the figures are un-perforated sections separating or between clusters or groups of through-holes 24 , however, in an alternate embodiment, the lands 26 are embodied as holes having much smaller diameters, i.e., holes too small for the nominal-sized granules in the hopper to pass through them. In yet another embodiment, the lands 26 are embodied as narrow slots, whose widths are too small for granules to fall through. For purposes of claim construction, the lands, should be construed to include not only the un-perforated areas shown in the figures but any other structure that does not allow at least the nominally-sized seasoning or seasoning granules to pass through the disc or other seasoning-measuring member, when it is being filled with granules from the hopper 12 .
[0046] In a preferred embodiment, the return spring 30 is embodied as a flat or leaf-type spring. Alternate equivalent embodiments use a coil spring as well as a torsion spring and a constant-force spring to return the actuator 20 to its starting location.
[0047] While the foregoing description is of a preferred embodiment, the invention should not be construed to be limited to that which is described above. The true scope of the invention is defined by the appurtenant claims.
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Fixed amounts of granular and granulated seasonings are dispensed from a rotatable disc that lies flat or horizontal and which includes a through-hole or void. The void is gravity-filled with granulated seasonings from a hole in the bottom of a hopper. A screen below the disc is formed to have open, through-holes and a solid land. The void in the disc fills with granules when the void is beneath a hole in the hopper but over a solid land thus preventing granules to spill through the disc. Rotation of the disc moves the void away from the land, allowing granules in the void to fall through holes in the screen. A gasket provides a seal between the disc and the hopper. The disc is rotated back and forth around its axis by vertical movement of an actuator about the horizontal hinge.
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FIELD OF THE INVENTION
[0001] The present invention relates to the field of pharmacological treatment of chronic pain.
BACKGROUND OF THE INVENTION
[0002] Differently from acute pain, which exerts an important physiological action alerting the organism towards an incoming danger or damage, chronic pain is not involved in any protective action.
[0003] Chronic pain may be divided in two main categories: chronic inflammatory pain and neuropathic pain. The latter is due to a direct lesion on the nervous pathways by the noxa, which can be infectious, metabolic, vascular or other. In chronic inflammatory pain the lesioned tissues release algogenic factors which in turn damage nerve terminals creating a vicious mechanism which maintains and potentiates the perception of pain (hyperalgesia) or transforms into pain other types of perception (allodynia).
[0004] Chronic pain, of both neuropathic and inflammatory origin, is an important epidemiologic aspect of a high unmet medical need condition; in fact this is a therapeutic area presently characterized by modestly effective and poorly tolerated treatments.
[0005] An increasing number of patients suffer from iatrogenic neuropathic pain, induced by anti-tumor therapies used in modern oncology. In particular taxol derived drugs, cisplatin and vincristine are among the drugs which more often induce painful neuropathies. Currently no effective and/or well tolerated treatments exist for this kind of pain. In fact classical antiepileptic or antidepressive agents successfully used in other forms of neuropathic pain, such as lamotrigine (Renno S. I. 2006, J. Clin. Oncol. ASCO Annual Meeting Proceeding Part I vol. 24, No 18S:8530), gabapentin (Wong G. Y. 2005 , J. Clin. Oncol. ASCO Annual Meeting Proceeding Part I vol. 23, No 16S:8001) or nortriptyline (Hammack J. E. 2002, Pain 98:195-203) are absolutely unsatisfactory on the basis of their therapeutic index.
[0006] Nucleoside analogue reverse transcriptase inhibitors (ddC, d4T, AZT) are commonly used as antiviral drugs in the treatment of AIDS. These drugs often cause the insurgence of peripheral neuropathies with different degrees of severity after prolonged treatment. As in the case of chemotherapeutic agents, these symptoms may be so strong to induce shortening or suspension of these life-saving therapies. The patterns of these neuropathies are clearly different from those induced by the progression of AIDS; they are in fact characterized by the sudden onset of very intense burning discomfort in both hands and feet at about the tenth week of treatment. HIV-induced neuropathies, on the contrary, have a very slow progression (Dubinsky R. M. 1989 , Muscle Nerve 12:856-860). As for chemotherapy-induced neuropathies, it is difficult to treat this kind of pain.
[0007] The tricyclic antidepressant amitryptiline and the sodium channel blocker mexiletine, effective on various forms of painful peripheral neuropathies, did not show any significant effect on this kind of neuropathic pain (Kieburtz K. 1998 Neurology 51:1682-1688). Gabapentin showed some efficacy, although patients with severe syndromes rarely reach satisfactory results and the additional administration of narcotics is required (McArthur J. C. 2001 , The Hopkins HIV report. http://www.hopkins-aids.edu/publications/report/may01 — 2.html).
[0008] Other forms of neuropathic pain may be caused by viral infections. Postherpetic neuralgia, for instance, is caused by the reactivation, long after the infection, of the varicella-zoster virus. This kind of neuropathy is characterized by the development of strong mechanical allodynia, frequent loss of sensitivity towards thermal stimuli and spontaneous intermitting pain. Pain intensity compromises the quality of life of patients suffering from this condition.
[0009] Of high epidemiological relevance is the pain referred to as cephalalgia. This is localized to the head, face and neck. When cephalea occurs in a paroxystic way, with recurrent episodes lasting from hours to days and is associated to general sickness, it is called migraine. Several forms of migraine are recognized such as common, classical, hemiplegic, vertebro-basilar, etc.
[0010] The current treatment for migraine entails the use of different kinds of analgesic agents, from non-steroidal anti-inflammatory drugs (NSAIDs) to opioids, antihistaminic drugs and ergotamine derivatives. In the last decade triptan 5HT2 antagonists have been used; they are often able to block an attack at its insurgence, if promptly administered. All these treatments show serious limits in terms of both efficacy and tolerability. In the most severe cases, in which painful attacks recur many times a week, a pre-emptive therapy with antiepileptic, beta blocker and antidepressant drugs is performed. The maximum result which can be achieved with these pre-emptive therapies is 50% reduction in the frequency and intensity of the painful attacks, but not their definitive remission.
[0011] Inflammatory pain is another form of chronic pain. It is caused by the release of mediators which either directly activate the nociceptors localized on primary afferents, or lower their activation threshold, thus increasing their sensitivity to either painful or non-painful stimuli of different nature. Excited primary afferents may in turn release neurotransmitters which can stimulate immune cells recruited by the inflammatory process causing the release of additional inflammatory mediators.
[0012] This phenomenon, defined ‘neurogenic inflammation’, leads to an autoamplification of the symptomatology of the patient. Osteoarthritis is a particularly severe and painful form of this kind of pathology. Osteoarthritis is a form of degenerative arthritis causing the breakdown and eventual loss of the cartilage of one or more joints. The most common symptom related to this pathology is pain in the affected joint after repetitive use or after prolonged periods of inactivity (night and rest pain). Even if a certain correlation between pain and the extension of the damage at the joint has been demonstrated, the precise etiology of this kind of pain is still obscure; in fact, patients with relatively small damages at the joints suffer from very intense pain and viceversa; this finding suggests that it is not a merely inflammatory pain, but that a neuropathic component is present as well. Recommended treatments include NSAIDs, steroids and opioids, but the use of these drugs is associated with the insurgence of severe side-effects; in addition, they do not show full efficacy in many instances (Altman R. D. 2000 Arthritis Rheum. 43:1905-1915).
[0013] The fibromyalgia syndrome is the most frequent cause of chronic, widespread pain, associated with auxiliary symptoms, such as sleep disturbances and chronic fatigue (Rao S. G. 2007 , Psychopharmacol. Bull. 40:24-67). Nearly 2% of the general population in the United States suffers from fibromyalgia, with females of middle age being at increased risk. Patients with fibromyalgia display quantitative abnormalities in pain perception under experimental conditions, in the form of both allodynia and hyperalgesia: these data are suggestive of a state of sensitized pain perception.
[0014] Recently, pregabalin and duloxetine showed some efficacy in clinical trials for the treatment of the muscle pain in fibromyalgia (Crofford L. J. 2005 , Arthritis Rheum. 52:1264-1273; Maizels M. 2005 , Am. Fam. Physician 71:483-490). Nonetheless, at present, the medical treatment for pain relief in fibromyalgia is unsatisfactory (Offenbaecher M. 2005 , CNS Spectr. 10:285-297) and fibromyalgia represents a high unmet medical need.
[0015] Dimiracetam (2,5-dioxohexahydro-1H-pyrrolo[1,2-a]imidazole) is a bicyclic pyrrolidinonic derivative of formula (I)
[0000]
[0016] Patent application EP-A-335483 claims its pharmaceutical use as a nootropic agent, i.e. able to improve learning and memory in humans and animals. Dose-response data show that the nootropic activity of dimiracetam tends to lower for oral doses greater than 10 mg/kg ( J. Med. Chem., 1993, 36:4214-4220). Patent application WO-A-93/09120 claims a process for the preparation of dimiracetam and of its enantiomers.
[0017] WO-A-2004/085438 claims a set of derivatives of 2,5-dioxohexahydro-1H-pyrrolo[1,2-a]imidazole; a typical feature of these compounds is the presence, in position 3 of the imidazole ring, of an aromatic carbocyclic or heterocyclic ring; these compounds, notwithstanding their utility in the treatment of painful conditions, show a therapeutic index which is not fully satisfactory.
[0018] In view of the above mentioned background the need is felt for new drugs endowed with high antihyperalgesic and antiallodynic activity towards chronic pain, and characterized by a high therapeutic index. The need is also felt for the treatment of specific forms of neuropathic pain which are not well treated with traditional antihyperalgesic agents.
SUMMARY OF THE INVENTION
[0019] The present inventors have studied the behaviour of dimiracetam at different doses with respect to those previously described for this compound, considering also possible variations of toxicity associated to the new doses. During these studies a new pharmacological window has been found, within which dimiracetam exerts a strong regression effect on chronic painful phenomena of neuropathic or inflammatory origin, without showing any toxic effect. The possibility to treat these debilitating pathologies with an effective and essentially atoxic compound is therefore disclosed.
BRIEF DESCRIPTION OF FIGURES
[0020] FIG. 1 : Oxaliplatin-induced neuropathy
[0021] *p<0.01 vs oxaliplatin/vehicle treated group. Each value represents the mean±S.E.M. of 8-11 rats. Compounds were administered starting three days before oxaliplatin treatment.
[0022] FIG. 2 : ddC-induced neuropathy
[0023] *p<0.01, ̂p<0.05 vs ddC/vehicle group. Each value represents the mean±S.E.M. of mechanical threshold expressed as grams, with a total of 10 rats per group.
[0024] FIG. 3 : ddC-induced neuropathy
[0025] *p<0.01 vs ddC/vehicle group. Each value (with the exception of the control group) represents the mean±S.E.M. of 18 rats in two experiments.
[0026] FIG. 4 : MIA-induced osteoarthritic pain in rats
[0027] *p<0.01 vs MIA/vehicle group. Each value represents the mean±S.E.M. of 18 rats in two experiments.
[0028] FIG. 5 : Motor coordination in rats (rotarod)
[0029] Each value represents the mean±S.E.M. of the number of falls in 30 sec. of groups of 8 rats.
[0030] FIG. 6 : Motor coordination in rats (rotarod)
[0031] Each value represents the mean±S.E.M. of the number of falls in 30 sec. of groups of 8 rats. *p<0.01 vs vehicle-treated animals.
[0032] FIG. 7 . Motor activity in mice (hole board)
[0033] *p<0.01 vs vehicle treated group. Each value represents the mean±S.E.M. of 18 mice. The test was performed 30 min after the oral administration of drugs.
DETAILED DESCRIPTION OF THE INVENTION
[0034] A first object of the present invention is the use of dimiracetam, or a pharmaceutically acceptable solvate thereof, in the manufacture of a medicament useful for treating and/or preventing chronic pain. The invention is also directed to dimiracetam, or a pharmaceutically acceptable solvate thereof, for use in the treatment and/or prevention of chronic pain
[0035] A further object of the present invention is a method for treating and/or preventing chronic pain, consisting in the administration of a pharmaceutically effective dose of dimiracetam to a patient in need thereof.
[0036] Dimiracetam is a chiral compound. For the scope of the present invention, the term “dimiracetam” identifies the isolated (R) or (S) enantiomers of dimiracetam, or mixtures thereof in which the two enantiomers are present in equal or different amounts. It is therefore intended that the use, method and pharmaceutical compositions which are the object of the present invention are extended to those mixtures or the single enantiomers of dimiracetam.
[0037] According to the present invention, dimiracetam may be administered as such or in association with any other active principle useful for the treatment or prevention of chronic pain or diseases causing it.
[0038] It is also part of the invention the administration of dimiracetam in association with active principles which present as side effect the insurgence of chronic pain, in particular antitumor and antiviral drugs; non-limiting examples of such drugs are taxol, vincristine, cisplatin, oxaliplatin, nucleoside reverse transcriptase inhibitor antivirals (ddC, d4T, AZT), many of which are gold standard antiviral drugs in HIV infection therapy.
[0039] By means of the claimed use and method it is possible to treat effectively and with high safety all kinds of chronic pain, either neuropathic or inflammatory in origin. Preferred examples of chronic pain treated according to the present invention are the following:
1. pain induced by chemotherapeutic agents or other antiblastic therapy (e.g. radiotherapy); among the chemotherapeutic agents responsible for neuropathies, taxol, vincristine, cisplatin, oxaliplatin are mentioned; 2. pain induced by antiviral agents such as nucleoside reverse transcriptase inhibitors (ddC, d4T, AZT); 3. complex regional pain syndrome, phantom limb, thalamic syndromes, spinal syndromes; 4. pain induced by osteoarthritis, rheumatoid arthritis, autoimmune osteoarthrosis forms; 5. pain induced by cephalea (cephalea in general and hemicranic forms; cephalea due to vascular, infective, autoimmune, dysmetabolic and tumoral causes, cephalea from endocranial hypertension, cephalea from pseudotumor cerebri, classic hemicrania with and without aura, hemiplegic hemicrania and with other motor complications, childhood and juvenile hemicrania, Bickerstaff's syndrome, etc.). 6. pain induced by fibromyalgia
[0046] Of outstanding efficacy, and therefore preferred in the scope of the invention, is the treatment of pain induced by antiviral agents, osteoarthritis, rheumatoid arthritis and autoimmune osteoarthritis.
[0047] In the scope of the invention, in the present treatment the antihyperalgesic effect of dimiracetam is exerted in a range of oral dosages between 10 and 300 mg/kg, preferably between 100 and 300 mg/kg. The antihyperalgesic effect may be achieved also by routes of administration different from the oral route, i.e. intramuscular or intravenous: in these cases dimiracetam is administered in amounts which allow to obtain haematic levels comparable to those obtained after oral administration of 10-300 mg/kg. Reference values useful for intramuscular administrations range from about 5 to about 150 mg/kg; reference values useful for intravenous administrations range from about 2 to about 60 mg/kg.
[0048] The invention encompasses therefore pharmaceutical compositions of dimiracetam useful for the above mentioned treatments. These compositions contain an amount of this active principle which is greater than that previously proposed for the nootropic activity.
[0049] The amounts of the active principle, expressed in mg/kg, are those cited above. These compositions have a dosage unit useful to administer the above mentioned dosages. Typically they contain from 500 to 15000 mg in case of oral compositions; from 250 to 7500 mg in case of intramuscular compositions; from 100 to 3000 mg in case of intravenous compositions.
[0050] Dimiracetam may be pharmaceutically formulated according to known methodologies. The various pharmaceutical compositions may be selected according to the needs of the treatment.
[0051] Such compositions can be prepared by mixing and can be suitably adapted for oral or parenteral administration, and as such, can be administered in the form of tablets, capsules, oral preparations, powders, granules, pellets, liquid solutions for injection or infusion, suspensions or suppositories.
[0052] Tablets and capsules for oral administration are usually supplied in dosage units and may contain conventional excipients such as binders, fillers, diluents, tabletting agents, lubricants, detergents, disintegrants, colorants, flavors and wetting agents. Tablets may be coated in accordance to methods well known in the art.
[0053] Suitable fillers include for example cellulose, mannitol, lactose and similar agents. Suitable disintegrants include starch, polyvinylpyrrolidone and starch derivatives such as sodium starch glycolate. Suitable lubricants include, for example, magnesium stearate. Suitable wetting agents include for example sodium lauryl sulfate.
[0054] These solid oral compositions can be prepared with conventional mixing, filling or tabletting methods. The mixing operations can be repeated to disperse the active agent in compositions containing large quantities of fillers. These operations are conventional.
[0055] The oral liquid compositions can be provided in the form of, for example, aqueous or oily suspensions, solutions, emulsions, syrups or elixirs or in the form of a dry product to be reconstituted with water or with a suitable liquid carrier at the time of use. The liquid compositions can contain conventional additives such as suspending agents, for example sorbitol, syrup, methylcellulose, gelatin, hydroxyethylcellulose, carboxymethylcellulose, aluminium stearate gel or hydrogenated edible fats, emulsifying agents, for example lecithin, sorbitan monooleate, or acacia; non aqueous carriers (which can include edible oil) for example almond oil, fractionated coconut oil, oily esters such as glycerin esters, propylene glycol or ethyl alcohol; preservatives, for example methyl or propyl p-hydroxybenzoate or sorbic acid and if desired, conventional flavours or colorants.
[0056] Oral formulations also include conventional sustained release formulations, such as tablets or granules with enteric coating.
[0057] For parenteral administration, fluid dosage units can be prepared containing the active compounds and a sterile carrier. The active compounds, depending on the carrier and concentration, can be suspended or dissolved. The parenteral solutions are normally prepared by dissolving the compound in a carrier and sterilizing by filtration, before filling suitable vials or ampoules and sealing. Adjuvants such as local anaesthetics, preservatives and buffering agents can be advantageously dissolved in the carrier. In order to increase stability, the composition can be frozen after filling the vial and the water removed under vacuum. The parenteral suspensions are prepared essentially in the same way, with the difference that the active compounds can be suspended rather than dissolved in the carrier, and can be sterilized by exposure to ethylene oxide prior to being suspended in the sterile carrier. A surfactant or humectant can be advantageously included to facilitate uniform distribution of the compound of the invention.
[0058] A further method of administration for the compound of the invention refers to a topic treatment. Topic formulations may contain for example ointments, creams, lotions, gels, solutions, pastes and/or may contain liposomes, micelles and/or microspheres.
[0059] A further method of administration for the compounds of the invention is transdermal delivery. Typical transdermal formulations include conventional aqueous and non-aqueous vectors, such as creams, oil, lotions or pastes or may be in the form of membranes or medicated patches.
[0060] As is the common practice, the compositions are normally accompanied by written or printed instructions, for use in the treatment concerned.
[0061] Examples of the present invention are provided in what follows, purely for illustrative and non-limiting purposes.
EXPERIMENTAL PART
1. Methods
1.1 Chemotherapy-Induced Peripheral Neuropathy (CIPN)
[0062] Peripheral neuropathy is induced by repeated administration of vincristine, taxol or oxaliplatin to adult male Sprague-Dawley rats (150-200 g, supplier Harlan).
[0063] The following protocols were used respectively:
Vincristine: the drug was injected by intravenous route at the dose of 150 μg/kg. The treatment was performed every 2 days, for 5 times, until a cumulative dose of 750 μg/kg was reached. Paw pressure test was performed 4 days after the last injection (Marchand F. et al. 2003 , Brain Res. 980:117-120). Taxol: taxol neuropathy was induced by intraperitoneal administration of 0.5 mg/kg once a day, on days 1, 3, 5 and 8. Cumulative taxol dose was 2 mg/kg. The pharmacological test was performed 14-18 days after the last taxol injection (Polomano R. C. et al. 2001 , Pain 94:293-304). Oxaliplatin: 2.4 mg/kg were injected by intraperitoneal route for 5 consecutive days followed by 2 days suspension (one cycle). A total of 3 cycles was performed, reaching a cumulative dose of 36 mg/kg (Cavaletti G. 2001 , Eur. J. Cancer 37:2457-2463). The test was performed 48 h after the last oxaliplatin injection.
1.2 Antiviral-Induced Neuropathy
[0067] Adult male Sprague Dawley rats (150-200 g, supplier Harlan) were treated by intravenous route with a single administration of 25 mg/kg of nucleoside reverse transcriptase inhibitors ddC (2′,3′-dideoxycytidine) or d4T (2′,3′-didehydro-3′-deoxythymidine). Administration of these anti-HIV drugs induced a marked allodynic response to a mechanical stimulus (Joseph E. K. 2004 , Pain 107:147-158). The maximum reduction of the paw pressure threshold is developed between day 5 and day 10 after injection. The test was performed on day 10.
1.3 Cephalea
[0068] Experimental models in rats demonstrated that meninges and cerebral blood vessels are pain-sensitive structures and are heavily innervated by the trigeminal nerve. Activation of trigeminal fibers causes a neurogenic inflammatory response of meningeal tissues, that has been proposed as an essential mechanism for migraine pain and other headaches. (Bolay H. 2002 , Nature Medicine 8:136-142). On these basis, animal models of blood vessel neuro-inflammation following electrical trigeminal stimulation were commonly utilized to discover potential effective drugs. Adult male Sprague-Dawley rats (150-200 g weight, Harlan) were anaesthetized with pentobarbital Sodium® (60 mg/kg i.p.), and placed in a stereotaxic frame. An ipsilateral electrode was then inserted and trigeminal nucleus was stimulated to induce a meningeal neuroinflammation, which can be detected by the amount of extravasated Blue Evans dye or radiolabelled bovine serum albumine.
1.4 Arthritic Pain in Rats
[0069] Joint inflammation was induced by intra-articular injection of 0.1 ml of Freund's complete adjuvant (CFA) in anaesthetized rats (male adult Sprague Dawley rats, 150-200 g, supplier Harlan). Mechanical hyperalgesia was evaluated using the paw pressure test 14 days after CFA administration (Shan S 2006 , Pain 129:64-75).
1.5 Osteoarthritis-Related Pain in Rats
[0070] Osteoarthritis was induced by a single administration of 2 mg (in a volume of 25 μl) of sodium 2-iodoacetate into the left knee joint of anaesthetized rats (male adult Sprague Dawley rats, 150-200 g, supplier Harlan) (Fernihough J. 2004 , Pain 112:83-93). This treatment induces the progressive degeneration of the joint and the development of hyperalgesia, mimicking at the histological and behavioral levels what observed in humans. Pharmacological test was performed 7 days after treatment.
1.6a Evaluation of Mechanical Hyperalgesia: Paw Pressure Test
[0071] Mechanical hyperalgesia in rats (male adult Sprague Dawley rats, 150-200 g, supplier Harlan) was determined using the paw pressure test. The nociceptive threshold was determined with an analgesimeter (Ugo Basile, Italy), exerting a force that increases at constant rate (32 g/s) according to the method described by Leighton G. E. 1988 , Br. J. Pharmacol. 93:553-560. The stimulus causing paw withdrawal was evaluated before and at different times after treatment. Results represent the mean of mechanical thresholds expressed as grams. To avoid any possible damage to the animal paw the maximum applied force was fixed at 240 g.
1.6b Evaluation of Mechanical Allodynia: Von Frey Test
[0072] Rats (male adult Sprague Dawley rats, 150-200 g, supplier Harlan) were placed in a chamber with a mesh metal floor covered by a plastic dome that enabled the animals to walk freely, but not to jump. The mechanical stimulus was delivered in the mid-plantar skin of left hind paw using an electronic von Frey apparatus. The cut-off was fixed at 50 g, while the increasing force rate (ramp duration) was settled at 20 sec.
1.7 Irwin Test in Rats
[0073] To verify if the administration of the compound may induce centrally mediated side effects, adult male Sprague Dawley rats (150-200 g, supplier Harlan) were treated with dimiracetam by subcutaneous and oral routes and monitored according to the “Irwin test” protocol (Irwin 1968 , Psychopharmacologia 13:222-257), a systematic and quantitative procedure for assessing the behavioral and physiological modifications induced in animals by the drug treatment.
[0074] Rats were constantly monitored for 30 min after administration. Monitoring was iterated every morning at 9 a.m. for 4 days after administration.
1.8 Motor Coordination in Rats
[0075] The rotarod test allows the evaluation of the effects of a compound on motor coordination. Adult male Sprague Dawley rats (200-220 g, supplier Harlan, Milan) were placed on a plastic rod 6 cm in diameter and 35 cm in length, rotating at constant speed (16 rpm) at a height of 25 cm. The rod is divided in 4 equal sections, thus up to 4 animals may be tested simultaneously. The animals were required to walk against the motion of the rotating drum over 30 seconds. The time taken to fall off the rotarod was recorded as number of falls in 30 seconds, following the method of Vaught et al. 1985 , Neuropharmacology 24:211-216. In each experiment motor coordination is measured before (pre-test) and after administration of the tested compound. Rats scoring less than 3 and more than 6 falls in the pretest are rejected.
1.9 Rotarod/Ataxia Test in Rats
[0076] The test was performed according to the method described by Veneroni et al 2003 , Pain 102:17-25. Neurological deficits were evaluated by the inability of the rats to remain on the rotating rod (10 rpm) for the test period. The toxic dose was calculated as the dose causing 25% (TD 25 ) or 50% (TD 50 ) of the fallen rats (only for gabapentin, the toxic dose was TD 16 =16% of fallen rats).
1.10 Hole Board in Mice
[0077] The hole board test allows to study the behavior of rodents when confronted with a new environment (Boissier J R 1964, Therapie 19:571-583). The test enables to evaluate the initial exploratory activity of the animal and its possible variations induced by drug administration.
[0078] The hole board test uses a 40 cm square plane with 16 flush-mounted cylindrical holes (diameter 3 cm) distributed 4 by 4 in an equidistant, grid-like manner. Mice (male Swiss Webster mice weighing 25-30 g, supplier Morini) are placed one by one in the center of the board and allowed to move freely, each for a period of 5 min. Two photoelectric beams, crossing the plane from mid-point to mid-point of opposite sides, and thus dividing the plane into four equal quadrants, automatically record the movements of the animals on the plane surface. Miniature photoelectric cells in each of the 16 holes record the exploration of the holes (head plunging activity) by the mice.
2. Results (Antihyperalgesic Activity)
2.1 Oxaliplatin-Induced Neuropathy in Rats
[0079] The effect of dimiracetam was evaluated in the oxaliplatin-induced neuropathy model after repeated administration with the paw pressure test. Results are reported in FIG. 1 . Dimiracetam was administered at doses of 100 and 300 mg/kg p.o. once a day, starting three days before oxaliplatin treatment and during the treatment itself. At the dose of 300 mg/kg, dimiracetam significantly reduced mechanical hyperalgesia. The effect was statistically significant between 30 min and 4 h after administration.
2.2 Antiviral-Induced Neuropathy
[0080] Test results (von Frey test) are reported in FIG. 2 . At the dose of 100 mg/kg, 15-30 min after administration, dimiracetam fully reverted ddC-induced allodynia, the mechanical threshold being at the same level in treated and control animals. The effect was still statistically significant 45 min after treatment.
[0081] Dimiracetam is a racemic compound; the two corresponding enantiomers were synthesized and separately tested in the ddC-induced neuropathy model. The two compounds were administered orally at doses of 150 and 300 mg/kg and their antihyperalgesic activity was evaluated with the paw pressure test. Results are reported in FIG. 3 . (R)-dimiracetam induced a significant reduction of the pain mechanical threshold at 300 mg/kg, 15-45 min after administration. The (S) enantiomer induced a significant effect at 300 mg/kg, 15 min after administration. These data demonstrate the efficacy also of the single enantiomers of dimiracetam.
2.3 Osteoarthritic Pain in Rats
[0082] The antihyperalgesic potential of dimiracetam was evaluated (paw pressure test) in the osteoarthritic pain model induced by the intra joint injection of sodium monoiodoacetate (MIA). Test results are reported in FIG. 4 . Both dimiracetam and its (R) enantiomer at the dose of 150 mg/kg, 15-30 min after administration, showed a statistically significant effect in reverting MIA-induced hyperalgesia. At the dose of 300 mg/kg dimiracetam fully reverted MIA-induced hyperalgesia, the mechanical threshold being at the same level in treated and control animals between 15 and 45 min after administration; the effect was still statistically significant 60 min after administration. The effect of the (R) enantiomer was still statistically significant 45 min after treatment.
3. Results (Tolerability)
[0083] In order to verify if dimiracetam may induce unwanted side effects, the compound was tested in the rotarod model (motor coordination and ataxia) in rats and in the hole board model (spontaneous and exploratory activity) in mice.
3.1 Rotarod Test in Rats
[0084] In acute toxicity experiments, dimiracetam, administered at 3000 mg/kg p.o. (20-fold the dose used in the previous pharmacological activity tests) does not alter rats motor coordination in the rotarod test, as shown in FIG. 5 .
[0085] Differently, as shown in FIG. 6 , reference compound I-(3-cyanophenyl)-tetrahydropyrrolo[1,2-a]imidazole-2,5-dione (representative of compounds of formula (I) of WO2004/085438, see example 13) significantly altered animals motor coordination, increasing the number of falls starting from the dose of 300 mg/kg; these data show a lower tolerability level for the said reference compounds.
3.2 Rotarod/Ataxia Test in Rats
[0086] The TD 25 of dimiracetam was 6000 mg/kg p.o., thus demonstrating a very high safety and tolerability of the compound.
[0087] Among the reference standards, tramadol exhibited the highest toxicity, with a TD 50 of 253 mg/kg p.o., while pregabalin and levetiracetam showed TD 50 s of 536 and 2000 mg/kg p.o. respectively. Gabapentin showed a TD 16 of 1000 mg/kg p.o.
3.3 Irwin Test in Rats
[0088] Dimiracetam administered at the dose of 1000 mg/kg by subcutaneous route and at the dose of 3000 mg/kg p.o. did not show any effects on all the behavioral parameters observed.
3.4 Hole Board Test in Mice
[0089] In the hole board test, dimiracetam, administered at 3000 mg/kg p.o. does not significantly reduce either spontaneous activity (number of movements of each animal on the plane) or curiosity (number of head plungings), as shown in FIG. 7 .
[0090] On the contrary, gabapentin administered at 1000 mg/kg causes a statistically significant reduction of both the evaluated parameters.
3.5 Preliminary Toxicity in Rats: Single Dose by Oral and Intravenous Route
[0091] Oral or intravenous administration of a single dose of 3000 mg/kg of dimiracetam to Sprague Dawley rats is substantially well tolerated. No signs of toxicity were observed during the experiment. Behavioral observation, blood and urine analyses did not show any dose-related variation of the measured clinical parameters.
3.6 Repeated Toxicity in Rats: 4 and 13 Weeks p.o.
[0092] Oral repeated administration of dimiracetam to Sprague Dawley rats, for 4 weeks and up to a maximal dose of 2500 mg/kg/day did not produce any changes in terms of mortality, symptomatology or changes of the normal behavior.
[0093] Oral repeated administration of dimiracetam to Sprague Dawley rats for 13 weeks and up to a maximal dose of 2500 mg/kg/day was well tolerated. No mortality or relevant clinical signs, as well as changes in terms of body weight, water and food consumption or in body temperature were seen at all dose levels. Hematology, clinical chemistry, coagulation parameters and urinalysis did not reveal drug related variation of the different parameters evaluated at all tested doses. No macro- or microscopic lesions or abnormalities correlated with the administration of dimiracetam were noticed.
3.7 Repeated Toxicity in Cynomolgus Monkeys: 4 and 13 Weeks p.o.
[0094] Oral repeated administration of dimiracetam in Cynomolgus monkeys for 4 weeks and up to a maximal dose of 2000 mg/kg/day, was well tolerated by the animals. A slight reduction in food consumption and body weight was observed in some animals treated with the maximal dose of 2000 mg/kg.
[0095] Oral repeated administration of dimiracetam in Cynomolgus monkeys for 13 weeks and up to a maximal dose of 2000 mg/kg/day was well tolerated by the animals. No mortality or relevant clinical signs, as well as changes in terms of body weight, water and food consumption or in body temperature were seen at all dose levels. Hematology, clinical chemistry, coagulation parameters and urinalysis did not reveal drug related variation of the different parameters evaluated at all tested doses. No macro- or microscopic lesions or abnormalities correlated with the administration of dimiracetam were noticed.
[0096] Taken together, these data show the insurgence of a strong antihyperalgesic activity for dimiracetam within the dosage ranges typical of the present invention. The high potency of action is confirmed by the fact that this compound showed remarkably higher efficacy than gabapentin, considered up to now the gold standard in chronic pain treatment therapy. Activity was found versus chronic pain of different origins (i.e. chemotherapy-induced pain, antiviral-induced pain, osteoarthritic pain, cephalea etc.) demonstrating the broad spectrum of applicability of the treatment proposed herein. In addition, data shown in said animal models highlight a special efficacy of dimiracetam versus chronic pain associated with antiviral treatment and osteoarthritic pain and related pathologies. In addition, at doses typical for the present invention, dimiracetam proved to be much more tolerable than gabapentin or pyrroloimidazole derivatives of prior art.
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The use of dimiracetam in the treatment of chronic pain is disclosed. At doses higher than those previously disclosed in relation with its cognition enhancing activity (i.e. amelioration of learning and memory), dimiracetam was able to completely revert hyperalgesia or allodynia associated with several animal models of chronic pain. Dimiracetam showed high activity in iatrogenic neuropathies associated with antiviral and chemotherapeutic drug treatments and in painful conditions caused by osteoarthritis. In addition, dimiracetam was devoid of toxicity even at doses 10-fold higher than the highest therapeutic dose. The possibility of treating such debilitating pathologies with a highly effective and essentially non-toxic compound is therefore disclosed.
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FIELD OF THE INVENTION
The present invention relates to LED (light-emitting diode) driver circuits for adjusting luminance of an LED, and more specifically to an LED driver circuit suitable for, for example, a light dimmer circuit enabling expression of a subtle change in background brightness on a dome screen at a planetarium without causing an unnatural sensation.
BACKGROUND OF THE INVENTION
Unlike incandescent lamps and electric-discharge lamps, LEDs are readily switched on with a direct-current power supply and have a long lifespan. Recently, blue and white LEDs have been put to practical use. Efficiency of LEDs also has reached a level that is better than efficiency of not only incandescent lamps but also fluorescent lamps. LEDs are increasingly widely used not only as display light sources of indicators or the like but also as ordinary illumination light sources or the like. Constant brightness is sufficient for ordinary illumination, whereas dimming for changing the brightness as desired is desirable for some types of interior illumination, stage illumination, and effects illumination at facilities such as planetariums. Changing the brightness of interior illumination as desired allows people to enjoy a change in atmosphere. At bedtime, dim illumination can substitute a function provided by traditional night light bulbs or the like. Stage illumination not only can express a brightness change corresponding to a scene but also can create various scenes by changing the brightness of light sources of individual colors such as red, green, and blue to control hue and saturation. At planetariums, the color and the brightness of illumination are changed as desired not only to use the illumination as houselights when an audience enters or exits but also to express daytime and nighttime scenes. A subtle change in brightness from daytime to dusk and to nighttime is expressed by changing the brightness of illumination.
To dim an LED, a method of changing drive current, a method based on PWM (pulse width modulation) control, and other methods are used. In general, the method based on PWM control is often used because of simple circuitry. Since the amount of LED light responds to current in 1 ms or less, which is extremely fast, LEDs have a property in which the brightness and the pulse width are directly proportional to each other. This property enables accurate brightness control.
However, in the case where LEDs are used in the aforementioned illumination applications, an issue that is not caused by the hitherto used light sources such as incandescent lamps may occur. The issue is that the brightness change is perceived as a stepped change at low illuminance. In PWM control, a command regarding a pulse width can be numerically given, and the pulse width can be accurately specified using a digital circuit. For example, in the case of a PWM signal of 12-bit resolution, the minimum brightness is 1/4,096. Although this brightness seems extremely low, even this minimum brightness is sufficiently bright for humans because the dynamic range of the human eye for brightness is extremely wide. For example, suppose that the maximum brightness is 500 lx. In this case, the minimum brightness of 1/4,096 is equal to 0.12 lx, which is sufficiently bright to be sensed by eyes. When the brightness is increased by one step, the brightness is equal to 0.24 lx, that is, is steeply doubled. Consequently, the stepped brightness change is visually noticeable.
To address this issue, a solution for increasing the resolution of the PWM signal has been conceived. For example, in the case of 16-bit resolution, the minimum brightness is equal to 0.0076 lx, and a significant improvement is expected. However, increasing the resolution in this manner may cause another issue. Specifically, in the case where PWM control is performed at a brightness at which no flicker is noticeable, for example, at approximately 200 Hz, one period is 5 ms. When control is performed at 16-bit resolution, the minimum pulse width is equal to 5 ms/65,536=76.3 ns. Although this is not a speed that is difficult to handle as a speed of a signal of digital circuits, noise is likely to occur if current for causing an LED to emit light is repeatedly supplied and cut at this speed. Consequently, neighboring electronic devices may be affected by noise or noise suppression may become difficult. In addition, if the speed at a rise or fall of the current waveform changes due to a factor such as external noise, the brightness at the lowest illuminance may vary or a flicker may occur, making the brightness change unpleasant to see.
These issues are overlooked in ordinary illumination applications as requirements therefor are met even if such issues occur. However, particularly in applications in which brightness control at low illuminance is important, for example, illumination at planetariums or the like, a subtle nighttime brightness needs to be reproduced by an illumination device. Thus, the above-described issues hinder the stage effects.
Many proposals such as LED driver circuits including a LED dimmer circuit unit for changing the brightness of an LED by using PWM control have been made. Such driver circuits are used in illumination devices, on-vehicle illumination devices, or the like. However, none of many hitherto proposed LED driver circuits are capable of exerting effects assumed by the inventor of this application. Specific issues will be described by using some related-art literatures regarding configurations that functionally operate in a way similar to that of a configuration of an LED driver circuit proposed by the inventor herein, that is, regarding adjustment of the brightness of an LED by using PWM control.
JP 2007-317443(A) has proposed a circuit that enables continuous dimming from the lower limit to the upper limit of an output without complicating circuitry in an illumination system for which dimming control is performed by controlling on/off of power from a power supply based on a PWM signal. In this illumination system, a PWM signal is supplied to a gate of an FET (field effect transistor) that controls an LED from a microprocessor including a ROM (read-only memory) to control the brightness of the LED. In the case where a pulse-on time of the PWM signal based on a control command is finer than a resolution of the clock of the microprocessor, a plurality of pulses having different on times are combined together to create a combined PWM signal so that the average of the pulse-on times becomes equal to the pulse-on time based on the control command. In this way, the continuous dimming from the lower limit to the upper limit of an output is realized. However, in JP 2007-317443(A), pulse width modulation for a low illuminance region and pulse width modulation for a high illuminance region are not used as control signals in order to increase a dynamic range for a LED brightness change, which is aimed by the present invention. Thus, JP 2007-317443(A) does not aim to smooth the brightness change in the low illuminance region.
JP 2011-171231(A) aims to provide an LED lighting circuit capable of performing dimming control in a range below the lower limit of PWM-based dimming. To this end, the LED lighting circuit includes a step-down chopper circuit that supplies an LED current to an LED light source unit as a result of oscillation control of a switching element, and a dimming control unit that controls the LED current by performing oscillation control of the switching element. The dimming control unit includes an oscillation frequency control unit that controls an oscillation frequency, a PWM control unit that controls a PWM on-duty, and a driver unit that switches on/off the switching element on the basis of the oscillation frequency and the PWM on-duty. Operation details are as follows. In a range in which the dimming degree is at or above the lower limit of PWM-based dimming, the PWM control unit changes the PWM on-duty to perform dimming control. In a range in which the dimming degree is below the lower limit of PWM-based dimming, the PWM on-duty is kept unchanged and the oscillation frequency is set to be higher than that for the lower limit of PWM-based dimming. The brightness of an LED is controlled by inputting a signal to the control terminal of the switching element from the driver unit to which the PWM signal from the PWM control unit and the oscillation frequency controlled by the oscillation frequency control unit are input. As in JP 2007-317443(A), pulse width modulation for a low illuminance region and pulse width modulation for a high illuminance region are not used as control signals, and control for mainly changing a pulse width that is input to a driver that causes flow of a small current in the low illuminance region and for mainly changing a pulse width input to a driver that causes flow of a large current in the other illuminance region is not performed.
An apparatus for generating a drive signal for an illumination device as described in JP 2013-519988(A) aims to provide a concept for driving an LED or an LED spot for an HDTV (high-definition television) camera while making requirements for a drive signal generator for the LED or the LED spot lower than in the related art. To this end, the apparatus according to JP 2013-519988(A) includes a pulse generator that generates a first pulse train in response to a first brightness request for a first brightness and generates a second pulse train in response to a second brightness request for a second brightness. The first pulse train has a first frequency, and the second pulse train has a second frequency different from the first frequency. The second pulse train includes two neighboring pulses of the first pulse train and an additional pulse between the two neighboring pulses. The additional pulse is not included in in the first pulse train. Operation details are as follows. Two pulse trains having different frequencies, the additional pulse being inserted to one of the two pulse trains, are input to drive the LED or the LED spot of the HDTV camera. However, this configuration is different from the configuration of the LED driver circuit proposed by the inventor of this application. In addition, the object is not to address the operation in which a brightness change is perceived as a stepped change in a very low light amount region or light abruptly goes out when the brightness of the LED is changed by using PWM control.
SUMMARY OF THE INVENTION
Aspects of the present invention address various issues described above and aim to provide an LED driver circuit capable of overcoming the issues in that a brightness change is perceived as a stepped change in a very low light amount region or light abruptly goes out when the brightness of an LED is changed by using PWM control and of realizing smooth dimming even at a very low amount of light.
To this end, in accordance with a first aspect of the invention, an LED driver circuit includes at least one driver circuit connected to an LED. The at least one driver circuit includes a plurality of current-limiting circuits for which currents that flow therethrough are certain current set values that are different from one another, and a plurality of pulse width modulation circuits. The LED driver is configured to mainly control a pulse width for a current-limiting circuit having a small current set value, among the plurality of current-limiting circuits, in a low light amount region and mainly control a pulse width for a current-limiting circuit having a large current set value, among the plurality of current-limiting circuits, in a high light amount region, whereby an amount of light of the LED is smoothly changed in a wider dynamic range than in a case of using a single driver circuit.
In accordance with a second aspect of the invention, in the first aspect of the invention, the at least one driver circuit may be a plurality of driver circuits, and each of the plurality of driver circuits may be connected to a corresponding one of LEDs.
In accordance with a third aspect of the invention, in the first aspect of the invention, the at least one driver circuit may be a plurality of driver circuits, and the plurality of driver circuits may be connected in parallel to one another and be connected in common to the LED.
In accordance with a fourth aspect of the invention, in the first aspect of the invention, the current-limiting circuit may be a resister.
In accordance with a fifth aspect of the invention, in the first aspect of the invention, the current-limiting circuit may be a constant-current diode.
In accordance with a sixth aspect of the invention, an LED driver circuit used in an illumination device that illuminates background on a dome screen at a planetarium includes at least one driver circuit connected to an LED. The at least one driver circuit includes a plurality of current-limiting circuits for which currents that flow therethrough are certain current set values that are different from one another, and a plurality of pulse width modulation circuits. The LED driver circuit is configured to mainly control a pulse width for a current-limiting circuit having a small current set value, among the plurality of current-limiting circuits, in a low light amount region and mainly control a pulse width for a current-limiting circuit having a large current set value, among the plurality of current-limiting circuits, in a high light amount region, whereby an amount of light of the LED is smoothly changed in a wider dynamic range than in a case of using a single driver circuit.
In accordance with a seventh aspect of the invention, in the sixth aspect of the invention, the at least one driver circuit may be a plurality of driver circuits, and each of the plurality of driver circuits may be connected to a corresponding one of LEDs.
In accordance with an eighth aspect of the invention, in the sixth aspect of the invention, the at least one driver circuit may be a plurality of driver circuits, and the plurality of driver circuits may be connected in parallel to one another and be connected in common to the LED.
In accordance with a ninth aspect of the invention, in the sixth aspect of the invention, a plurality of the illumination devices may be provided in the vicinity of a periphery of the planetarium.
In accordance with a tenth aspect of the invention, in the sixth aspect of the invention, a brightness of the illumination device may be controlled by manual operation or be automatically controlled by a control system at the planetarium.
In accordance with an eleventh aspect of the invention, in the sixth aspect of the invention, a control system at the planetarium may store a real-time solar altitude, calculate a brightness on the basis of the solar altitude, and send a command input based on the calculated brightness to the illumination device to reproduce a change between daytime and nighttime.
With the configuration above, a change in background brightness on a dome screen can be smoothly expressed if the LED driver circuit according to the aspects of the invention is applied to an illumination device at planetariums.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a circuit diagram illustrating an LED driver circuit according to an embodiment of the present invention;
FIG. 2 is a graph illustrating characteristics of a conversion function used to obtain, for a change in a dimming command value, an actual brightness change in a wide dynamic range implemented by the circuit illustrated in FIG. 1 ;
FIG. 3 is a graph illustrating an example of an actual brightness change controlled based on a change in the dimming command value, the graph being an enlarged illustration of output characteristics implemented by a PWM circuit of 12-bit resolution in a low light flux region;
FIG. 4 is a graph illustrating examples of pulse widths respectively for PWM signal generators L and H of the circuit illustrated in FIG. 1 in response to a dimming command value;
FIG. 5 is a graph illustrating an example of an actual brightness change controlled based on a change in the dimming command value, the graph being obtained by superimposing the value of the graph in FIG. 4 on the value in FIG. 3 ;
FIG. 6 is a circuit diagram of an LED driver circuit according to another embodiment of the present invention and illustrates an example in which a PWM_H circuit and a PWM_L circuit are assigned to different LEDs;
FIG. 7 is a diagram illustrating an overview of a planetarium apparatus that uses illumination devices each including the LED driver circuit according to the embodiments of the present invention; and
FIG. 8 is a graph illustrating an example of a brightness change controlled based on a change in the solar altitude in the case where the illumination devices illustrated in FIG. 7 are automatically controlled.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Embodiments of the present invention will be described in detail below with reference to the accompanying drawings.
FIG. 1 is a circuit diagram illustrating an LED driver circuit according to an embodiment of the present invention. Two driver circuits (i.e. a driver circuit including a register (hereinafter also referred to as current-limiting transistors) RH and a power transistor TRH, and a driver circuit including a resistor RL and a power transistor TRL) are connected to a light-emitting diode LED. A PWM signal generator circuit (hereinafter also referred to as a PWM signal generator) H outputs a PWM signal (pulse train A) having a certain pulse width to drive the power transistor TRH. Similarly, a PWM signal generator circuit (hereinafter also referred to as a PWM signal generator) L outputs a PWM signal (pulse train B) having a certain pulse width to drive the power transistor TRL. When the power transistor TRH is in an on-state, a current flows through the LED via the current-limiting resistor RH. When the power transistor TRL is in the on-state, a current flows through the LED via the current-limiting resistor RL. When both the power transistors TRH and TRL are in the on-state, a current that flows through the LED is equal to the sum of currents that flow through the current-limiting resistors RH and RL. The current that flows through the LED is set by the individual current-limiting resistors RH and RL.
For example, it is assumed that a power supply voltage VCC is 5V and a forward-direction voltage of the LED is 3V. In such a case, the current that flows through the current-limiting resistor RH is (5−3)/RH=2/RH, and the current that flows through the current-limiting resistor RL is (5−3)/RL=2/RL. A dimming command value has 8-bit resolution. That is, a value ranging from 0 to 255 is supplied to the PWM signal generators H and L. Each of the PWM signal generators H and L converts this dimming command value into a pulse width by using a certain conversion function stored therein and outputs the pulse width. The pulse width has 12-bit resolution. That is, the pulse width is specified by a value ranging from 0 to 4,095. When the pulse width is 0, the duty cycle is equal to 0%. When the pulse width is 4,095, the duty cycle is equal to 100%. Now, it is assumed that a resistance of the current-limiting resistor RH is 10 Ω and a resistance of the current-limiting resistor RL is 1 kΩ. In this case, the current that flows through the current-limiting resistor RH is 2/10=0.2 A, and the current that flows through the current-limiting resistor RL is 2/1,000=2 mA. A ratio between these currents is 100:1. That is, a ratio between amounts of lights to be emitted for the same pulse width given by the PWM signal generators L and H is 1:100.
A specific example of the conversion function for converting the dimming command value into the pulse width of the PWM signal will be described next. The sensitivity of the human eye is not necessarily linear. Thus, a smoother result is obtained in the case where a relationship between the dimming command value and the actual brightness is based on a certain function than in the case where the relationship is linear. For example, a function is set such that a brightness=an input raised to the power of 2.7 so as to obtain a brightness change in a wide dynamic range for a limited number of input command values denoted by 8 bits. FIG. 2 illustrates an example of this function. The dimming command value is given as an 8-bit gradation ranging from 0 to 255, whereas the output changes according to a curve of a function of the power of 2.7. FIG. 3 is an illustration obtained by enlarging output characteristics implemented, for example, by a PWM circuit of 12-bit resolution in a low light flux region. With 12-bit resolution, one step is equal to 1/4,096 of the maximum value (i.e. 1), that is, is equal to approximately 0.000244. In the case of illumination having the maximum illuminance of 100 lx, this value is equal to approximately 24 mlx. This brightness change is sufficiently noticeable as a stepped change when the eyes are adjusted to the dark.
Pulse widths respectively for the PWM signal generators L and H in the circuit illustrated in FIG. 1 are set as illustrated in FIG. 4 . In a low light amount region up to the dimming command value of approximately 50, the value for the PWM signal generator L is changed. In a region of a greater light amount, the value for the PWM signal generator H is changed. When the duty for the PWM signal generator L is equal to 1, 1% of the maximum light amount is obtained. When the duties for both the PWM signal generators L and H are equal to 1, the maximum light amount is obtained. Tables 1-1 and 1-2 illustrate an example of these values. The dimming command value takes a value ranging from 0 to 255. A value PWM_L denotes a pulse width output by the PWM signal generator L and takes a 12-bit gradation value ranging from 0 to 4,095. The same applies to a value PWM_H. The brightness of the LED is denoted by (PWM_L/4,095)*0.01+(PWM_H/4,095). Tables 1-1 and 1-2 illustrate this brightness value.
TABLE 1-1
Command Value
PWM_L
PWM_H
Brightness
0
0
0
0.000000
1
0
0
0.000000
2
0
0
0.000000
3
2
0
0.000005
4
5
0
0.000012
5
10
0
0.000024
6
16
0
0.000039
7
24
0
0.000059
8
35
0
0.000085
9
49
0
0.000120
10
65
0
0.000159
11
84
0
0.000205
12
106
0
0.000259
13
132
0
0.000322
14
161
0
0.000393
15
195
0
0.000476
16
232
0
0.000567
17
273
0
0.000667
18
319
0
0.000779
19
369
0
0.000901
20
424
0
0.001035
21
483
0
0.001179
22
548
0
0.001338
23
618
0
0.001509
24
693
0
0.001692
25
774
0
0.001890
26
861
0
0.002103
27
953
0
0.002327
28
1052
0
0.002569
29
1156
0
0.002823
30
1267
0
0.003094
31
1384
0
0.003380
32
1508
0
0.003683
33
1639
0
0.004002
34
1777
0
0.004339
35
1921
0
0.004691
36
2073
0
0.005062
37
2232
0
0.005451
38
2399
0
0.005858
39
2573
0
0.006283
40
2755
0
0.006728
41
2945
0
0.007192
42
3143
0
0.007675
43
3350
0
0.008181
44
3564
0
0.008703
45
3787
0
0.009248
46
4019
0
0.009814
47
4095
1
0.010244
48
4095
4
0.010977
49
4095
6
0.011465
50
4095
9
0.012198
51
4095
12
0.012930
52
4095
15
0.013663
53
4095
17
0.014151
54
4095
21
0.015128
55
4095
24
0.015861
56
4095
27
0.016593
57
4095
30
0.017326
58
4095
34
0.018303
59
4095
37
0.019035
60
4095
41
0.020012
61
4095
45
0.020989
62
4095
49
0.021966
63
4095
52
0.022698
64
4095
57
0.023919
65
4095
61
0.024896
66
4095
65
0.025873
67
4095
69
0.026850
68
4095
74
0.028071
69
4095
79
0.029292
70
4095
83
0.030269
71
4095
88
0.031490
72
4095
93
0.032711
73
4095
98
0.033932
74
4095
104
0.035397
75
4095
109
0.036618
76
4095
114
0.037839
77
4095
120
0.039304
78
4095
126
0.040769
79
4095
132
0.042234
80
4095
138
0.043700
81
4095
144
0.045165
82
4095
150
0.046630
83
4095
156
0.048095
84
4095
163
0.049805
85
4095
169
0.051270
86
4095
176
0.052979
87
4095
183
0.054689
88
4095
190
0.056398
89
4095
197
0.058107
90
4095
205
0.060061
91
4095
212
0.061770
92
4095
220
0.063724
93
4095
227
0.065433
94
4095
235
0.067387
95
4095
243
0.069341
96
4095
251
0.071294
97
4095
260
0.073492
98
4095
268
0.075446
99
4095
277
0.077643
100
4095
286
0.079841
101
4095
294
0.081795
102
4095
304
0.084237
103
4095
313
0.086435
104
4095
322
0.088632
105
4095
332
0.091074
106
4095
341
0.093272
107
4095
351
0.095714
108
4095
361
0.098156
109
4095
371
0.100598
110
4095
382
0.103284
111
4095
392
0.105726
112
4095
403
0.108413
113
4095
413
0.110855
114
4095
424
0.113541
115
4095
436
0.116471
116
4095
447
0.119158
117
4095
458
0.121844
118
4095
470
0.124774
119
4095
482
0.127705
120
4095
494
0.130635
121
4095
506
0.133565
122
4095
518
0.136496
123
4095
530
0.139426
124
4095
543
0.142601
125
4095
556
0.145775
126
4095
569
0.148950
127
4095
582
0.152125
TABLE 1-2
Command Value
PWM_L
PWM_H
Brightness
128
4095
595
0.155299
129
4095
609
0.158718
130
4085
623
0.162137
131
4095
637
0.165556
132
4095
651
0.168974
133
4095
665
0.172393
134
4095
679
0.175812
135
4095
694
0.179475
136
4095
709
0.183138
137
4095
724
0.186801
138
4095
739
0.190464
139
4095
754
0.194127
140
4095
770
0.198034
141
4095
786
0.201941
142
4095
801
0.205604
143
4095
818
0.209756
144
4095
834
0.213663
145
4095
850
0.217570
146
4095
867
0.221722
147
4095
884
0.225873
148
4095
901
0.230024
149
4095
918
0.234176
150
4095
936
0.238571
151
4095
954
0.242967
152
4095
971
0.247118
153
4095
990
0.251753
154
4095
1008
0.256154
155
4095
1026
0.260549
156
4095
1045
0.265189
157
4095
1064
0.269829
158
4095
1083
0.274469
159
4095
1102
0.279109
160
4095
1122
0.283993
161
4095
1142
0.288877
162
4095
1162
0.293761
163
4095
1182
0.298645
164
4095
1202
0.303529
165
4095
1223
0.308657
166
4095
1244
0.313785
167
4095
1265
0.318913
168
4095
1286
0.324042
169
4095
1307
0.329170
170
4095
1329
0.334542
171
4095
1351
0.339915
172
4095
1373
0.345287
173
4095
1395
0.350659
174
4095
1418
0.356276
175
4095
1440
0.361648
176
4095
1463
0.367265
177
4095
1487
0.373126
178
4095
1510
0.378742
179
4095
1534
0.384603
180
4095
1557
0.390220
181
4095
1582
0.396325
182
4095
1606
0.402186
183
4095
1630
0.408046
184
4095
1655
0.414151
185
4095
1680
0.420256
186
4095
1705
0.426361
187
4095
1731
0.432711
188
4095
1757
0.439060
189
4095
1783
0.445409
190
4095
1809
0.451758
191
4095
1835
0.458107
192
4095
1862
0.464701
193
4095
1889
0.471294
194
4095
1916
0.477888
195
4095
1943
0.484481
196
4095
1971
0.491319
197
4095
1999
0.498156
198
4095
2027
0.504994
199
4095
2055
0.511832
200
4095
2084
0.518913
201
4095
2112
0.525751
202
4095
2142
0.533077
203
4095
2171
0.540159
204
4095
2200
0.547241
205
4095
2230
0.554567
206
4095
2260
0.561893
207
4095
2290
0.569219
208
4095
2321
0.576789
209
4095
2352
0.584359
210
4095
2383
0.591929
211
4095
2414
0.599499
212
4095
2446
0.607314
213
4095
2478
0.615128
214
4095
2510
0.622943
215
4095
2542
0.630757
216
4095
2574
0.638571
217
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2707
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2741
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FIG. 5 is obtained by superimposing this value on the value in FIG. 3 . Dimming is implemented even at a low amount of light much smoother than that denoted by the curve of ordinary 12-bit PWM. In addition, dimming is performed using the pulse width PWM_H at and above a certain amount of light. Because there is already a certain amount of light in that range, the stepped brightness change is unobtrusive even at the dimming resolution of the pulse width PWM_H. An actual dynamic range is calculated. The minimum luminance obtained based on the pulse width PWM_L is 1/4,096/100=2.44×10 −6 , and the dynamic range is 409,600. Because the dynamic range of ordinary 12-bit PWM is 4,096, a resolution that is 100 times as high as that of ordinary 12-bit PWM is achieved. This embodiment has described the example where two PWM circuits are used and a ratio between current values is set to 100, however a configuration using three or more PWM circuits is also possible. In such a case, the dynamic range can be increased further by 100 times, and the constraint is substantially removed.
FIG. 6 illustrates an embodiment in which PWM circuits are assigned to different LEDs. An LED LED_H is switched on based on a PWM signal generated by the PWM signal generator H. An LED LED_L is switched on based on a PWM signal generated by the PWM signal generator L. In this case, because the brightness of both the LEDs LED_H and LED_L are changed, the brightness can be changed not only by changing the values of the current-limiting resistors but also by changing the number of lamps or models actually used in the LEDs LED_H and LED_L or the presence or absence of an optical filter. Also, in this embodiment, the brightness is controlled by setting pulse trains A′ and B′ to have a relationship between the dimming command value and the pulse width illustrated in FIG. 4 .
FIG. 7 illustrates an embodiment in which illumination devices produced based on this circuitry are used at a planetarium. The illumination devices each including an LED and a driver circuit are installed at a periphery of a dome screen so as to illuminate the entire dome screen. The brightness of the illumination devices are controlled by manual operation performed by a presenter or automatically controlled by a control system at the planetarium. FIG. 8 illustrates an example of a relationship of the brightness against a change in the solar altitude used in the case of automatic control. The planetarium control system stores therein a real-time solar altitude. The planetarium control system calculates a brightness based on the graph illustrated in FIG. 8 by using this altitude and sends the calculated brightness value to the illumination devices as a command input, thereby being able to reproduce a change between daytime and nighttime. The use of the circuit according to the embodiments of the present invention allows a subtle brightness change of the night sky during a very dim time period after sunset to be reproduced naturally.
With the embodiments of the present invention, LEDs can be smoothly dimmed further from an extremely low illuminance, without increasing the PWM frequency unnecessarily. In the case where the resolution is increased by increasing the number of bits used for PWM control, current needs to be switched at an extremely high speed in order to implement the small pulse width, causing issues related to stability of the circuit and occurrence of noise. In contrast, the method according to the embodiments of the present invention enables smooth dimming even at low illuminance through PWM control using a small number of bits.
The embodiments above have described the case where one LED is used and the case where two LEDs are used respectively for a low illuminance region and a high illuminance region, however the advantageous effects of the embodiments of the present invention are also exerted even in the case where an LED is further inserted in series to circuit portions each including an LED. In addition, the example of using resistors to limit the current has been described, however currents at two PWM circuits on the PWM signal generator H side and the PWM signal generator L side can be limited to be different current values by using constant-current diodes instead of the resistors. Further, the example case of setting the ratio between the two current values to 100 has been described, however the ratio may be less than or greater than 100.
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An LED driver circuit capable of overcoming the issues in that a brightness change is perceived as a stepped change in a very low light amount region or light abruptly goes out by using PWM control and of realizing smooth dimming even at a very low amount of light is provided. In the LED driver circuit, a first circuit including a first resistor and a first power transistor connected in series and a second circuit including a second resistor and a second power transistor connected in series are connected in parallel with each other and are connected to an LED. First and second PWM signal generator circuits drive the first and second power transistors, respectively. When the first and second power transistors are in an on-state, currents flow through the LED via the first and second resistors, respectively, which enable a smooth brightness change even in a low illuminance region.
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CROSS-REFERENCE TO RELATED APPLICATION
This application claims the benefit of Korean Patent Application No. 2014-0082319, filed on Jul. 2, 2014 in the Korean Intellectual Property Office, the disclosure of which is incorporated herein by reference.
BACKGROUND
1. Field
Embodiments of the present invention relate to a high pressure accumulator, and more particularly, to a high pressure accumulator of a brake system capable of attenuating pressure pulsation of oil discharged from a pump.
2. Description of the Related Art
In general, in an electronic brake system, in order to control brake hydraulic pressure transmitted toward a brake of a vehicle, a plurality of solenoid valves disposed on a modulator block, a low pressure accumulator and a high pressure accumulator that temporarily store oil, and an electronic control unit (ECU) having a pump disposed between the low pressure accumulator and the high pressure accumulator to pump the oil stored in the low pressure accumulator and a motor for driving the pump are provided, the electronic brake system includes the ECU controlling components used to electrically operate these elements.
Such an electronic brake system has been used by employing various structures in which the high pressure accumulator having a predetermined damping space is disposed to reduce pressure pulsation generated as liquid pressure of brake oil discharged from the pump is formed at a high pressure and an orifice part is disposed in an outport discharged through the high pressure accumulator. For example, Korean Unexamined Patent Application Publication No. 10-2001-0046429 discloses a structure for reducing pressure pulsation by separately disposing an elastic member and an orifice in a high pressure accumulator. Also, Korean Unexamined Patent Application Publication No. 10-2010-0135236 discloses a configuration in which a pulsation attenuation capsule having an elastic force is disposed in a high pressure accumulator to reduce pressure pulsation and an orifice is separately disposed in the high pressure accumulator. That is, referring to the disclosed literatures, an orifice part is obligatorily mounted in an outport discharged through the high pressure accumulator to attenuate pressure pulsation.
However, since the orifice should be separately assembled, as mentioned above, an additionally processing time for installing the orifice and an assembling time therefor increase, and of course, cost increases.
In addition, pressure pulsation attenuation caused by elastic deformation is induced by installing an elastic member formed of a spring or a rubber material in the high pressure accumulator. Thus, there is a problem in that the function may be lowered by lowered durability of components when they are used for a long time and a pressure pulsation attenuation effect is limited.
SUMMARY
Therefore, it is an aspect of the present invention to provide a high pressure accumulator of a brake system in which an orifice part is integrally formed so that a processing time for installing an orifice separately and an assembling time therefor can be reduced.
It is another aspect of the present invention to provide a high pressure accumulator of a brake system in which a damping chamber disposed to attenuate pressure pulsation is optionally partitioned into a plurality of layers to change characteristics of a flow of brake oil so that pressure pulsation can be efficiently reduced.
Additional aspects of the invention will be set forth in part in the description which follows and, in part, will be obvious from the description, or may be learned by practice of the invention.
In accordance with one aspect of the present invention, a high pressure accumulator of a brake system disposed on a modulator block to reduce pressure pulsation of brake oil pressed by driving of a pump and pumped, the high pressure accumulator includes: a closing member that closes one end of a bore having one opened end and is in communication with an inport through which the brake oil is introduced and an outport through which the brake oil is discharged; and a damping housing that is installed in the bore and has a damping chamber formed therein in communication with the inport and the outport, wherein an orifice part may be formed integrally with the damping housing in a portion in which the brake oil is discharged through the outport, and a damping member may be installed in the damping housing and may partition the damping chamber into a plurality of layers so that the partitioned plurality of layers may be in communication with each other, and the damping member may include a body part having one opened side to partition the damping chamber into a plurality of layers and a connection hole formed in a bottom surface of the body part in communication with the adjacent damping chamber partitioned by the body part, and an inclined part may be formed on the bottom surface of the body part so that the brake oil may easily flow into the adjacent damping chamber, and the connection hole may be formed in distal ends of the inclined part.
The orifice part may include an insertion part inserted into and coupled to the outport and an orifice formed in the insertion part so that the damping chamber and the outport are in communication with each other.
A stepped part for supporting the damping member may be formed in the damping housing.
A plurality of damping members may be provided, the plurality of damping member being stacked and disposed in series.
An introduction hole that is in communication with the inport may be formed in the damping member disposed in a position corresponding to the inport.
The plurality of damping chambers, each of which is partitioned into a plurality of layers by the damping members, may be optionally formed to have the same heights according to heights of the damping members or may be optionally formed to have different heights.
The plurality of damping members may have diameters at which they correspond to each other, and may be installed in the damping housing, and one end of each of the damping housing and the damping member may be pressed in and coupled to the closing member.
A coupling jaw corresponding to an inner diameter of each of the damping members may be formed at an inside of the closing member.
BRIEF DESCRIPTION OF THE DRAWINGS
These and/or other aspects of the invention will become apparent and more readily appreciated from the following description of the embodiments, taken in conjunction with the accompanying drawings of which:
FIG. 1 is an assembling cross-sectional view illustrating a state in which a high pressure accumulator of a brake system is assembled, in accordance with an embodiment of the present invention;
FIG. 2 is a cross-sectional view illustrating a state in which the high pressure accumulator of the brake system illustrated in FIG. 1 is assembled to a bore in a modulator block;
FIG. 3 is a cross-sectional view illustrating a high pressure accumulator of a brake system in accordance with another embodiment of the present invention; and
FIG. 4 is a view illustrating a flow of brake oil, pressure pulsation of which is attenuated through the high pressure accumulator of the brake system illustrated in FIG. 3 .
DETAILED DESCRIPTION
Reference will now be made in detail to the embodiments of the present invention, examples of which are illustrated in the accompanying drawings, wherein like reference numerals refer to like elements throughout. The following embodiment is proposed to sufficiently convey the spirit of the invention to one of ordinary skill in the art. The invention is not limited by the proposed embodiment but may be embodied in different shapes. In the drawings, for clarity, illustration of unrelated parts to description is omitted, and for understanding, sizes of components may be slightly exaggerated.
FIG. 1 is an assembling cross-sectional view illustrating a state in which a high pressure accumulator of a brake system is assembled, in accordance with an embodiment of the present invention, and FIG. 2 is a cross-sectional view illustrating a state in which the high pressure accumulator of the brake system illustrated in FIG. 1 is assembled to a bore in a modulator block.
Referring to the drawings, a high pressure accumulator 100 of a brake system according to an embodiment of the present invention is installed on a modulator block 10 of an electronic brake system (not shown) and attenuates pressure pulsation. In this case, the electronic brake system (not shown) is a device in which in order to control brake hydraulic pressure transmitted toward a brake of a vehicle, a plurality of flow paths are formed in the modulator block 10 , a solenoid valve, a low pressure and a high pressure accumulators, a pump, and a motor are installed, and thus are electronically controlled. Such an electronic brake system is a well-known technology and thus, a detailed description thereof will be omitted.
The high pressure accumulator 100 according to an embodiment of the present invention is installed in a bore 11 formed in the modulator block 10 in communication with an inport 12 through which high-pressure brake oil discharged from the pump is introduced and an outport 13 through which the introduced brake oil is discharged. In more detail, the high pressure accumulator 100 includes a closing member 110 that closes one end of the bore 11 having one opened end formed in a cylindrical shape and a damping housing 120 that is installed in the bore 11 and has a damping chamber 121 formed therein in communication with the inport 12 and the outport 13 .
The closing member 110 is installed to close the opened end of the bore 11 so that an inside of the bore 11 may be formed by the damping chamber 121 together with the damping housing 120 . A coupling protrusion 114 through which the closing member 110 may be coupled to a damping member 140 that will be described later is formed at an inside of the closing member 110 . Hereinafter, the coupling protrusion 114 will be described again.
The damping housing 120 is installed in the bore 11 , has the opened end in the cylindrical shape, and has the damping chamber 121 formed therein. In the damping housing 120 , an inlet 122 is formed in a position corresponding to the inport 12 so that the brake oil may be introduced through the inport 12 , and an orifice part 130 is formed integrally with the damping housing 120 in a position corresponding to the outport 13 so that the introduced brake oil may be discharged toward the outport 13 .
The orifice part 130 includes an insertion part 133 inserted into and coupled to the outport 13 and an orifice 131 formed in the insertion part 133 so that the damping chamber 121 and the outport 13 are in communication with each other. As the orifice part 130 is formed integrally with the damping housing 120 , an orifice does not need to be separately installed compared to the related art so that a processing time and an assembling time may be reduced.
Meanwhile, the damping member 140 is installed within the damping housing 120 so that the damping chamber 121 may be partitioned into a plurality of layers and the partitioned plurality of layers may be in communication with each other. In this case, a stepped part 124 for stably supporting the damping member 140 is formed in an inner side surface of the damping housing 120 .
The damping member 140 includes a body part 141 having one opened side to partition the damping chamber 121 into a plurality of layers and a connection hole 143 formed in a bottom surface of the body part 141 in communication with the adjacent damping chamber 121 partitioned by the body part 141 . That is, as illustrated in the drawings, the damping member 140 is disposed in the damping housing 120 to partition the damping chamber 121 into two layers so that pressure pulsation of the brake oil introduced under high pressure may be attenuated in two layers and a pressure pulsation attenuation effect may be improved.
Also, an inclined part 144 is formed on a bottom surface of the damping member 140 so that the brake oil may easily flow into the adjacent damping chamber 121 . The inclined part 144 is formed to be inclined in a direction through which the brake oil flows, and the connection hole 143 is formed in distal ends of the inclined part 144 . Thus, the brake oil flows toward the outport 13 by the inclined part 14 so that, although the damping chamber 121 is partitioned into the plurality of layers, the brake oil may flow smoothly.
The damping member 140 is installed in the damping housing 120 and is pressed in and coupled to the closing member 110 together with the damping housing 120 . As described above, the damping member 140 is pressed in and coupled to the coupling protrusion 114 of the closing member 110 . Thus, the coupling protrusion 114 is formed to have a diameter corresponding to an inner diameter of the damping member 140 . In this case, the damping member 140 is pressed in and coupled to the closing member 110 together with the damping housing 120 . However, the present invention is not limited thereto, and the damping housing 120 may also be directly pressed in and coupled to the closing member 110 . When the damping member 140 is pressed in and coupled to the closing member 110 together with the damping housing 120 , an introduction hole 142 is formed in a position of the damping member 140 corresponding to the inlet 122 formed in the damping housing 120 so that the brake oil may be introduced into the damping housing 120 through the inport 12 . If the damping housing 120 is directly pressed in and coupled to the closing member 110 , the damping member 140 is installed to be located under the inlet 122 formed in the damping housing 120 .
In the above-described high pressure accumulator 100 of the brake system, the orifice part 130 is integrally formed so that a processing time for installing an orifice separately and an assembling time therefor may be reduced. Also, the damping chamber 121 is partitioned into a plurality of layers so that pressure pulsation may efficiently be reduced. Also, the damping chamber 121 is formed of a material having rigidity, for example, steel or a plastic material. Thus, although the damping chamber 121 is used for a long term, durability of the damping chamber 121 is not lowered, and as the function of partitioning the damping chamber 121 into a plurality of layers is permanently maintained, a continuous pressure pulsation attenuation function may be performed.
Meanwhile, the high pressure accumulator 100 of the brake system according to an embodiment of the present invention includes one damping member 140 to partition the damping housing 120 into two layers. However, the present invention is not limited thereto, and two or more damping members may be disposed to optionally increase the number of layers of the damping housing 120 . For example, FIG. 3 illustrates a high pressure accumulator 100 ′ having two or more damping members 140 ′ of a brake system according to another embodiment of the present invention. Here, like reference numerals that are the same as those of the previous drawings are used for like elements having the same functions.
The high pressure accumulator 100 ′ of the brake system according to the current embodiment includes a damping housing 120 that is installed in a bore 11 in a modulator block 10 and has an orifice part 130 integrally formed in the damping housing 120 , a closing member 110 that closes one end of the bore 11 , and at least two or more damping members 140 ′ that are installed in the damping housing 120 and partition the damping chamber 121 into a plurality of layers. Three damping members 140 ′ are provided, as illustrated in the drawings, and are stacked and disposed in series.
In this case, the plurality of damping members 140 ′ have diameters at which they correspond to each other, and the damping member 140 ′ disposed at the lowermost end is supported by the stepped part 124 formed in the damping housing 120 , and the damping member 140 ′ disposed at the uppermost end is pressed in and coupled to the closing member 110 . Also, an introduction hole 142 ′ that is in communication with the inport 12 is formed in the damping member 140 ′ disposed in the position corresponding to the inport 12 .
Each damping member 140 ′ includes a body part 141 ′, an inclined part 144 ′ formed on a bottom surface of the body part 141 ′ to be inclined, and a connection hole 143 ′ formed in the inclined part 144 ′. Each damping member 140 ′ is installed in the damping housing 120 so that the damping chamber 121 partitioned into four layers by the damping member 140 ′ are in communication with the connection hole 143 ′. In this case, the damping chamber 121 partitioned into a plurality of layers by the damping member 140 ′ may be optionally formed to have the same heights according to heights of the damping members 140 ′ or may be optionally formed to have different heights. That is, the heights of the damping members 140 ′ may differ so that heights of the partitioned layers of the damping chamber 121 may be changed and thus characteristics of a fluid flow may be changed. Thus, as illustrated in FIG. 4 , brake oil pumped by a pump (not shown) is introduced into the damping chamber 121 through the inport 12 so that pressure pulsation may be attenuated through the damping chamber 121 that are primarily partitioned into four layers and may be secondarily reduced through the orifice part 130 formed integrally with the damping housing 120 and thus the brake oil is discharged through the outport 13 . Thus, pressure pulsation and noise generated by the high-pressure brake oil may efficiently be reduced.
The above-described high pressure accumulator 100 ′ according to the current embodiment may be used to reduce pressure pulsation using various structures in which the damping chamber 121 is partitioned into four layers to reduce pressure pulsation of the brake oil. However, the number of layers of the damping chamber 121 may be optionally increased/decreased according to a capacity of a chamber of the brake system and the size of the bore 11 may be changed.
As described above, in a high pressure accumulator of a brake system according to the one or more of the embodiments of the present invention, an orifice part for reducing pressure pulsation is formed integrally with a damping housing so that a process of installing an orifice separately can be removed and thus an assembling time and a processing time can be reduced compared to the related art.
In addition, a damping chamber formed in the high pressure accumulator is optionally partitioned into a plurality of layers according to a capacity of a chamber so that pressure pulsation can efficiently be reduced. In this case, a damping member that partitions the damping chamber into a plurality of layers is formed of a material having rigidity so that, although the damping member is used for a long term, a problem relating to lowering of the function of the damping member caused by lowered durability can be solved.
Although a few embodiments of the present invention have been shown and described, it would be appreciated by those skilled in the art that changes may be made in these embodiments without departing from the principles and spirit of the invention, the scope of which is defined in the claims and their equivalents.
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Disclosed herein is a high pressure accumulator of a brake system capable of attenuating pressure pulsation of oil discharged from a pump. The present invention is directed to a high pressure accumulator a brake system in which a damping chamber disposed to attenuate pressure pulsation is optionally partitioned into a plurality of layers to change characteristics of a flow of brake oil so that pressure pulsation can be efficiently reduced. Therefore, it is an aspect of the present invention to provide a high pressure accumulator of a brake system in which an orifice part is integrally formed so that a processing time for installing an orifice separately and an assembling time therefor can be reduced.
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FIELD OF THE INVENTION
The present invention relates to databases in general. In particular, the present invention relates to a slow materialization sort of presorted inputs in a database system.
BACKGROUND OF THE INVENTION
A common form of an information retrieval system for managing computerized records contained in a database is a relational database management system. Between an actual database (that is, data stored for use by a computer) and users of an information retrieval system for managing is a software layer known as the relational database management system (RDBMS or DBMS). The RDBMS is responsible for handling all requests for access to the database and shielding the users from the details of any specific hardware and/or software implementation. Using relational techniques, the RDBMS stores, manipulates and retrieves data in table form. Typically, these relationships are defined by a set of columns and a set of rows. The columns are also referred to as attributes, or data types. The rows are also referred to as records or tuples, of data.
A standard language for dealing with DBMSs is the Structured Query Language (SQL). SQL comprises both data definition operations and data manipulation operations. To maintain data independence, a set of SQL commands, referred to as a query, provides the RDBMS with instructions to perform. However, the query does not describe directions for performing the instructions. Thus, the RDBMS comprises a query processor for generating various query plans of execution and choosing a preferred plan. Due to the high-level nature of relational expressions and a variety of implementation techniques, automatic query optimization is possible and often necessary to ensure efficient query processing.
In accordance with well-known query translation processes, an SQL query is processed in stages. The initial stage casts the source query into an internal form such as the Query Graph Model (QGM) following the preliminary steps of lexing, parsing and semantic checking. The goal of the QGM is to provide a more powerful and conceptually more manageable representation of queries to reduce the complexity of query compilation and optimization. The internal QGM is a data structure for providing the semantic relationships of the query for use by query translator and optimizer components for rewriting the query in a canonical form. A plan optimizer produces a query execution plan such as by generating alternate plans and choosing a best plan based on estimated execution costs. A plan refinement stage may be employed to refine the optimum execution plan in accordance with run-time requirements.
Often, for the query results to be utilized in a meaningful way, the query is also sorted. However, database tables can be very large and processing tables for sorting can be expensive in terms of computer resources. Therefore, it is important that techniques for sorting tables be as efficient as possible.
Known database systems provide a sorting operation that executes completely on a table. That is, when a sorting operation is used in executing an application such as a query plan in a database system, output rows are returned from the sorting operation only when the sorting operation has been executed on the entire table. Thus, the sorting operation acts as a barrier for outputting rows. Consequently, the application or query waits until the sorting operation is completed before receiving any sorted rows. This waiting period increases the application execution time, which may be especially high for external sorting operations. External sorting operations are generally performed when the data to be sorted is too large to place in a main memory. Such sorting operations seek to minimize disk accesses for the sort. What is therefore needed is a system and associated method that reduce the waiting time for sorting operations executed on tables. The need for such system and method has heretofore remained unsatisfied.
SUMMARY OF THE INVENTION
The present invention satisfies this need, and presents a system, a computer program product, and an associated method (collectively referred to herein as “the system” or “the present system”) for providing an information retrieval system for a slow materialization sort of a partially presorted input for effectively pipelining a query. Advantageously, the invention reduces the waiting period for obtaining results from a sorting operation under certain circumstances. Thus, applications may access sorted rows faster than previously possible for performing subsequent operations, reducing overall application execution time.
In accordance with an aspect of the present embodiment, there is provided, for an information retrieval system adapted to process a query having an associated plan, the associated plan comprises sorting an input that is at least partially sorted such that a slow materialization sort can be applied, a method of applying the slow materialization sort, the method comprising determining a sequence of subsets in accordance with the partially sorted input, and, outputting the subset for further processing, as each of the subsets is determined.
In accordance with another aspect of the invention, there is provided an information retrieval system adapted to process a query having an associated plan, the associated plan comprises sorting an input that is at least partially sorted such that a slow materialization sort can be applied, the information retrieval system for applying the slow materialization sort, the information retrieval system comprising means for determining a sequence of subsets in accordance with the partially sorted input, and, means for outputting the subset for further processing, as each of the subsets is determined.
In accordance with yet another aspect of the invention, there is provided a computer program product having a computer readable medium tangibly embodying computer executable code for directing an information retrieval system to apply a slow materialization sort, the information retrieval system adapted to process a query having an associated plan, the associated plan comprises sorting an input that is at least partially sorted such that a slow materialization sort can be applied, the computer program product comprising code for determining a sequence of subsets in accordance with the partially sorted input, and, code for outputting the subset for further processing, as each of the subsets is determined.
In accordance with yet another aspect of the invention, there is provided an article comprising a computer readable modulated carrier signal being usable over a network, and comprising means embedded in the computer readable modulated carrier signal for directing an information retrieval system to apply a slow materialization sort, the information retrieval system adapted to process a query having an associated plan, the associated plan comprises sorting an input that is at least partially sorted such that a slow materialization sort can be applied, the article comprising means in the medium for determining a sequence of subsets in accordance with the partially sorted input, and, means in the medium for outputting the subset for further processing, as each of the subsets is determined.
BRIEF DESCRIPTION OF THE DRAWINGS
The various features of the present invention and the manner of attaining them will be described in greater detail with reference to the following description, claims, and drawings, wherein reference numerals are reused, where appropriate, to indicate a correspondence between the referenced items, and wherein:
FIG. 1 is a schematic illustration of an exemplary operating environment in which a slow materialization sorting system of the present invention can be used;
FIG. 2 is a process flow chart illustrating operation of a method for a slow materialization sort in accordance with an embodiment of the invention;
FIG. 3 is a table representing a sample, presorted table eligible for a slow materialization sort in accordance with an embodiment of the invention; and
FIG. 4 is a diagram illustrating an exemplary optimizer plan in accordance with an embodiment of the invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The following detailed description of the embodiments of the present invention does not limit the implementation of the invention to any particular computer programming language. The present invention may be implemented in any computer programming language provided that the Operating System (OS) provides the facilities that may support the requirements of the present invention. A preferred embodiment is implemented in the C or C++ computer programming language (or other computer programming languages in conjunction with C/C++). Any limitations presented would be a result of a particular type of operating system or computer programming language, or data processing system and would not be a limitation of the present invention.
FIG. 1 portrays an exemplary overall environment in which a system and associated method for slow materialization sorting of partially ordered inputs in a database system according to the present invention may be used. A data processing system 100 comprises a memory 112 for storing a database 102 , an information retrieval system shown as a relational database management system (RDBMS) 104 , a query 106 and a query result 107 . The RDBMS further comprises a query compiler 108 for reading the query 106 and subsequently generating an executable query 110 . Output of the executable query 110 is the query result 107 .
The invention provides a slow materialization sort of a partially ordered input in a database system for effectively pipelining a query. The slow materialization sort system and method includes a software programming code or computer program product that is typically embedded within, or installed on a computer. Alternatively, the slow materialization sort can be saved on a suitable storage medium such as a diskette, a CD, a hard drive, or like devices. A slow materialization sort averts wasting central processor unit (CPU) and disk resources and reduces spilling large sorts of already ordered data. A slow materialization sort is a sort performed on a stream of data, or input, that is already in at least a partially desired order. It is used to accumulate a subset of the sort, and then have that subset consumed, while the remainder of the sort proceeds. Thus, it is possible for rows to be output from the sort while the sort is still executing.
However, the ability to provide a slow materialization sort relies on the input being at least partially ordered. The following is a general description of a slow materialization sort in accordance with an embodiment of the invention.
In the present embodiment, a query desires a sort for a set of records, where the records comprise columns or fields C 1 , C 2 , C 3 , . . . Cn for some integer value of n>1. The input records are to be sorted on columns C 1 , C 2 , . . . , Cm, where m≦n and m>1. The input records are already partially sorted. Specifically, the records are presorted on C 1 , C 2 , . . . , Cj, where 1≦j≦m. Therefore, if m=j, an easy solution is to feed the input to the output since it is already sorted as desired. Columns C 1 , C 2 , . . . , Cn refer to a specific, predefined order of columns and not necessarily to contiguous columns.
Referring to FIG. 2 , a flow chart illustrating operation of a method for the slow materialization sort is shown generally by numeral 200 . Step S 201 comprises reading an input row C 1 , C 2 , C 3 , . . . , Cn into memory and noting values for C 1 , . . . , Cj. Step S 202 comprises incrementing a row indicator or pointer. Step S 203 comprises reading a subsequent row into memory and comparing its values for C 1 , . . . , Cj with the previous row's values for values for C 1 , . . . , Cj. In step S 209 , if the values are the same, a subsequent row is read into memory and the steps S 202 and S 203 are repeated until the values differ. Once it is determined at step S 209 that the values differ for C 1 , . . . , Cj, the operation proceeds to step S 204 . Step S 204 comprises determining a subset of rows. It is known that a subset of rows having the same values for C 1 , . . . , Cj is stored in memory. Further, it is known that the input is sorted in accordance with C 1 , . . . , Cj, and all rows having the same values for C 1 , . . . , Cj are grouped together. Thus, there are no more rows in the input that can have the same values for C 1 , . . . , Cj as those stored in the subset.
In step S 205 , the subset of rows determined in step S 204 is output for performing subsequent operation on the data. In the present embodiment, the subsequent operations order the data in accordance with the values for Cj+1, . . . , Cm. The sorting methods used for the subsequent operations ordering the data comprise standard and proprietary sorting methods, as may be appreciated by a person skilled in the art and may further comprise internal and external sorts.
In step S 206 , a check is made to determine if more rows are available for processing. If more rows are available, processing proceeds to step S 202 . If no further rows exist for processing, then processing ends at step S 207 .
Concurrently with the subsequent operations ordering the data, the row indicator is incremented in step S 202 . In step S 203 a subsequent row from the table is read into memory. Steps S 202 to S 204 are repeated for a second subset of rows. The entire process is repeated until all rows in the input table are sorted. Therefore, the sort outputs subsets of rows as they are determined so the application can begin to receive results quickly, even while the slow materialization sort is still executing.
Referring to FIG. 3 , a sample table T 1 is shown for illustrating the operations described above. The table T 1 comprises three columns C 1 , C 2 , and C 3 and a plurality of rows R 1 , R 2 , etc. The table T 1 is indexed in accordance with column C 1 . Thus, the table T 1 is sorted in accordance with column C 1 , but not columns C 2 and C 3 . A query is applied to the table T 1 as follows:
select * from T 1 where C 1 ≧100 order by C 1 , C 2 , C 3
Since the table T 1 is indexed on C 1 , it is easy to determine for which of the rows R 1 , R 2 , etc. the predicate C 1 >100 is true. In the present example, only the first row R 1 does not satisfy the predicate. The second row R 2 is read into memory and its value for C 1 , that is 100, is noted. The third row R 3 is read into memory and its value for C 1 is compared with the previous row's value for C 1 . Since the values are the same, the fourth row R 4 is read into memory and its value for C 1 is compared with the previous row's value for C 1 . This continues until the sixth row R 6 , which has a value of 101 for C 1 . Accordingly, since the table is indexed and thus ordered on column C 1 , there are no more rows R 1 , R 2 , etc. having a value of 100 in the table T 1 . Thus, a first subset comprises the second row R 2 through fifth row R 5 in the table T 1 . This subset is then sorted in accordance with column C 2 and then column C 3 . Once the subset is completely sorted it is returned as output.
While the first subset is being sorted further, the process continues sorting the table T 1 . The seventh row R 7 is read into memory and its value for C 1 is compared with the value of the previous row R 6 for C 1 . This continues until the next mismatch, which occurs for the eleventh row R 11 , which has a value of 103. Thus, a second subset comprises the sixth row R 6 through tenth row R 10 in the table T 1 . This subset is then further sorted in accordance with columns C 2 and C 3 . Once the subset is completely sorted it is returned as output.
The operations described above continue until the last row is read from the table. Thus, it can be seen that the slow materialization sort effectively pipelines the sort, resulting in a faster throughput for the query.
It may be appreciated by one skilled in the art, that the sorting on columns C 2 , C 3 can also occur with their acceptance into the subset being accumulated and not as a separate process after the subset is established. For example, step S 202 could also comprise processing to insert the row into a sort. Thus, when the subset is output for further processing at step S 205 , the output is a completed sort on the subset. The operation resets the SORT for the next subset.
The operation described above is fairly rigid in that it requires that the presorted portion of the table be the highest order of the required sort. That is, if the sort is required for columns C 1 , C 2 , . . . Cm, only tables presorted as C 1 , C 2 . . . Cj, where j<m, can be applied. Thus, for the example described with reference to FIG. 2 , if the table T 1 was sorted on C 2 instead of C 1 , it would not be possible to apply the slow materialization sort.
However, for operations such as GROUP BY in a database system, a sort is required but the column order of the sort is not important for sorting and grouping the output. This characteristic can be exploited for improving the flexibility of the slow materialization sort by rearranging the order of the sort in the query to suit the order in which the table is partially sorted. The following is a general description how this characteristic can be exploited for a GROUP BY operation.
A GROUP BY operation specifies a sort on columns C 1 , . . . , Cm, and the input is sorted on Ci 1 , Ci 2 , . . . , Cij, where 1<=j<m, Cix <> Ciy for ix <> iy, i 1 <=ix<=ij and i 1 <=iy<=ij. That is, the input is sorted on columns in a different order than that specified by the GROUP BY operation. However, since the order of a sort in a GROUP BY operation is inconsequential, the rows can be sorted on any permutation of C 1 , . . . , Cm. For example, a valid sort order could be Cm, Cm−1, . . . , C 2 , C 1 , which reverses the columns, and sorts on Cm first.
Thus, for such “permutable” sorts, a strategy is to permute the sort columns in the query for arranging the column in order such that Ci 1 , . . . , Cij are the first sort columns in the query. The remaining columns in the sort Cij+1, . . . , Cm can be placed next, in any order. This new sort order allows a slow materialization sort to execute using the operations described with reference to FIG. 2 .
The costs of the different sorts that could be generated by the optimizer, that is sorts using the original sort order and the new sort order, are evaluated. The optimizer selects the sort that is the most efficient with respect to a predefined estimated performance metric, such as response time.
An example of reorganizing a GROUP BY operation is given as follows. A query is provided for counting the number of rows in tables R and F that have an equivalent value in column A, for each value that satisfies a predefined predicate. Specifically, the query is given as follows:
Select R.A, R.B, count (*) from R, F where R.A=F.A group by R.B, R.A
Further, an index is available only on column A of table R. Therefore, if it was required to strictly adhere to the order of the sort, a slow materialization sort would not be applicable since the slow materialization sort is applied first to column B of table R. However, since a GROUP BY operation does not depend on the order of the columns of the sort, the query can effectively be reordered without adversely affecting the results as follows:
Select R.A, R.B, count (*) from R, F where R.A=F.A group by R.A, R.B
Since the sort to be performed is on a partially sorted list, that is the index of table R on column A provides the ordering for R.A, the slow materialization sort of the present invention can be applied. As each subset is determined by the slow materialization sort, the subset is returned for further processing by the query. Thus, the result of the query can be determined faster than if a slow materialization sort had not been used.
In yet an alternate embodiment, the slow materialization sort can be used for assisting with symmetric multiprocessing (SMP). SMP generally refers to processing of programs by multiple processors that share a common operating system and memory. To efficiently run a query using SMP, it is necessary to SMP parallelize a plan. When SMP parallelizing a plan, it is sometimes necessary to introduce a sort to partition data for a join or for rebalancing workload between processors, or agents. Currently, even though a stream is properly ordered a sort still has to be performed before proceeding with the execution of the query. Consequently, the agents have to wait until the sort is completed before proceeding.
However, by using the slow materialization sort agents can take advantage of the fact that each subset is complete for the indexed column. Thus once each subset is complete, the subset of data is available to one or more of the agents for further processing. The sort operation required for SMP is an inter-partition parallelism sort on a data stream that already has the order that would be imposed by the sort. Thus, using the slow materialization sort provides the added function that an SMP agent that has been populating the sort occasionally checks its own sort bin to determining the presence of a record. If the SMP agent finds such a record, it stops processing the sort and instead processes the record in its sort bin. When an agent checks its sort bin and the bin is empty, the agent checks the plan to determine if the slow materialization sort is complete. If the slow materialization sort is incomplete, the agent proceeds to sort the next section of the index. This continues until either a record is found in the agent's sort bin, or the input to the sort is exhausted, as is described in detail below.
Referring to FIG. 4 , an optimizer plan is illustrated generally by numeral 400 . The optimizer plan shown is designed for two agents, AGENT# 1 and AGENT# 2 . One of the techniques that Inter Partition Parallelism uses to perform a Merge Scan Join (MSJN) is to data partition inputs to the MSJN such that each agent can perform the join for its own partition. The first partition for the first agent AGENT# 1 comprises a SCAN 403 , a SORT 404 , an index SCAN (ISCAN) 405 , and a first index Index 1 409 . Similarly, the second partition for the second agent AGENT# 2 comprises a SCAN 406 , a SORT 407 , an ISCAN 408 and a second index Index 2 410 .
SORT 404 and SORT 407 are slow materialization SORTs. AGENT# 1 starts the ISCAN 405 . AGENT# 1 reads rows from Index 1 409 for insertion into SORT 404 . SORT 404 performs a slow materialization sort on the index Index 1 409 based on the column used in the MSJN 402 predicate. Once a subset is completed, the rows in the subset are hashed into one of two SORT Bins, Bin# 1 or Bin# 2 , one for each of the two agents involved. A hashing algorithm hashes the sorted rows in the two bins for dividing work evenly between the agents performing the join. Once AGENT# 1 completes sorting the first subset, it checks its SORT Bin, SORT 404 , Bin# 1 . If the bin is empty, it sorts the next subset of rows from the index Index 1 409 .
When AGENT# 1 finds a row in its SORT Bin, SORT 404 , Bin# 1 , it proceeds to the SCAN 403 , which reads the row from SORT 404 , Bin# 1 . AGENT# 1 then processes the MSJN 402 , which causes AGENT# 1 to try to read from SORT 407 , Bin# 1 for applying the MSJN.
If SORT 407 , Bin# 1 is empty, AGENT# 1 starts the ISCAN 408 . As with ISCAN 405 , AGENT# 1 selects rows from index Index 2 410 , for inserting into SORT 407 . A slow materialization sort is performed by SORT 407 and the next subset resulting from the SORT 407 is hashed into one of two SORT bins, Bin# 1 and Bin# 2 . Once AGENT# 1 finishes with the subset of rows from the index Index 2 410 , it checks SORT 407 , Bin# 1 . If the bin is empty, it reads and sorts the next subset of rows from the index Index 2 410 .
When AGENT# 1 finds a row in its SORT Bin, SORT 407 , Bin# 1 , it proceeds to the SCAN 406 , which reads the row from SORT 407 , Bin# 1 . AGENT# 1 then processes the MSJN 402 that joins the output of SORT 404 , Bin# 1 with the output of SORT 407 , Bin# 1 .
Concurrently, AGENT# 2 performs the same functions as AGENT# 1 . That is, AGENT# 2 reads rows from Index 2 410 for insertion into SORT 407 . SORT 407 performs a slow materialization sort on the index Index 2 410 based on the column used in the MSJN 402 predicate. Once a subset is completed, the rows in the subset are hashed into one of two SORT Bins, Bin# 1 or Bin# 2 , one for each of the two agents involved. A hashing algorithm hashes the sorted rows in the two bins. Once AGENT# 2 completes sorting the first subset, it checks its SORT Bin, SORT 407 , Bin# 2 . If the bin is empty, it sorts the next subset of rows from the index Index 2 410 .
When AGENT# 2 finds a row in SORT 404 , Bin# 2 , it proceeds to SCAN 403 and processes the MLJN 402 . The MLJN causes AGENT# 2 to try to read from SORT 404 , Bin# 2 for applying the MSJN. If the read of SORT 407 , Bin# 2 fails, AGENT# 2 reads ISCAN 405 , sorts the next subset using SORT 404 , and hashes the rows into the appropriate bins. When AGENT# 2 finds a row in its SORT Bin, SORT 404 , Bin# 2 , it proceeds to the SCAN 403 , which reads the row from SORT 404 , Bin# 2 . AGENT# 2 then processes the MSJN 402 , which joins the output of SORT 407 , Bin# 2 with the output of SORT 404 , Bin# 2 .
The two agents continue to work between the two SORTs 404 and 407 until they have completed processing the MSJN 402 . Using a slow materialization sort for processing a SMP parallelization plan benefits greatly from an early stop capability of MSJN, whereby a MSJN may stop processing an inner or outer join if the outer or inner join has been exhausted. A fully materialized sort, that is a sort wherein an entire input stream is processed before results are output, cannot benefit from this feature since by the time sort is complete, it is too late to apply an early stop decision.
One key challenge is ensuring SMP agents remain appropriately synchronized through the operation of the slow materialization sort. If one should happen to get ‘stuck’, overloaded, or poorly balanced, a sort bucket may be spilled to disk. To inhibit such expensive disk accesses, one simple control is to have all of the agents stop and wait for the other agent to read from its SORT Bin. Alternately, a dynamic rebalancing of the two slow materialization sorts could be allowed for redistributing the rows more evenly among the agents. Alternatively, an adaptive hashing algorithm may be employed. While the slow materialization sort for SMP is described with reference to two agents and the number of sorts and joins illustrated in FIG. 4 , a person of ordinary skill in the art may appreciate the exemplary nature of this description.
It may be appreciated that persons skilled in the art may implement an aspect of the invention as a computer program product having a computer-readable medium tangibly embodying computer executable instructions for directing a data processing system to implement the method(s) described above. It may be appreciated that the computer program product may be a floppy disk, hard disk or other medium for long term storage of the computer executable instructions.
It may be appreciated that persons skilled in the art may implement an aspect of the invention as a computer-readable signal-bearing medium, and having means in the medium for directing a data processing system to implement any method(s) described above. It may be appreciated that a supplier of the compiler may upload the article to a network (such as the Internet) and users may download the article via the network to their respective data processing systems.
It is to be understood that the specific embodiments of the invention that have been described are merely illustrative of certain application of the principle of the present invention. Numerous modifications may be made to the system and method for slow materialization sorting of partially ordered inputs in a database system invention described herein without departing from the spirit and scope of the present invention.
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The present system improves the performance of a query in a database system when a plan for the query comprises sorting an input that is at least partially sorted such that a slow materialization sort can be applied. The invention applies the slow materialization sort by determining a sequence of subsets in accordance with the partially sorted input. As each of the subsets is determined, the subset is output for further processing. Advantageously, the invention reduces the waiting period for obtaining results from a sorting operation under certain circumstances.
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BACKGROUND
Annular seals are a common part of virtually all hydrocarbon recovery systems. Such seals come in many different configurations and ratings. Such seals are a necessary and important part of hydrocarbon recovery efforts and generally function well for their intended purposes. In situation where there is a high differential pressure across the seal however extrusion of the seal becomes a concern. Extrusion occurs axially when the seal is extruded through a small gap between the tubular at an inside surface of the seal and the tubular at the outside surface of the seal. The gap is there because in order to run a tubular into a casing, clearance is necessary. This is also the reason that a seal is needed in the first place. While many configurations have been created to limit the gap and improve extrusion resistance, the art is always receptive to alternative methods and particularly to configurations capable of accommodating higher pressure differentials.
SUMMARY
A resettable antiextrusion system including a backup ring, a ramp in operable communication with the backup ring, and a gauge ring attached to the ramp.
A method for sealing a tubular including compressing a resettable antiextrusion system including a backup ring, a ramp in operable communication with the backup ring, a gauge ring attached to the ramp, urging the backup ring along the ramp to gain a greater radial dimension than the gauge ring, deforming an element at the system into contact with the tubular adjacent the backup ring.
BRIEF DESCRIPTION OF THE DRAWINGS
Referring now to the drawings wherein like elements are numbered alike in the several Figures:
FIG. 1 is a cross section view of a resettable antiextrusion backup system in an unsealed condition;
FIG. 2 is a cross section view of a resettable antiextrusion backup system in a sealed condition;
FIG. 2 a is a view similar to FIG. 2 but with the backup ring in contact with a tubular;
FIG. 3 is a perspective view of a backup ring as disclosed herein;
FIG. 4 is a perspective view of a ramp as disclosed herein;
FIG. 5 is a perspective view of a gauge ring as disclosed herein;
FIG. 6 is a perspective view of an assembly of FIGS. 3 and 4 ;
FIG. 7 is a perspective view of an assembly of FIGS. 3 , 4 and 5 ;
DETAILED DESCRIPTION
Referring to FIGS. 1 and 2 a cross section of a resettable antiextrusion backup system 10 is illustrated in an unset ( FIG. 1 ) and set ( FIG. 2 ) condition respectively. Focusing upon FIG. 1 , the system 10 is illustrated in cross section within another tubular structure 12 such as a casing segment. It will be apparent that there is a clearance 14 between a gauge ring 16 and an inside surface 18 of the casing 12 . This clearance is taken up by an element 20 when the system 10 is compressed. This is similar to prior art devices in that those devices cause an element to expand into contact with an inside surface of a tubular in which they are set but due to the size of the clearance, extrusion of such elements is possible. In the system disclosed herein, extrusion is prevented by a backup ring 22 that is displaceable to occupy the clearance space entirely (see FIG. 2 a ). With the backup ring 22 in place, it is impossible for the element 20 to extrude in the direction of the backup ring 22 . Advantageously, in the system disclosed, it is also possible to retract the backup ring 22 to an outside dimension less than that of the gauge ring 16 . Moreover, setting and unsetting of the system 10 is possible for a great number of cycles.
In order to actuate the backup ring 22 , a number of other components of the system 10 are utilized. A ramp 24 exhibits a frustoconical surface 26 that interacts with the backup ring 22 during axial compression of system 10 to cause the backup ring 22 to gain in radial dimension resulting in the backup ring spanning the entirety, in one embodiment ( FIG. 2 a ), or at least a substantial portion of, in other embodiments, the clearance 14 . In one embodiment the frustoconical surface 26 has an angle of about 40 to about 60 degrees and in a specific embodiment has an angle of about 50 degrees. In this position, the backup ring 22 effectively prevents extrusion of the element 20 due to differential pressure thereacross.
The ramp 24 is fixedly connected at one or more connections 28 to the gauge ring 16 such that the ramp 24 and the gauge ring 16 always move together in an assembled system 10 . In order to provide a greater understanding of the backup ring 22 , ramp 24 and gauge ring 16 , reference is made to FIGS. 3-7 in which is illustrated each one of these components in perspective view in FIGS. 3 , 4 , and 5 and then combinations of these components in FIGS. 6 and 7 . The backup ring 22 includes one or more openings 30 that allow for the fixed connections 28 between the ramp 24 and the gauge ring 16 . The fixed connections 28 , in one embodiment hereof comprise a thread 32 at an inside surface 34 of the gauge ring 16 and a thread 36 at an outside surface 38 of the ramp 24 . The two threads are complementary and engage one another through the openings 30 when the backup ring 22 , ramp 24 and gauge ring 16 are assembled. It will be noted by the astute reader that the openings 30 are larger in the axial direction that the thread 36 is in the axial direction. This is to allow for axial movement of the backup ring 22 relative to the fixedly connected ramp 24 and gauge ring 16 . Axial movement is provided to allow for the backup ring 22 movement up the frustoconical surface 26 of the ramp 24 which in turn causes the backup ring 22 to gain in radial dimension and fill the clearance 14 . A review of FIGS. 6 and 7 will make the assembly clear to one of ordinary skill in the art.
Referring back to FIG. 1 , the ramp is slidably in contact with a booster sleeve 40 that in turn is supported by more downhole components not germane to this disclosure but represented schematically by the structure identified with numeral 42 . At an opposite end of the system 10 is another schematically represented structure 44 representing components more uphole of the system 10 which again are not germane to the disclosure. These two illustrated structures are only illustrated to show a structure to which certain components of the system 10 are attached. Booster Sleeve 40 is one such component of the system 10 and is attached to structure 42 via a thread 46 . A spacer 48 is supported by the structure 42 in some embodiments to limit overall stroke of the system 10 to prevent damaging the element 20 . Spacer 48 is sized to be contacted by a connector sleeve 50 that is itself fixedly connected to structure 44 . This connection is via a thread 52 in one embodiment though any fixed connection could be substituted. Structure 44 is also fixedly connected to backup ring 22 at thread 54 . Finally a retraction dog 56 is disposed in a slot 58 in ramp 24 to ensure that with a tensile load placed on system 10 , the load is transferred to the Booster Sleeve 40 and subsequently reduces the radial dimension of the Back Up Ring 22 to an outside dimension less than the outside dimension of the Gage Ring 16 .
In operation, the system 10 provides, as above noted, up to a full clearance 14 obstruction and upon unsetting, the backup ring 22 can be brought back to a sub gauge dimension. This is exceedingly beneficial to the art because it means that extrusion of seals can be reliably and effectively prevented while the system 10 can be repositioned in the wellbore without concern for becoming stuck or doing damage to other wellbore tools due to an antiextrusion configuration having an outside dimension greater that gauge size.
While preferred embodiments have been shown and described, modifications and substitutions may be made thereto without departing from the spirit and scope of the invention. Accordingly, it is to be understood that the present invention has been described by way of illustrations and not limitation.
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A resettable antiextrusion system including a backup ring, a ramp in operable communication with the backup ring, and a gauge ring attached to the ramp. A method for sealing a tubular.
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BACKGROUND OF THE INVENTION
The present invention relates to important improvements in the weft transport grippers for shuttleless looms, of the type wherein a first gripper (carrying) grasps the weft thread at one side of the loom and carries it to the centre of the warp shed, while the second gripper (drawing) receives the weft thread at the centre of the warp shed from the carrying gripper, and transports it to the opposite side of the loom, where it releases the same.
The pair of grippers according to the invention comprises grippers of reduced weight and dimensions which cooperate with each other without penetrating one into the other and which may move along a common plane, which may be differently oriented in respect of the plane of the loom reed.
SUMMARY OF THE INVENTION
The improved pair of weft transport grippers according to the invention is essentially characterized in that, in both grippers, the weft thread grasping and holding members are mounted on head parts of the grippers disposed on opposite sides of a sliding plane, along which said head parts move side by side, cooperating between them for grasping and releasing the weft thread. Said sliding plane may be parallel, perpendicular or differently inclined in respect of the plane of the loom reed.
The carrying gripper of the pair of grippers according to the invention is characterized by a rear part, whose side close to the sliding plane projects beyond said plane in respect of the head part of the gripper, so as to form a guide for the weft thread parallel to the plane itself, said head part comprising a pair of pegs for positioning the end of the weft thread, said pegs being arranged close to the free end of the thread grasping and holding means, on one side and on the other thereof, and in a position such as to cause the weft thread to be positioned between said guide and the first of said pegs only slightly inclined (about 25° at the most) in respect of the sliding plane.
Moreover, said carrying gripper mainly comprises a basic gripper body, the rear part of which is fixed to the gripper advancement strap and forms said guide for the weft thread, and the head part of which is equipped with said weft thread grasping and holding means, and a adapted to be applied on said basic body and comprising an opening for housing said weft thread grasping and holding means, said pegs projecting from said cover and fitting into said basic body or viceversa.
The drawing gripper of the same pair of grippers is also characterized by the fact that the thread guard of its head part comprises a profiled appendix, extending parallel to the gripper body for covering the weft thread grasping and holding means.
The invention also comprises shuttleless weaving looms using the aforespecified grippers.
BRIEF DESCRIPTION OF THE DRAWINGS
In the accompanying drawings:
FIG. 1 is a front view of a loom part corresponding to the warp shed, showing a first type of a pair of weft thread transport grippers according to the invention, in a thread exchange position;
FIG. 2 is a section along the line II--II of FIG. 1;
FIG. 3 is a top view according to the arrow III of the arrangement of FIG. 1;
FIG. 4 is a view similar to that of FIG. 1, but showing a modified embodiment of the pair of grippers according to the invention on the loom, in the position of weft thread exchange;
FIG. 5 is a top view according to the arrow V of the arrangement of FIG. 4;
FIG. 6 is a top view of a third embodiment of the pair of grippers according to the invention in a condition which slightly precedes the weft thread exchange between the two grippers;
FIG. 7 is a front view of the body part of the carrying gripper, with the cover removed;
FIG. 8 is a bottom plan view of FIG. 7;
FIG. 9 is a bottom plan view of the removed cover of the carrying gripper;
FIG. 10 is a front view of the removed cover of the carrying gripper; and
FIGS. 11 and 12 are a schematic side view and a fragmentary perspective view of the head part of the drawing gripper, illustrating the appendix for protecting the thread guard of said gripper.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
As shown in the drawings, the pair of grippers according to the invention comprises a carrying gripper 1 and a drawing gripper 2, in which the weft thread grasping and holding means 3 and 4 are mounted on head parts 5 and 6 of the grippers themselves which are arranged on one side and, respectively, on the other side of a plane α along which the gripper head parts 5 and 6 slide on each other in their working motion, cooperating between them with the mutually sliding parts of each disposed only on one side of that plane for exchanging the weft thread f.
In the arrangement of FIGS. 1 to 3, the plane α is perpendicular to the plane of the reed P, parallel to which are arranged the gripper advancement straps or tapes 7 and 8, sliding in special guiding supports 9, and the grippers themselves.
In the arrangement of FIGS. 4 and 5, the plane α and the grippers are again arranged as in FIGS. 1 to 3, while their advancement straps are arranged along a plane parallel to the plane α and move along the same.
In the arrangement of FIG. 6, the plane α is parallel to the plane of the reed P and the grippers and straps are arranged, more traditionally, perpendicular to said reed plane and parallel to the top plane of the sley (as well as perpendicular to the plane α).
Although not shown, other arrangements of the grippers and straps could be provided, with the plane α lying inclined to different extents in respect of the plane of the reed and of the plane of the sley.
The carrying gripper of the pair of grippers according to the invention (FIGS. 1 to 10) comprises a head part 5, in which are mounted the weft thread grasping and holding members 3, consisting of a longitudinal elastic lamina 10, pressed by a leaf spring 11, which may for example correspond to those of U.S. Pat. No. 3,580,291 and of a pair of pegs 12 and 13, arranged close to the point of said elastic lamina, on one side and on the other thereof. The head comprises moreover a rear part 14, whose side close to the sliding plane α projects beyond said plane.
The carrying head 5 is formed (FIGS. 7 to 10) by two elements of plastic material associated with each other: a basic head body 16, the rear part of which 14' is fixed to the advancement strap 7, and the head part of which is equipped with the elastic lamina 10, for grasping and holding the weft thread, and with the associated leaf spring 11; and a cover 17, applied to the basic body 16 and comprising an opening 18 for the lamina 10 and related leaf spring 11. The rear part 14 of the cover 17 has its side close to the sliding plane α projecting beyond said plane and beyond the corresponding side of the rear part 14' of the underlying basic gripper body 16. On said cover side is formed a hollow guide 15 for the weft thread, which is parallel to and spaced away from the plane α. The pegs 12 and 13 are carried by the cover 17, being fitted into the assembly in appropriate seats in the body 16 (of course, it could also be viceversa). The removed cover 17 is separately shown in FIGS. 9 and 10, which latter figure shows the cover in the same position as in FIG. 6.
The head part 5 of the carrying gripper 1 further comprises a top fin 19, emerging perpendicular from the end of the body 16 which is not covered by the cover 17, with the function of protecting the warp yarns by preventing the weft thread grasping members from hitting the same. It is moreover appropriate to create in the gripper body 16 a hardened zone cooperating with the elastic lamina 10, for example by applying to said body a hard metal element, or in some other way.
The drawing gripper 2 according to the invention has its head part 6 (FIGS. 11 and 12) shifted sideways in respect of the rear part 20 connected to the advancement strap 8. On the head part 6 of the gripper are arranged (FIGS. 11 and 12) weft thread grasping and holding means 4, of the type described in U.S. Pat. No. 4,040,454. The gripper 2 draws the weft thread from the gripper 1 when--as in FIGS. 1 to 6--these two members meet and their heads 5 and 6 come up side by side on a single side. Such means comprise a fixed hook 21 and an oscillating lever 22, whose head wedges into the hook 21 so as to lock therein the weft thread under the action of spring means 23 (FIGS. 1 to 6). According to the invention, the head part 6 of gripper 2 is provided (FIGS. 11 and 12) with a thread guard 24 comprising a profiled appendix 25 extending substantially parallel to the gripper 2 for covering the hook 21.
With the pair of grippers heretofore described and illustrated, the weft thread f will lie in the guide 15 of head part 5, in alignment with its feeding path and very slightly inclined (no more than 25°) in respect of this alignment (and thus in respect of the sliding plane α between the heads of the grippers) in the area between the guide 15 and the peg 12 of the head 5 of the gripper 1, namely in the area in which the weft thread is grasped by the grasping elements 4 of gripper 2. Between the peg 12 and the peg 13, the weft thread f is instead arranged to extend between these pegs, being engaged by the elastic lamina 11.
The arrangement according to the invention introduces the use of light and slender grippers (particulary remarkable in the case of the carrying gripper, up to date always very bulky), which exchange the weft at the centre of the warp shed by simply coming close to each other with their head parts, on one side only, with evident progress and advantage compared to the known technique of inserting the whole head of the drawing gripper into an appropriate housing of the carrying gripper.
In fact, the surfaces of the two grippers coming into contact at the moment of thread exchange are reduced to a third, or even to a fourth, thereby preventing or highly reducing impacts, frictions, possible jamming and failed grasping of the weft thread.
A further remarkable improvement and advantage is obtained, according to the invention, thanks to the arrangement of the weft thread, which is slightly inclined in respect of its feeding alignment, in the gripping area between the guide 15 and the peg 12 of the head 5 of the carrying gripper 1. Thanks to this arrangement, the weft thread is not subjected, at the moment of exchange, to the traditional front impact (substantially at 90° over a very short thread length) by the hook of the drawing gripper; on the contrary, the engagement takes place very smoothly, progressively and over a very long thread length; this helps to prevent, or at least to highly reduce cases of tears, abrasions and weakening of the weft thread, in general, which compromise the proper outcome of the thread exchange. This latter may be carried out with a reduced braking of the thread and consequently with less breaks. Also the vibrations characteristic of the thread upon its exchange, are reduced, thereby improving even further the operation. On the other hand, it should also be said that it is the actual aforedescribed arrangement of the weft thread in the grasping area which allows the construction of compact and light grippers, which are well balanced as to the distribution of the masses and which make it hence possible--as confirmed by practical experience--to obtain weft insertion speeds which are clearly higher than those obtained with the traditional systems, though keeping the mechanical stresses within reasonable limits.
The reduced dimensions and the specific shape of the grippers, as described, allow one to eliminate in the carrying gripper according to the invention the normal profile protecting the warp yarns, with remarkable advantages and, that is, extreme easiness of insertion, and consequent reduction of the weft stresses and of the brakings required in order to overcome the inertia of the thread, as well as the facilitated drawing out of the weft thread from the carrying gripper upon thread exchange, due to the absence of the slippage and consequent frictions which normally take place on the thread guard. The easiness of the weft disinsertion is also improved by the considerable simplicity and freedom of the weft thread guiding elements on the carrying gripper.
Finally, it should be noted that the appendix provided on the drawing gripper to protect the hook, favours the grasping of the weft by the appropriate members of such gripper, in that it opposes the possible "ballon" of the weft thread resulting from the deceleration of the grippers movement upon thread exchange, thus allowing one to reduce the braking power for the weft thread to be inserted.
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A pair of grippers for shuttleless loams without shuttle, of the type wherein a first gripper (carrying) grasps the weft thread at one side of the loom and carries it to the center of the warp shed, while the second gripper (drawing) receives the weft thread at the center of the warp shed from the carrying gripper, and transports it to the opposite side of the loom, where it releases the same. The weft thread grasping and holding members mounted on head parts of the grippers disposed on opposite sides of a sliding plane. Along said sliding plane said head parts move side by side, cooperating between them for grasping and releasing the weft thread.
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BACKGROUND OF THE INVENTION
This invention relates to an adaptive arrangement for the identification of a periodic signal comprising an evaluation circuit for digitizing the signal and for detecting its extreme value, as well as subsequent means for detecting the fundamental oscillation of the signal.
Arrangements of this type are used to identify periodic signals having an unkown frequency, amplitude and offset position, as well as dips in the amplitude in the region of its extreme value. These parameters of the signal to be identified, abbreviated to signal hereinafter, are furthermore also subjected to variations in time. Examples of signals of this type are signals from speed sensors which are used in, for example, anti-locking systems, anti-slip systems etc. Speed sensors of this type usually produce a relatively small, fluctuating sensor signal on which a d.c. voltage is superposed. Via a subsequent comparator this changing sensor signal, beset with fluctuations, is usually digitized, that is to say it is converted into a corresponding square-wave signal and applied to a further evaluation circuit.
Identification or measuring arrangements of this type are known. They usually have a gear wheel whose signal indicates the number of revolutions and is sampled via, for example, a magnetically operating speed sensor. The German Patent Application P 3926617.6, which corresponds to U.S. Application Ser. No. 562,526, filed Aug. 3, 1990, corresponding arrangement which comprises means for amplifying, comparing and evaluating the sensor signal of the speed sensor to produce a corresponding digital output signal. In accordance with said arrangement, the signal must be unambiguously identified and evaluated, for which purpose a window comparator having a controllable window is provided as a comparator means which, via at least one logic circuit member drives a flip-flop for the supply of the output signal and is followed by means which, in dependence on the offset position continuously produce corresponding reference signals for the window comparator. The comparator and evaluation devices of this prior art arrangement furthermore include an oscillator for adapting the window range to the signal to be identified. For the case in which the signal has a dip in the regions of its peak value, there is provided in accordance with this prior art arrangement an oscillator frequency which is not significantly greater than the frequency of the signal so that the window of the window comparator does not track the signal anymore, but tracks it with some delay, the degree of this delay being limited by the oscillator frequency. At low frequencies of the signal the signal is also tracked in the region of the dips so that, as regards dips in the signal to be identified in the region of its extreme values, this prior art arrangement is not entirely reliable.
SUMMARY OF THE INVENTION
The present invention has for an object to provide an adaptive arrangement for identifying a periodic signal, which also in the case of high offset voltage tolerances, shifts and dips produces an output signal which is proportional to the fundamental oscillation (i.e. frequency) of the signal and has a simple structure, and which also operates reliably in the event of other types of interferences.
According to the invention, this object is accomplished in that the subsequent means include a mean value producing circuit and a comparator, and that, depending on whether the digital signal corresponds to a reference value which the mean value producing circuit recursively forms from the extreme values of the digitized signal, the comparator produces a variable output signal which is proportional to the fundamental oscillation of the signal.
Basically, the arrangement of the invention includes an evaluation circuit, a mean value circuit and a comparator. The evaluation circuit includes an analog/digital converter which operates in accordance with the compensation mode and includes a counting device (abbreviated to A/D converter hereinafter), to whose input the signal to be identified is applied, and a subsequent extreme value identification member whose output is connected to the mean value circuit and applies a clock signal thereto in response to the fact that an extreme value is reached. The output of the A/D converter is connected to the mean value circuit and the comparator. The analog input of the A/D converter also is connected to the extreme value identification member, which determines the extreme value from a comparison between the analog input signal and the digital signal corresponding thereto.
If in the ideal case an interference-free, sinusoidal input signal is present at the input of the evaluation circuit, then this circuit first determines whether the signal has passed through an extreme value, that is to say whether it has passed through a maximum or a minimum. These points are determined with the aid of the A/D converter in the compensation mode in that the counting direction of the converter counting device reverses after an extreme value. Advantageously, the detection of an extreme value in the evaluation circuit is not effected until a presettable minimum turn-over voltage has been reached after an extreme value.
Because of this delay small interferences in the input signal are already compensated. The value of the minimum turn-over voltage consequently also determines the lowest detectable input amplitude. The output signal can then be derived from the direction in which the converter counting device counts.
Any occurring harmonics, more specifically for signals from a magnetic field sensor the third harmonic oscillation, are frequently located within the circuit sensitivity. The effects of these harmonics, namely dips in the region of the extreme (peak) values of the signal, are identified as errors in accordance with the invention and are suppressed. The subsequent mean value circuit advantageously comprises a series arrangement of an adder member, a divider member and a storage member, the output signal of the storage member being applied as a reference value to the comparator and fed back to the input of the adder member, the adder member further having its input connected to the output of the A/D converter. Preferably, the storage member receives clock pulses from the output of the extreme value identification member.
In accordance with an advantageous embodiment of the invention, the adder member continuously produces the sum of its input signals. The subsequent divider member divides the sum by two and the storage member which follows the divider member stores at the instant a clock signal occurs the signal value then present and passes it on from its output to the input of the comparator as a reference value, and also via its input to the adder member.
All of the extreme values, consequently also the extreme values of the harmonics, are therefore applied to a recursive mean value producing circuit, that is to say at the instant an extreme value is detected, the actual digital signal value of the A/D converter is as it were added to the input of the storage member. The result of the addition then arrives, after it has been divided by two, as a new signal value in the storage member and represents the latest signal mean value following after the measuring signal, so the reference value.
In accordance with the invention, the comparator is connected at its input end to the output of the A/D converter and to the storage member of the mean value circuit and, at the instant the signals applied thereto are identified, produces a digital output signal which is proportional to the fundamental oscillation of the signal to be identified.
In addition, it is advantageous to provide a charging circuit which loads the available signal value in the storage member when the arrangement is put into use. Otherwise, for example when a zero value has been stored in the storage member, the reference value will need some periods to approach the signal.
For certain signals to be identified, in which the harmonic oscillations are not within the circuit sensitivity, a simplified, adaptive arrangement for identifying a periodic signal, including an evaluation circuit for digitizing the signal and for detecting the extreme values of this signal, can be provided in accordance with the invention, in which advantageously the evaluation circuit includes an A/D converter to the input of which the signal to be identified is applied, and a subsequent extreme value identification member, which when a presettable minimum turn-over voltage is reached after a detected extreme value, produces a variable output signal which is proportional to the fundamental oscillation of the signal.
Further preferred embodiments of the arrangement in accordance with the invention are defined in the dependent claims.
BRIEF DESCRIPTION OF THE DRAWING
An embodiment of the invention will now be described by way of example with reference to the accompanying drawing, in which:
FIG. 1 shows an output signal U A of an arrangement in accordance with the invention on the basis of a non-distorted signal U S taking account of a minimum turn-over voltage U M ,
FIG. 2 shows a faulty output signal U A of an arrangement according to the invention without a mean value circuit in the case of signal harmonic oscillations within the circuit sensitivity,
FIG. 3 is a block circuit diagram of an arrangement according to the invention including a mean value circuit, and
FIG. 4 shows an output signal U A of an arrangement according to the invention including a mean value circuit in the case of signal harmonic oscillations within the circuit sensitivity.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows two diagrams. The upper diagram shows the signal U S to be identified over the period of time t and the lower diagram shows a digital output voltage U A on the basis of an ideal sinusoidal undisturbed signal U S . The signal U S to be identified is shifted upwards from the zero position. Throughout the permissible operating range U D of an arrangement 10 of the invention, whose basic circuit diagram is shown in FIG. 3, this shift is indicated by means of a lower permissible signal U Min and an upper permissible signal U Max . The signal U S to be identified, shown in FIG. 1, is, for example, the signal at the output of a magnetically operating speed sensor of an anti-blocking or anti-slip system or such provided at the input side of the arrangement of the invention. As is shown in FIG. 1 and is explained in detail hereinafter, the pulses for producing the output signal U A are not set accurately on reaching the extreme value of the signal U S , but follow these extreme values with some time delay. This delay can be influenced by means of a presettable minimum turn-over voltage U M . Disturbances in the signal U S which, as regards their value, are within the minimum turn-over voltage U M can already be compensated for thereby. Simultaneously, the minimum turn-over voltage U M determines the lowest detectable amplitude of the signal U S to be identified, which consequently limits its magnitude, that is to say the minimum turn-over voltage U M has a value less than the value of twice the amplitude of the minimum detectable signal U S . In other words, the voltage U M must be smaller than the peak-to-peak value of the signal U S in order to make it possible to make a distinction between a signal and a disturbance.
It should here be noted that the description given in the foregoing with reference to FIG. 1 of the diagrams as regards the magnitudes shown there also holds, in essence, for the diagrams shown in FIGS. 2 and 4. In addition, it should be noted that the signals U S to be identified and shown in the FIGS. 1, 2 and 4 represent both analog and the approximately digital variation of these signals.
FIG. 2 shows a disturbed variation of the signal U S , in which the harmonic oscillations of the signal U S cause dips therein in the region of its extreme values. A magnetic field sensor of a speed sensor also produces, for example, in the case of poorly functioning sensor wheels also, the third harmonic oscillation in addition to the fundamental oscillation. The third harmonic oscillation is within the sensitivity of the arrangement, that is to say the dips caused thereby have a value higher than the minimum turn-over voltage U M and consequently produce a faulty output signal U A , as is shown in the lower diagram of FIG. 2.
In order to unambiguously prevent interferences caused by harmonic oscillations, the arrangement 10 of the invention, shown in FIG. 3, comprises an evaluation circuit 11, a mean value circuit 12, and also a comparator 13 at whose output a variable output signal U A is present and which is now only proportional to the fundamental oscillation of the signal U S . The analog signal U S is applied for that purpose to an A/D converter 14 of the evaluation circuit 11 and is digitized thereby and this digitized signal U SD is transferred to an extreme value identification member 15 of the evaluation circuit 11, to the comparator 13 and to the input of an adder member 16 of the mean value circuit 12. The analog signal U S is further coupled to the extreme value identification member 15 via a control terminal. The analog signals U S is effectively compared in the apparatus 15 with the digitized signal U SD at the output of the compensation-type converter 14. If the difference of these signal voltages exceeds U M , a change of state occurs at the output of the peak value identification member 15 when the polarity of the difference changes. Thus, in the evaluation circuit 11 the digitized signal U SD is analysed to detect whether it has passed through a maximum or a minimum. These points are determined with the aid of the A/D converter 14 in accordance with the compensation method in that the counting direction of the counter in the A/D converter 14 changes direction after it has passed through an extreme value. As has already been mentioned in the foregoing, small interferences in the signal are compensated as the arrangement responds only to a minimum turn-over voltage U M after a minimum or a maximum has been passed.
In a manner similar to that described in the aforesaid German Patent Application P 3926617.6, the compensation-type A/D converter 14 may comprise a hysteresis comparator having one input for receiving the analog signal U S . The output of the comparator is connected to an input of an up/down counter having a clock input coupled to an output of an oscillator. The digital output of the counter is applied to a D/A converter whose analog output signal is coupled to a second input of the hysteresis comparator. The digital output signal (U SD ) of the counter is applied to a D/A converter in the member 15. The analog output of the latter D/A converter is compared in a comparator in member 15 with the analog signal U S applied to the input of the A/D converter 14. The output of the latter comparator is a control signal output of member 15 destined for use in storage member 17.
The input analog signal U S is compared in the hysteresis comparator with the converter analog signal produced by the first mentioned D/A converter in response to the digital output of the up-down counter. If the converter signal is smaller than the analog input signal U S , the counter counts up. When the counter reaches a value that corresponds to the analog input signal (U S ), it stops counting. The control loop is then in equilibrium. If the input signal U S increases further, the counter follows this signal and counts up. Consequently, there is no change in the counting direction. Only after the input signal U S decreases and drops below the equivalent count in the counter, the counter starts counting down and thus reverses its counting direction. The hysteresis U M built into the comparator prevents a disturbance signal below U M from causing a change in the counting direction. Therefore, a change in the counting direction occurs only when the two analog signals differ by more than U M and the sign changes simultaneously.
For the case in which the dips caused by an interference have a value less than the minimum turn-over voltage U M , then, in accordance with a preferred embodiment of the invention, the signal already produced at the output of the extreme value identification member 15 can be further processed as an error-free output signal. If however, the interferences are larger than U M as shown in FIG. 2, then in accordance with the invention the control signal present at the output of the extreme value identification member 15 is applied as a clock signal or a charging pulse signal to a storage member 17 of the mean value circuit 12. The storage member 17 receives the signal values to be stored from a preceding divider member 18, which itself is arranged subsequently to the adder member 16, and applies the stored signal value to both the comparator 13 as a reference value U V and to the input of the adder member 16 via a feedback branch. Because of this combination within the mean value circuit 12 a recursive mean value formation can be effected. Then the digitized signal U SD is available at the input of the adder member 16 as a signal value, as is also the signal value of the storage member 17 corresponding to the preceding charging pulse, that is to say corresponding to the last extreme value. The adder member 16 continuously forms the sum from the signal values present at its input. This sum is divided by two in the subsequent divider member 18 so that this function is available approximately in real time at the input of the storage member. If now a new charging pulse is applied from the extreme value identification member 15 to the storage member 17, then the corresponding function value of the signal U SD is stored as a new signal value in the storage member 17 and applied to the input of both the comparator 13 and the adder member 16.
The comparator 13 employs this reference signal U V originating from the storage member 17 and compares it to the digitized signal U SD , which is also made available to it as an input signal via the A/D converter 14. At each instant at which the input signals of the digital comparator 13 are in agreement, it produces a change in its output state, in response to which the output signal U A of the arrangement in accordance with the invention is formed.
Referring to FIG. 4, the comparator 13 determines the points of intersection of the digital signal U SD and the staircase reference signal U V trailing this signal U SD , as it is available at the output of the mean value circuit 12. As is shown in FIG. 4, the points of intersection of these two curves are proportional to the fundamental oscillation of the signal U S , without interfering harmonic oscillations having any influence on the output signal U A .
As has already been mentioned in the foregoing, FIG. 4 shows in a simplified manner the variation of the analog signal U S , although actually the signal U SD digitized by the A/D converter 14 is involved. If, for example, the storage member 17 contains the value zero at the beginning of an identification, then, as is shown above the staircase reference signal U V in FIG. 4, this may result, for small signals U S with a large offset, in the suppression of some starting periods as the content of the storage member 17 must first approach the input signal U S . By means of a charging circuit, not shown, it is possible to load, in accordance with the invention, the store of the storage member 17 with the instantaneous digitized signal U SD , on making the arrangement operative, which enables a fast start of the arrangement according to the invention.
It should here be noted that all of the mentioned signal values and signal magnitudes, respectively, are advantageously electric voltages. The characterizing features of the invention disclosed in the preceding description, in FIGS. 1, 2, 3 and 4 and also in the claims, may be essential for realising the invention in its different embodiments, both individually and in any combination.
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An adaptive arrangement for the identification of a periodic input signal (U S ), for example, a signal supplied by magnetic field speed sensors. An evaluation circuit (11) is provided for digitizing the signal (U S ) and for detecting the extreme values thereof, an interference-free output signal being present at the output of the evaluation circuit (11) in the event of small interferences which are less than a presettable minimum turn-over voltage (U M ). In the event of larger interferences, subsequent means are provided for detecting the fundamental oscillation of the signal (U S ). The subsequent means (12, 13) include a mean value producing circuit (12) and a comparator (13). The comparator compares the digitized signal (U SD ) with a reference value signal (U V ) which the mean value producing circuit (12) recursively forms from the extreme values of the signal (U S ). The comparator produces an interference-free output signal (U A ) which is proportional to the fundamental oscillation frequency of the periodic signal (U S ).
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FIELD OF THE INVENTION
[0001] The present invention generally relates to apparatus for erecting a retractable wall system. More particularly, this invention relates to a retractable wall system and its components which may be used to divide a room or space, create an acoustic barrier, create a freestanding structure, or provide an awning.
BACKGROUND
[0002] Roller shades may be useful for blocking out light and enhancing privacy for windows. Retractable walls may provide the ability to divide a room or provide shade for exterior porches. Still, a need exits for improved retractable wall systems that may span longer distances and utilize heavier fabrics.
SUMMARY
[0003] Hence, the present invention is directed to a track for a retractable wall system which includes an elongated member having a first cross-sectional profile. The first cross-sectional profile may include a front wall, a rear wall spaced from the front wall, and a bottom wall connecting the front wall and the back wall. The first cross-sectional profile may include a first top wall adjacent the front wall, a second top wall adjacent the rear wall, and an open channel disposed between the first top wall and the second top wall. The open channel may include a first side wall connected to the first top wall, a second side wall connected to the second top wall, a first ledge extending from the first side wall into the open channel, and a second ledge extending from the second side wall into the open channel. The first and second ledges may define a slot between the first side wall and the second side wall. The first cross-sectional profile further may include a conduit disposed between the front wall and the rear wall which is connected to the open channel via the slot.
[0004] In another aspect of the invention, the first cross-sectional profile further may include a lateral wall that extends from the front wall to the back wall. The conduit may be formed by the first ledge, the second ledge, the first side wall, the second side wall, and the lateral wall. The lateral wall may be connected to the first side wall and the second side wall.
[0005] In another aspect of the invention, the first cross-sectional profile may include an interior wall that extends from the front wall to the back wall. The front wall, lateral wall, rear wall and interior wall may define a first interior channel. The front wall, interior wall, rear wall and bottom wall may define a second interior channel. The front wall, the first top wall, the first side wall and the lateral wall may define a third interior channel. And, the rear wall, the second top wall, the second side wall and the lateral wall may define a fourth interior channel.
[0006] In another aspect of the invention relates to a retractable wall system which may include a tube having with a longitudinal axis, a first track disposed perpendicular to the longitudinal axis, a second track spaced from the first track, and a third track. The third track may include a first traveling guide disposed in the open channel of the first track and a second traveling guide disposed in the open channel of the second track. The retractable wall system further may include a flexible membrane barrier sheet connected to the tube. The sheet may include first, second and third zippered sides. The first zippered side may be disposed in the conduit of the first track and secured to the first traveling guide. The second zippered side may be disposed in the conduit of the second track and secured to the second traveling guide. The third zippered side may be disposed in the conduit of the third track.
[0007] In another aspect of the invention, the tube may be a thin wall hollow member. The tube may have a cross-sectional profile that comprises a substantially circular outer wall. The cross-sectional profile further may include a plurality of interior structural members. The plurality of interior structural members may each define a chord within the tube.
[0008] In another aspect of the invention, each interior structural member may connect to an adjacent structural member to form an external node which is located about the circumference of the tube. Each interior structural member further may connect to a second adjacent structural member to form another external node that is located about the circumference of the tube. The intersection of two structural members at an external node may form a right angle.
[0009] In another aspect of the invention, each interior structural member may intersect another interior structural member to form an internal node. The intersection of two interior structural members at an internal node may form an obtuse angle, which may measure approximately 135 degrees.
DESCRIPTION OF THE DRAWINGS
[0010] The accompanying drawings, which are incorporated herein and constitute part of this specification, illustrate an embodiment of the invention, and together with the general description given above and the detailed description given below, serve to explain the features of the invention.
[0011] FIG. 1 is a perspective view of a covered patio enclosed on two sides by an embodiment of the retractable wall system of the present invention;
[0012] FIG. 2 is an exploded view of an exemplary embodiment of the retractable wall system of the present invention;
[0013] FIG. 3 is a partial sectional view of the first retractable wall system along line 3 - 3 of FIG. 1 ;
[0014] FIG. 4 is a sectional view of the tube of FIG. 3 ;
[0015] FIG. 5 is a sectional view of another embodiment of the tube of FIG. 3 ;
[0016] FIG. 6 is a perspective view of an exploded view of an idler and tube of FIG. 3 ;
[0017] FIG. 7 is a perspective view of the idler and tube of FIG. 6 being assembled;
[0018] FIG. 8 is a partial sectional view of the tube, horizontal track, and flexible barrier of FIG. 1 ;
[0019] FIG. 8 a is a partial sectional view of FIG. 8 ;
[0020] FIG. 9 is a partial cross-sectional view of the left side track and horizontal track of FIG. 1 , taken perpendicular to the longitudinal axis of the left side track;
[0021] FIG. 10 is a cross-sectional view of the horizontal track of FIG. 1 , taken perpendicular to its longitudinal axis;
[0022] FIG. 11 is a cross-sectional view of another embodiment of the horizontal track of FIG. 1 , taken perpendicular to its longitudinal axis;
[0023] FIG. 12 is a partial sectional view of the head rail of FIG. 1 , taken perpendicular to the vertical tracks and from below the tube and motor assembly;
[0024] FIG. 13 is a partial sectional view of the head rail, tube and motor assembly of FIG. 1 , taken parallel to the vertical tracks;
[0025] FIG. 14 is an exploded view of the right side end-cap assembly of the retractable wall system of FIG. 1 ;
[0026] FIG. 15 is a cross-sectional view of the right side track along with a partial cross-sectional view of the horizontal track of FIG. 1 .
[0027] FIG. 16 is a perspective view of a pair of adjacent tracks and end caps from abutting retractable wall systems of FIG. 1 .
[0028] FIG. 17 is a detailed view of a pair of tracks aligned to form a corner assembly;
[0029] FIG. 17 a is a view of the tracks of FIG. 17 fastened together to form a corner assembly;
[0030] FIG. 18 is a perspective view of a free standing retracting wall system structure;
[0031] FIG. 19 is a plan view of the free standing structure of FIG. 18 ;
[0032] FIG. 20 is a perspective view of an exemplary retractable awning system;
[0033] FIG. 21 is a sectional view of the left track of the retractable awning system of FIG. 20 ;
[0034] FIG. 22 is a side view of the retractable awning system of FIG. 20 ;
[0035] FIG. 23 is a sectional view of the front partition of the retractable awning system of FIG. 20 ;
DESCRIPTION
[0036] FIG. 1 is a perspective view of a patio enclosure 10 formed by three retractable wall systems 12 , 14 , 16 . The first retractable wall system 12 may be disposed perpendicular to the house and may extend from the side of the house to a first corner of the patio. The second retractable wall system 14 may be disposed perpendicular to the first retractable wall system 12 and may be parallel to the sliding door of the house. The third retractable wall system 16 may be next to the second retractable wall system 14 . The first retractable wall system 12 may be disposed in an opening under the roof structure of the house. The first retractable wall system 12 may include a head rail 18 , a left side track 20 , right side track 22 , and a horizontal track 24 disposed between the left side track 20 and the right side track 22 . In a preferred embodiment, the left side track 20 , the right side track 22 and the horizontal track 24 have the same cross-sectional profile.
[0037] In FIG. 1 , the first retractable wall system 12 is in a raised configuration. In the raised configuration the horizontal track 24 abuts the head rail 18 . Referring to FIG. 3 , the head rail 18 may contain a roll of flexible barrier material 26 a , as well as a mechanism (not shown) 28 for raising and lowering the flexible barrier membrane 26 . As shown in FIG. 2 , the mechanism 28 may include an electrical motor 42 , which may be controlled by a wireless remote or switch. Alternatively, the mechanism may include a hand crank or a chain drive with a looped strap for manually raising and lowering the flexible barrier membrane.
[0038] Referring to FIG. 1 , the left side track 20 of the first retractable wall system 12 may be secured to the building. By contrast, the right side track 22 of the first retractable wall system 12 may be connected to the left side track 32 of the second retractable wall system 14 at a 90 degree angle to form a corner assembly. The second retractable wall system 12 is shown in a partially lowered configuration. A flexible barrier material 34 may be disposed between the left side track 32 , right side track 36 and horizontal track 38 of the second retractable wall system 14 . The flexible barrier material 34 may extend from inside each of these three tracks 32 , 36 , 38 to create a wall.
[0039] As shown in FIG. 3 , the flexible barrier material 26 may be disposed on a tube 40 in the head rail. The flexible barrier material 26 may be rolled onto the tube 40 and unwound from the tube as the horizontal track 24 is lowered. Referring to FIG. 1 , the third retractable wall system 16 may be disposed parallel to the second retractable wall system 14 . The right side track of the second retractable wall system 14 and the left side track of the third retractable wall system 16 may be secured together or connected to a secondary structural member (e.g., a post or stud). The third retractable wall system 16 is shown in the lowered configuration.
[0040] FIG. 2 shows an exploded view of the first retractable wall system 12 . The retractable wall system 12 may include a left side track 20 , a right side track 22 , and a horizontal track (or weight bar) 24 extending between the left side track and the right side track. Additionally, the retractable wall system 12 may include a left side end-cap 46 which is secured into the left side track 20 and a left side feeder-clip 48 that is positioned in the left side end-cap 46 . Similarly, the retractable wall system 12 includes a right side end-cap which may be secured into the right side track 22 , as well as a right side feeder-clip 52 that may be disposed in the right side end-cap 50 . When the left side end-cap 46 is fully seated in the left side track 20 the left side feeder-clip 48 interlocks with features of the left side track 20 cross sectional profile to further secure the left end-cap to the left side track. Similarly, when the right side end-cap 50 is fully seated in the right side track 22 , the right side feeder-clip 52 interlocks with features of the right side track 22 cross-sectional profile to further secure the right end-cap to the right side track. Each end-cap 46 , 50 further may include a cylindrical stub 54 in the end-cap wall. The cylindrical stub 54 may receive the tube assembly and serve as axis of rotation for the tube 40 .
[0041] The roller tube assembly may include an idler 56 , a tube 40 having a central axis, and a mechanism 28 for rotating the tube 40 about the central axis of the tube. In a preferred embodiment, the mechanism 28 may include a motor 42 that is partially installed with the tube 40 . The motor 42 may include a built in radio control receiver that provides a user the capability to operate the motor with a remote control. For example, the motor may be a Somfy RTS motor.
[0042] In FIG. 2 , the mechanism 28 for rotating the tube includes a motor 42 with a remote control. The motor, which may be slidably received within the tube 40 , may include a drive 58 and a crown 60 . The drive 58 and crown 60 may be external features of the motor which interlock with an interior surface 62 of the tube so as to provide a mechanism for transferring rotational movement from the motor or the tube. The motor 42 further may include a drive wheel 64 at one end. The drive wheel 64 may be configured and dimensioned to be fixedly received within a motor bracket 66 . The motor bracket 66 may be secured to one end-cap 50 . The tube assembly 28 further may include a sheet of flexible material 26 . The sheet of flexible material 26 may include a zipper border 68 on at least three sides. The sheet of flexible material 26 may be cut to be received in a pair of traveling guide pieces 70 , 72 that are adapted to be received in the horizontal track 24 .
[0043] FIG. 3 shows a cross-section of the retractable wall system 12 taken perpendicular to the central axis 74 of the tube 40 . The tube 40 may be mounted on the cylindrical stub 54 of the left end-cap 46 . The tube 40 may be secured to the idler 54 with a fastener. Inside the tube 40 are interior wall segments 78 , which form a mating structure for the motor drive and crown. The interior wall segments 78 may be arranged to provide structural rigidity to the tube. In particular, the interior wall segments may span the internal space of the tube 40 so as to provide a three dimensional truss or space frame. Additionally, the tube may include a fabric pocket receiving channel 80 and a fabric zipper receiving channel 82 , which may be used to connect the flexible barrier material 26 to the tube 40 . Wrapped around the tube 40 is a sheet of flexible barrier material 26 a , which may include a heat bonded zipper edge 68 on the left side and the bottom side of the sheet.
[0044] The end-cap 46 may be situated within the left side track 20 . The left side of the flexible barrier material sheet 26 may be fed through the left side feeder-clip 48 into a rigid receiving channel 84 a in the left side track 20 . The bottom side of the flexible barrier material 26 sheet may be received within the horizontal track 24 . The cross-sectional profile of the left side track 20 and horizontal track 24 may be the same. Accordingly, the flexible barrier material 26 may be secured to the horizontal track 24 through a rigid receiving channel 86 in the horizontal track 24 . A slot 88 may connect the rigid receiving channel 88 to an internal anchoring cavity 90 that is configured and dimensioned to receive the bonded zipper edge 68 of the sheet. The rigid receiving channel 86 may be disposed between a pair of arcuate walls 92 . The internal anchoring cavity 90 may be disposed adjacent to the rigid receiving channel 86 .
[0045] The horizontal track 24 further may include a primary accessory receiving channel 94 , a secondary accessory receiving channel 96 , and a tertiary accessory receiving channel 98 . Weights, for example, steel bars 100 may be placed with the primary accessory receiving channel 94 or the secondary accessory receiving channel 96 of the horizontal track 24 to facilitate lowering of the flexible material barrier 26 . In another example, sound dampening material may be inserted in these spaces to increase the sound insulating properties of the retractable wall system. An elastomeric end cap, flexible seal, or brush may be inserted in the tertiary accessory receiving channel 98 to provide an improved connection with the ground surface for purposes such as, without limitation, increasing wall stability, slip resistance, draft prevention, or sound dampening.
[0046] FIG. 4 shows a cross section of a preferred embodiment of the tube 40 . Generally, the tube 40 may be a thin-wall hollow member. The outer surface 102 of the tube may be substantially circular, and the interior space of the tube may include a series of interior wall segments (or structural members) 78 , which may reinforce the tube against bending moments that may be generated from the weight of flexible barrier material on the tube when the tube is positioned between the end caps. Each structural member 78 may form a cord within the tube 40 . Each structural member 78 may connect to an adjacent structural member 78 to form an external node 104 , which is located about the circumference of the tube. Additionally, each structural member 78 may intersect two other structural members 78 to form a pair of internal nodes 106 . The intersection of a pair of structural members 78 at an external node 104 forms a right angle. The intersection of a pair of structural members 78 at an internal node forms an obtuse angle of approximately 135 degrees. The space between an internal node 106 and outer wall 108 of the tube may be used to house the pocket receiving channel 80 and the zipper receiving channel 82 . Additionally, a fastener alignment groove 110 may be disposed above one or more internal nodes on the outer surface 102 of the tube. The interior surface 62 of the tube may form an eight sided shape for receiving a motor (with a mating drive and crown) or an octangonal tube for non-motorized applications (e.g., 40 mm, 60 mm, or 80 mm tubes).
[0047] FIG. 5 shows the cross-section of another embodiment of the tube 40 ′. In this embodiment, the outer surface 112 of the tube 40 ′ is substantially circular and the interior space includes a series of structural members 114 that reinforce the tube 40 ′ from bending moments as in the previous embodiment. In contrast to the tube of FIG. 4 , however, each structural member 114 connects to the outer wall 116 of the tube at one location (or external node) 118 . Additionally, the opposite end of each structural member 114 may connect to an adjacent structural member 114 to form an internal node 120 . The interior surface 122 of the tube 40 ′ may form an eight sided shape for receiving a motor (with a mating drive and crown) or an octangonal tube for non-motorized applications (e.g., 40 mm, 60 mm, or 80 mm tubes). In this embodiment, the tube 40 ′ also may include a pocket receiving channel 124 , a zipper receiving channel 126 , and two fastener alignment grooves 128 .
[0048] Referring to FIGS. 4 and 5 , the tube 40 , 40 ′ may have an outer diameter of approximately 1.0 inches to approximately 6.0 inches, but other dimensions may be used where appropriate for the application. In an exemplary embodiment, the tube 40 , 40 ′ may have an outer diameter of approximately 3.5 inches and an interior surface 62 , 122 which is configured and dimensioned to receive a 60 mm octagonal tube. Additionally, the tubes 40 , 40 ′ may range from approximately one foot long to approximately 30 feet in length. The tube 40 , 40 ′ may be formed from aluminum or an aluminum alloy (e.g., 6061 aluminum alloy (International Alloy Designation System)), however, other suitable metals, alloys or materials may be used to form the tube provided the material has sufficient strength. For example, the tube 40 , 40 ′ may be formed from a carbon graphite reinforced polymer material. Preferably, the tube 40 , 40 ′ may be formed by materials having a high strength to weight ratio and the ability to be manufactured using extrusion technologies.
[0049] Referring to FIG. 4 , the flexible barrier material 26 may be secured to the tube 40 by a pocket of flexible barrier material 130 and rod 132 inserted within the pocket receiving channel 80 . In another alternative, the flexible barrier material 26 may be attached to a zipper 68 that is inserted into the zipper receiving channel 82 . Generally, the flexible barrier material 26 may range from approximately 1/32 of an inch in thickness to approximately ½ inch in thickness. The flexible barrier material 26 may be formed, without limitation, from natural fibers, leather, PVC, polyester, or acrylic materials. Preferably, the flexible barrier material 26 may range from approximately 7 ounces to 60 ounces in weight. In one example, the flexible barrier material 26 may be constructed from a 20 ounce vinyl fabric. In another example, the flexible barrier material 26 may be constructed from a vinyl fabric that is capable of receiving a print design. In another example, the flexible barrier material 26 may be constructed from a screen, a transparent material or a natural fabric.
[0050] The flexible barrier material 26 may be a single layer of material or a multilayer material formed from two or more layers of material. For example, the flexible barrier material 26 may be formed from three layers: a middle layer having enhanced sound dampening properties (e.g., mass loaded vinyl, Acoustiblok®) and two outer fabric layers (e.g., cotton, polyester, rayon, vinyl, wall paper, or wall covering material) to create an acoustic barrier. In another example, the flexible barrier material 26 may be formed from clear plastic sound blocking material. Preferably, a flexible barrier material with enhanced sound dampening properties may have a STC (Sound Transmission Class) Rating of 26 or greater.
[0051] FIG. 6 shows an exploded view of the idler 56 and the tube 40 of FIG. 4 . One end 134 of the idler 56 may be inserted into the tube 40 . The opposite end 136 of the idler 56 may be mounted on the end-cap cylindrical stub 54 (not shown) to form an axis of rotation. The tube 40 may include one or more fastener alignment grooves 110 . As shown in FIG. 7 , a drill (or fastener) 138 may be placed in a fastener alignment groove 110 to create a fastener alignment path 140 for securing the idler 56 to the tube 40 . The fastener alignment groove 110 may be located above an internal node 106 of the tube. Placement of a fastener alignment groove 110 above an internal node 106 provides a mechanism for promoting a repeatable, quick, and straightforward method of securing the idler 56 and the tube 40 with a fastener 138 . More particularly, the fastener path 140 connects the fastener alignment groove 110 and the internal node 106 of the tube. A fastener that is aligned in this manner may be expected to penetrate the tube 40 beneath the fastener alignment groove 110 and be guided by adjacent internal structural members 78 to a position above the internal node 106 . This fastener path may provide a secure connection because the fastener may be driven perpendicular to the outer surface of tube wall and through the internal node 106 before advancing into and securing the idler 56 .
[0052] FIG. 8 shows the left side of the flexible barrier member 26 disposed in the left side feeder-clip 48 and left side track 20 of the retractable wall system 12 . Also, the bottom of the flexible membrane barrier 26 is shown locked into the horizontal track 24 . As shown in FIG. 8A , the left side of the flexible material barrier is fully seated within the traveling guide pin 72 . The full length square cut double pin construction 142 provides rigid reinforcement of the flexible barrier material 26 at a leading edge 144 of the sheet. As the leading edge of the sheet 144 may be subject to compressive and sheering forces as the barrier is lowered, the traveling guide pin 72 may prevent the flexible barrier material 26 from wearing, tearing, bunching or binding in the vertical track 20 when the horizontal track 24 is lowered or raised.
[0053] Moreover, as shown in FIG. 9 , the traveling guide pin 72 may be configured and dimensioned to be slidably received within the rigid receiving channel 84 of the vertical track 20 . As the fasteners, which secure the flexible membrane barrier 26 to the traveling guide pin 72 are located with the rigid receiving channel 84 , they may be recessed or flush with the exterior surfaces of the traveling guide pin 72 . The zipper portion 68 of the flexible membrane barrier 26 , when disposed in the internal anchoring cavity 90 , pulls the traveling guide pin 72 into the rigid receiving channel 84 of the vertical track 20 . In this manner, the horizontal track 24 and the sides of the flexible membrane barrier 26 may be securely positioned within the left side track 20 and the right side track 22 .
[0054] The reinforcement of the flexible barrier material 26 and tension across the vertical tracks 20 , 22 may increase the structural integrity of retractable wall system 12 , provide for more reliable operation of the system, and reduce mechanical fatigue of the zipper-material interface. Also, the generally uniform tension across the flexible membrane barrier 26 may increase the aesthetic appeal of the retractable wall system 12 by enhancing a uniform appearance of the flexible barrier material across the structure. Moreover, in outdoor applications, this construction may prevent drafts. In sound barrier applications, this construction may promote the deployment of a continuous sound dampening barrier and prevent fugitive sound emissions from passing individual barrier elements to reduce the effective sound dampening properties of the retractable wall system. Sound dampening material may be placed in the primary accessory receiving channel 232 , the secondary receiving channel 234 , and the arcuate receiving channels 236 as well.
[0055] The vertical track 20 of the retractable wall system may be secured to a structural member such as a stud or post. A pilot hole may be drilled and then a larger access hole placed in the track 20 to allow a fastener 150 to be advanced though the opposite side the track and into external structural framing 148 to securely attach the vertical track 20 to structural framing of an adjacent wall or post.
[0056] Referring to FIGS. 10 and 15 , the horizontal track 24 , the left side track 20 , and the right side track 22 may share a single cross-sectional profile 152 . In FIG. 10 , the track profile 152 is shown in use as a horizontal track 24 . In this configuration, the primary accessory receiving channel 94 may accommodate a weight bar 100 , which may be a ½ inch by ¾ inch steel bar. The weight bar 100 may be positioned within the primary receiving channel 94 by the end-cap stem blocking member 154 , the upper rail guide 156 , and the lower rail guide 158 .
[0057] In FIG. 11 , the cross-sectional profile of the track 152 ′ is substantially the same as in FIG. 10 , but a front portion 160 of the track 24 ′ is removable and forms a cover. The removable portion 160 may be secured to the track 24 ′ with snap fittings 162 . This feature allows weight bars 100 to be installed in the horizontal track 24 ′ after the retractable wall structure 12 has been erected. This may improve constructability of the system and enhance the safety of workers because handling the horizontal track with preloaded weight bars 100 is significantly heavier than handling an empty horizontal track.
[0058] FIGS. 10 and 11 show an elastomeric cap 164 disposed in the tertiary accessory channel 96 . Arcuate receiving channels 166 , as well as the primary and secondary accessory receiving channels 94 , 96 may receive sound damping materials to enhance the sound dampening effect of the retractable wall system.
[0059] FIG. 12 shows the left feeder-clip 48 and its tapered guide hole 168 . The tapered guide hole 168 receives the zippered edge 68 of the flexible barrier material 26 as it spools off the tube (not shown). Similarly, FIGS. 12 and 13 show the right feeder-clip 52 and its tapered guide hole 170 , which receives the zippered edge 68 of the other side of the flexible barrier material 26 . The right feeder clip 52 may further include a circular passage 172 for receiving a power cord 174 from the motor 42 .
[0060] Referring to FIG. 14 , the right end-cap 50 may include a stem 176 having a rectangular channel 178 . The right side feeder-clip 52 may include a beveled top surface 180 , a central base portion 182 , and four plugs 184 , 186 , 187 , 188 . One end of the feeder-clip 52 may include an elongated and corrugated plug 184 . Next to the elongated and corrugated plug 184 and disposed in the middle of the feeder-clip 52 may be a second plug 186 . The second plug 186 may be wider and shorter than the elongated corrugated plug 182 . Also, a pair of contralateral plugs 188 , 190 may be disposed on the other side of the second plug 186 .
[0061] The right feeder-clip 52 may include a circular passage 172 that extends from the beveled top surface 180 through the second plug 186 . The passage 172 may be configured and dimensioned to receive an electrical cable for the motor. Additionally, the beveled top surface 180 may include a first tapered rectangular passage 170 which extends through the feeder-clip 52 . A second rectangular passage 192 may extend from the beveled top surface 180 through the feeder-clip 52 between the contralateral plugs 188 , 190 . The first rectangular passage 170 and the second rectangular passage 192 may be separated by a thin wall 194 . The thin wall 194 may include a tapered slit 176 which extends from the top of the thin wall to the bottom of the thin wall.
[0062] As shown in FIG. 15 the right feeder-clip 52 may be inserted into the rectangular channel 178 of the end-cap 50 . The stem 176 of the end-cap may be seated within the primary accessory channel 198 and may be positioned in the primary accessory channel 198 by the upper guide rail 200 , the lower guide rail 202 , and the end-cap stem blocking member 204 . The second plug 186 of the feeder-clip 52 may be received in the secondary accessory receiving channel 206 . The secondary accessory receiving channel 206 may be used to accommodate an electrical cable 174 that extends from the motor 42 to an electrical outlet outside the track. The pair of contralateral plugs 188 , 190 may be disposed in the opposing arcuate cavities 208 at the front of the track. The traveling guide member 72 may be disposed in the rectangular receiving channel 210 of the track and the zippered end 68 of the flexible membrane barrier 26 may be disposed in the internal anchoring cavity 212 . The material connecting the zipper 68 and the flexible membrane barrier 26 may be disposed in the slot 214 between the rectangular receiving channel 210 and the internal anchoring cavity 212 .
[0063] FIG. 16 shows an exemplary corner assembly 216 formed from a first end-cap and track 218 and a second end-cap and track 220 . The first end-cap and track 218 and the second end-cap and track 220 may be disposed at an approximately 90 degree angle. The corner assembly 216 may be used to construct adjacent retractable wall systems, as shown in FIG. 1 .
[0064] FIG. 17 shows an exemplary alignment of two tracks 22 , 20 which may be used to construct a corner assembly 216 . In the track alignment, the alignment groove 222 in the primary accessory receiving channel 198 may be disposed opposite the tertiary accessory groove 226 of the adjacent track. FIG. 17 a shows how the two tracks 20 , 32 may be securely fastened to each other. In a preferred method, a guide hole may be drilled between the upper and lower guide rails 200 , 202 in the primary accessory receiving channel 198 . The guide hole may be enlarged to an entry hole in order to provide access to the interior of the primary accessory receiving channel. A fastener 228 may be positioned in the alignment groove 222 ( FIG. 17 ) and advanced into the tertiary accessory groove 226 ( FIG. 17 ) of the adjacent track. The enlarged hole may be covered with a plastic cap 230 .
[0065] Referring to FIG. 18 , four corner assemblies 216 may be used to construct a free standing structure. The free standing structure may be formed from four (or more) retractable wall systems 240 a , 240 b , 240 c , 240 d , 240 e . Two retractable wall systems 240 c , 240 d may be joined together to form one side of the structure. One of the retractable wall systems 240 c may be used as a door for the structure.
[0066] Referring to FIG. 19 , a short ledge 242 may extend from the lower portion of the head rail into the enclosed space. The short ledges 242 of opposing retractable wall systems 240 b , 240 e may be used to support beams 244 , which may form a cover for the structure 238 . The beams may be used to form a continuous cover or a lattice cover. For example, wood boards (e.g., 1″×2″ or 2″×4″ boards) may be supported by the head rail ledges to form a lattice cover, which may allow the structure to be used as a temporary booth (or Sukkah) that is constructed for use during the Jewish festival of Sukkot.
[0067] Referring to FIG. 20 , the retractable wall system may be adapted for use as an awning 246 . A webbing material may 248 be molded to the flexible membrane barrier 250 that forms the awning cover in order to make the canopy stronger while maintaining light weight. The awning 246 may include a side pennant 252 . As shown, in FIG. 21 , the side track of the retractable wall system may be modified such that the side frame 254 incorporates a reinforced flexible membrane barrier connection 256 to provide a taunt but retractable ceiling canopy. The side frame 254 may include a roller track 258 for a wheel 260 which is connected to the front crossbar 262 . Also, the side frame 254 may include a gutter 264 for collecting and transporting rain water 266 . An exterior groove 268 on the side frame may be used to house a sealant for sealing the frame to a structure or an abutting awning frame.
[0068] As depicted in FIGS. 21-23 , a reinforced flexible membrane barrier connection 256 may be used to deploy a side pennant 252 with the ceiling canopy. Referring to FIG. 23 , the front cross bar 262 may support a bracket 270 that holds a loop of canopy material 272 to form a pocket to collect and direct rain water 266 to the gutter 264 . The front partition 274 of the awning structure 246 may include a channel 276 for receiving water from the gutter. In another embodiment, the gutter and wheel track may the same structure. The front partition 274 further may include a solenoid 278 that may be used to lock the awning in the deployed configuration. Additionally, a brake (not shown) may be available on the motor end and the non-motor end of the awning spool. The retractable wall system may be constructed from materials selected to better withstand changes in temperature, corrosion, or degradation from ultraviolet light.
[0069] While it has been illustrated and described what at present are considered to be preferred embodiments of the present invention, it will be understood by those skilled in the art that various changes and modifications may be made, and equivalents may be substituted for elements thereof without departing from the true scope of the invention. Additionally, features and/or elements from any embodiment may be used singly or in combination with other embodiments. Therefore, it is intended that this invention not be limited to the particular embodiments disclosed herein, but that the invention include all embodiments falling within the scope and the spirit of the present invention.
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The present invention is directed to an apparatus for erecting a retractable wall system. More particularly, this invention relates to a retractable wall system and its components which may be used to divide a room or space, create an acoustic barrier, create a freestanding structure, or provide an awning.
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CROSS-REFERENCE TO RELATED APPLICATION
This application claims the benefit under 35 U.S.C. §119(a) of European Patent Application No. 14176820.0, filed in the European Patent Office on Jul. 11, 2014, the entire disclosure of which is hereby incorporated by reference.
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a connector assembly, in particular for airbag restraint systems. The connector assembly comprises a connector housing and secondary locking means. The secondary locking means is assigned to the connector housing so that it is movable relative to the connector housing from an open position to a locked position.
BACKGROUND OF THE INVENTION
In many applications, the safe coupling of connectors is of high importance. For example, in the case of car safety systems, as e.g. airbag systems in passenger cars, the connectors used for the connection of an airbag to its ignition base have to be provided with reliable safety systems. To ensure that the connectors cannot become loose unintentionally, secondary locking means are used in addition to the primary locking means to guarantee a safe mechanical coupling.
An example of a connector with a secondary locking means is described in WO 97/41623 A1. This document discloses a connector which can be mated with a corresponding counter-connector being part of an airbag ignition mechanism. In assembled condition, (i.e. the connector is mated with the corresponding counter-connector), the connector is fixed to the counter-connector by means of flexible latching arms. During mating of the connectors, these arms are deflected and snap back into corresponding latching clearances of the counter-connector, when fully mated. For securing the mechanical coupling of the connectors, WO'623 suggests a secondary locking means that comprises locking arms that can be inserted into the mated connector assembly. Once the locking arms are inserted, they inhibit bending of the latching arms out of the corresponding latching clearances. Thus, the mechanical coupling of the connectors is secured.
A further development of a secondary locking means is disclosed in the patent application DE 100 05 858 A1. This document discloses a connector with a secondary locking device and a safety spring element, which serves to hold the secondary locking means in a position, in which the secondary locking means is mounted to the connector housing so that it does not hinder mating or un-mating of the connector with a corresponding counter-connector.
In patent application WO 2014/072081 A1, a connector assembly is disclosed that comprises a secondary locking means and a spring. The secondary locking means and the spring are assigned to a connector housing. Hereby the secondary locking means is movable between a first and a second position. When placed in its second position, it serves to secure the mating of the connector housing to a corresponding counter-connector. During mating, the spring is biased to cause the secondary lock to move automatically into a locked position when the connector assembly is fully mated with is corresponding counter-connector, without need for an operator to push the secondary locking means into the locked position.
The connector assemblies described above have in common that a partial mating of the connector and the corresponding counter-connector is possible, in which case the secondary locking means do not function satisfactorily.
If the connector is only partially mated, it might occur that the connector assembly electrically functions correctly, since the electrical contacts of the connector and the corresponding counter-connector are connected (i.e. current conduction is possible), but the mechanical connection is not according to the desired specification. In a highly safety relevant connector assembly, for example in airbag restraint systems, often detecting devices are integrated that are able to detect a correct mating of the counter-connectors based on electrical circuits that are opened respectively closed during the mating of the connector. If the connector and the corresponding counter-connector are partially mated, these detecting devices may report untruly a correct mating of the connectors. Further, with the prior art secondary locking means it was often possible to move the same in the locked position, thereby indicating to an operator, that the mating is complete. However, in case of only a partial mating, the prior art secondary locking means often fail to provide the desired secondary locking function. In the case of e.g. airbag restraint systems the electrically functional but mechanical disturbed connector might disengage due to vehicle vibration.
BRIEF SUMMARY OF THE INVENTION
The present application relates to a connector assembly, in particular for airbag restraint systems. The connector assembly comprises a connector housing and secondary locking means (i.e. a secondary lock).
The connector housing comprises at least one primary latching arm configured to latch with a corresponding counter-connector. The connector housing may comprise a plug-in portion and at least two primary latching arms that are arranged on opposite sides of the plug-in portion, whereby the plug-in portion enters the corresponding counter-connector at least partly upon mating. The latching arms of the plug-in portion are deflected during mating and snap back into corresponding latching grooves or recesses provided in the counter-connector, when mated. Thereby each latching arm can be deflected and mated individually.
The secondary locking means is assigned to the connector housing, and is arranged movable relative to the connector housing from an open position to a locked position. The secondary locking means may be guided in its movability by the connector housing, so that the trajectory from an open to a locked position of the secondary locking means is defined. The same applies for the movement of the secondary locking means form the locked in the open position.
After at least one of the latching arms is in its mated position, the secondary locking means can be moved in the mating direction, in accordance with the defined trajectory. The end point of said trajectory is defined as the locked position.
The secondary locking means comprises further blocking portions that are configured to block a release movement of the latching arms when the secondary locking means is in its locked position. These blocking portions of the secondary locking means may be arranged relative to the latching arms of the plug-in portion so that a deflection of the latching arms is made impossible or at least hindered. Thus, the latching arms cannot be released and the connector is secured by the latching arms and the blocking portions in the mated condition.
Advantageously, the secondary locking means of the invention comprises two separate locking members. The separate locking members are thereby two physical different parts. The two separate locking members may be formed symmetrically identical. However, any other suitable shaping of the separate locking members is possible. Further, each of the two separate locking members is assigned to one of the primary latching arms to block a release movement of the assigned latching arm. Thereby, each of the two separate locking members is configured to be independently moveable between the open position and the locked position along its own trajectory. Therefore, if the connector is unintentionally only partially mated, i.e. only one of the two latching arms is latched in its latching groove, the locking member assigned to the latched (i.e. mated) latching arm can be moved in its locked position, even if the locking member assigned to the not-latched latching arm cannot.
In this locked position, the single locking member blocks a release movement of the latched latching arm and the connector is sufficiently secured, even in such a partially mated condition. This secured, partially mated condition provides retention forces that are strong enough to avoid an unintentional disengagement of the connector.
According to one embodiment, the connector assembly is further provided with a spring, that is operationally connected to at least one of the locking members and possibly to both of the locking members, to bias the respective locking member into its locked position when the connector housing is fully mated with a corresponding counter-connector. Thus, the spring is configured to urge the locking members to move automatically into their locked position when the assigned latching arm of the connector housing is mated with is corresponding counter-connector without need for an operator to push the secondary locking member manually into the locked position.
The secondary locking members may each comprise at least one blocking portion, which is configured to block a release movement of the latching arm(s) when the secondary locking means is in the locked position. The blocking portion can for example be arranged on a dedicated element such as an actuating arm of the locking member or can be provided for example as part of other functional members of the locking member. This blocking portion may be arranged such that it blocks the latching arms of the connector housing in their respective positions, when the secondary locking means is in the locked position. Each locking members may further comprise at least one actuating arm each configured to latch to a corresponding counter-connector when mated and when the secondary locking means is in its locked position. Thereby, the locking member can be secured in the locked position.
In one embodiment, the connector assembly is further provided with a shortening element, which allows the monitoring of the mating process, respectively the monitoring of a correct mating between connector housing and corresponding counter-connector. The shortening element is an electrical contact element and configured to be actuated upon mating by coming into contact with a portion of the corresponding counter-connector. Thereby, the shortening element is disposed, to close or open an electrical circuit. The opening or closing of the electrical circuit allows a remote monitoring of the mating process. To this end, the shortening element may be provided such on the connector housing, that it is only disposed (thereby opening or closing the electrical circuit), upon fully and correct mating of counter-connector and connector housing.
Generally, the connector assembly of the present invention may also further comprise a corresponding counter-connector and the corresponding counter-connector may be an airbag squib socket and the connector housing accordingly may be an airbag squib connector housing.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
The present invention will now be described, by way of example with reference to the accompanying drawings, in which:
FIGS. 1 and 2 show schematic illustrations of a connector housing comprising two separate locking members in accordance with the present invention from different views;
FIG. 3 shows a schematic illustration of the connector housing illustrated in FIGS. 1 and 2 , whereby the cover of the connector housing is removed;
FIG. 4 shows a top view of the connector housing with removed cover;
FIG. 5 shows a side view of the connector housing in a partially mated and locked condition;
FIG. 6 shows an X-ray photo of the connector housing of FIG. 5 in a partially mated and locked condition;
FIG. 7 shows a partially cut view illustrating the interior of the connector housing upon mating in the open position; and
FIG. 8 shows the same partial cut as FIG. 7 , however, with the locking member 30 a in its locked position.
DETAILED DESCRIPTION OF THE INVENTION
In one aspect, the present invention improves the state of the art by providing a connector assembly with an improved secondary locking mechanism.
FIG. 1 shows a perspective, three-dimensional view of a connector housing 10 in accordance with the invention. The connector housing 10 comprises a main body 12 and a cover 11 which is removably latched to the main body 12 by means of latch connections 15 . At the bottom side of the main body 12 a cylindrical plug-in portion 13 is provided. The skilled person will recognize that the plug-in portion 13 is configured to co-operate with typical airbag squib sockets and that the device shown is thus an airbag squib connector. On opposite sides of the plug-in portion 13 , two latching arms 20 a , 20 b are arranged. In other words, the two latching arms 20 a , 20 b are arranged symmetrically on opposite sides of the plug-in portion 13 . The latching arms 20 a , 20 b provide the primary locking of the connector. Indicated by the reference number 30 , a secondary locking means is arranged moveable inside of the main body 12 of the connector housing 10 . Secondary locking means 30 is shown in its locked position and consists of two distinct locking members 30 a and 30 b . When coupled or mated to a corresponding counter-connector, the secondary locking means 30 will prevent an unintentional un-mating of the two connector parts, when in the position shown in FIG. 1 .
FIG. 2 shows the same device from a different angle. Further, in FIG. 2 a retainer 50 is shown for illustrative purposes. The skilled person will recognize that the retainer 50 is part of an airbag squib socket and thus forms part of the corresponding counter-connector. Also visible in the view of FIG. 2 is the spring 40 , which biases the secondary locking means 30 into its locked position. The spring 40 is such arranged in the connector housing 10 that upon mating the spring 40 will automatically move the secondary locking means 30 in the locked position shown in for example FIG. 2 .
FIG. 3 shows again the same arrangement as FIG. 2 from a different perspective, however with the cover 11 removed to allow a view of the interior construction of the connector housing 10 . From FIG. 3 one can see that cables 14 are mounted inside of the connector housing 10 . The cables 14 are partially covered by a ferrite element 16 , as it is well known to the skilled person. In the open view of FIG. 3 one can see that the spring 40 is made from a single wire of spring steel. Further, each locking member 30 a , 30 b comprises an actuating arm 31 a , 31 b (only actuating arm 31 b is visible in FIG. 3 due to the perspective).
Spring 40 comprises in the embodiment shown two spring arms 41 a , 41 b that are operationally connected to the locking members 30 a and 30 b . Further, as one can take from FIG. 2 or 3 , the coils 42 are arranged, such that the winding axis of each coil 42 is in a plane perpendicular to the mating direction of the connector housing 10 . It is clear for the skilled person, that the shown spring 40 is only one example and that it is possible to use also other constructions without deviating from the core idea thereof.
Turning back to FIG. 3 , one can see that the spring 40 is tensioned when the locking members 30 a , 30 b are in their open position. Upon mating, the spring 40 will automatically move the locking members 30 a , 30 b in the locked position. How this is achieved will be explained in more detail in the following with regard to FIGS. 6 and 7 .
Turning back to FIGS. 3 and 4 , one can see how the two spring arms 41 a , 41 b of spring 40 are operationally connected to the respective locking members 30 a , 30 b of the secondary locking means 30 . The position of secondary locking means 30 shown in FIGS. 3 and 4 is the so called open position. In this position it is possible to fully mate the connector housing 10 with the corresponding counter-connector, since the secondary locking means 30 , i.e. the locking members 30 a , 30 b do not block the latching arms 20 a , 20 b.
The spring 40 in accordance with the present invention comprises at least two spring arms 41 a , 41 b each actuating arm 31 a , 31 b being operationally connected to a respective one of the two locking members 30 a , 30 b , for biasing the locking members 30 a , 30 b individually in their locked position. This can for example be achieved, by a direct contact of the spring arm 41 a , 41 b and the locking members 30 a , 30 b , however, it could also be achieved indirectly by further elements which are being provided between the actuating arm 31 a , 31 b and the locking member 30 a , 30 b . It is however important, that the actuating arm 31 a , 31 b actively pushes or moves the locking member 30 a , 30 b from the open position into the locked position upon mating of connector housing 10 and corresponding counter-connector.
FIG. 5 shows the connector housing 10 in a partially mated condition, which might occur, if only one side of the edge of the connector housing 10 is pushed down. As a result, the connector housing 10 is mated oblique into the corresponding counter-connector. Locking member 30 a is still in its open position, whereas locking member 30 b has been moved to its locked position. The retention force of a partially locked connector is greater than 78 newtons (N) and may be greater than 135N. The retention force is the force that is necessary to unmate the connector housing 10 and the corresponding counter-connector when pulled in mating direction. The retention force is measured according to the test method described in ISO 19702-2, §4.4.
FIG. 6 shows an X-ray photo of the partially mated connector. To facilitate the understanding, the latching arms 20 a , 20 b and the actuating arms 31 a , 31 b of the locking members 30 a , 30 b are retraced. As one can see on the right side of FIG. 6 , latching arm 20 b is latched to the latching groove 55 and actuating arm 31 b of locking member 30 b blocks the latching arm 20 b , since the locking member 30 b is in its locked position. Latching arm 20 a is not latched, i.e. only a partial mating of connector housing 10 and corresponding counter-connector occurs. Further, since the latching arm 20 a is not latched, the locking member 30 a with actuating arm 31 a is still in its open position. Nevertheless, since the other locking member 30 b is in its locked position, the connection is sufficiently secured.
FIG. 7 shows a partially cut view of the connector during the mating process. From the cut view, one can see how the plug-in portion 13 is partially inserted into the retainer 50 . In the position shown, a stop member 51 of retainer 50 comes into blocking contact with a first actuating surface 32 a provided at the free end of an actuating arm 31 a of the locking member 30 a . Thereby, upon movement of the connector housing 10 in mating direction into the retainer 50 , the locking members 30 a , 30 b remain un-moved, i.e. they are hindered from moving in the mating direction since the first actuating surface 32 a rests on stop member 51 . Due to this blocking of the locking members 30 a , 30 b (due to the symmetrical arrangement, also the locking member 30 b rests on a corresponding stop member 51 of the retainer 50 ) the locking members 30 a , 30 b will bias the spring 40 when the connector housing 10 is moved into the mated position. In the position shown in FIG. 7 , the spring arms 41 a , 41 b of the spring 40 are thus under high tension and basically in the same position as shown in FIGS. 3 and 4 . However, since the locking members 30 a , 30 b still rest firmly on the stop member 51 , the spring 40 cannot yet move the locking members 30 a , 30 b into the locked position shown in FIGS. 1, 2 and 8 .
This is accomplished by means of an inclined deflection surface 17 provided in the connector housing 10 . This inclined deflection surface 17 comes into contact with a second actuating surface 33 a of actuating arm 31 a at the end of the mating process. A corresponding surface will have the same effect on actuating arm 31 b . When this happens, the inclined deflection surface 17 will push the actuating arm 31 a of the locking member 30 a outwardly, i.e. away from the plug-in portion 13 . The skilled person will recognize that thereby the first actuating surface 32 a will be lifted from the stop member 51 and the locking members 30 a , 30 b are released and the tensioned spring 40 will automatically move the locking members 30 a , 30 b in their locked position as shown in FIGS. 1, 2 and 8 . The skilled person will understand that the locking members 30 a , 30 b are only released after the latching arms 20 a , 20 b of the connector housing 10 can snap into the latching groove 55 of the corresponding counter-connector (i.e. it is in its latched position).
One can further see from FIG. 8 how the actuating arm 31 a of locking member 30 a is now arranged between the latching arm 20 a and a portion of the retainer 50 , respectively between the plug-in portions 13 . In the position shown in FIG. 8 , it is not possible to move the latching arm 20 a inwardly, i.e. towards the plug-in portion 13 so that it is impossible to bend the latching arm 20 a out of the locking engagement with latching groove 55 . The same applies for the not shown latching arm 20 b and locking member 30 b . An un-mating of the two connectors is only possible, after an operator manually releases the secondary locking means 30 , i.e. both locking members 30 a , 30 b , by pulling it against the mating direction and the biasing force of spring 40 .
Reference number 18 denotes electrical female terminals provided in the plug-in portion 13 . The inventive concept of providing a locking means in form of two distinct locking members 30 a , 30 b allows a secure and reliable secondary locking of the mating, even if the primary locking means are only partially locked. The skilled person will thus recognize that the spring 40 of the illustrated embodiment is only an advantageous feature but not necessary for the inventive concept.
LIST OF REFERENCE NUMERALS
10 Connector Housing
11 Cover
12 Main body of connector housing
13 Plug-in portion
14 Electrical cables
15 Latch connection
16 Ferrite element
17 Inclined deflection surface
18 Electrical female terminals
20 a ; 20 b Latching arms
30 Secondary locking means
30 a locking member
30 b locking member
31 a ; 31 b Actuating arm of the locking members
32 a First actuating surface
33 a Second actuating surface
40 Spring
41 a ; 41 b Spring arms
42 Spring coil
43 U-shaped frame
50 Retainer (part of counter-connector)
51 Stop member
52 Socket housing
55 Latching groove
62 Contact insertion length
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The present invention relates to a connector assembly for airbag restraint systems. The connector assembly comprises a connector housing and secondary locking means assigned to the connector housing. The secondary locking means is arranged movable relative to the connector housing and can be moved from an open position to a locked position. Further the secondary locking means comprises two separate locking members wherein each of the two separate locking members is configured to be independently movable.
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TECHNICAL FIELD
[0001] The present invention relates to a method of selecting bulk wood units for chemical pulping under alkaline conditions. As used herein, the term “bulk wood units” refers to logs or log segments or large planks of wood; the method of the present invention is designed predominantly for use in selecting or classifying unsawn logs, but it could also be used for selecting or classifying log segments or large sawn planks. As used herein, the term “chemical pulping” includes semi-chemical pulping, i.e. processes in which wood is chemically pre-treated in a manner similar to chemical pulping, and then mechanically pulped.
BACKGROUND ART
[0002] The chemical pulping of wood to produce pulp for papermaking may be carried out by a number of different known techniques: the present invention relates specifically to those techniques which involve digesting the chipped wood in a bath of digester fluid which is alkaline based. This digester process generally is carried out at an elevated temperature and pressure.
[0003] The object of all of the digestion processes is to dissolve the lignin in the wood to release the individual fibres, leaving the cellulose and alkali-resistant hemicelluloses in the fibre walls. A typical wood sample has about 30 percent lignin, and this is reduced during the digestion processes to about 5%: the remaining 5% is removed from the pulp by bleaching. The lignin in the wood glues the fibres together and infiltrates between the cellulose and other constituents of the wood. It follows that the higher the percentage of cellulose and alkali-resistant hemicelluloses in the wood, the less lignin there is to be dissolved during the digestion stage, and the lees bleaching is required; thus, the lower the percentage of lignin, (or the higher the percentage of cellulose) the lower the process costs. Hereinafter, the term ‘cellulose’ is taken to include both cellulose and residual alkali-resistant hemicellulose.
[0004] The most commonly used chemical pulping process is the sulphate or Kraft process, in which the wood chips are cooked in a mixture of caustic soda and sodium sulphide. The method of the present invention has been developed with the special reference to the Kraft process and therefore will be described with particular reference to this process. However, it will be appreciated that the method of the present invention also may be applied to select wood for any of the alkaline-based chemical or semi chemical pulping processes, (i.e. where the pH >7).
[0005] It is well established in the industry that some wood has a higher cellulose content, and therefore would be more efficient to process by chemical pulping. However, identifying which wood has a higher cellulose content simply cannot be achieved using current log sorting methods.
[0006] The traditional method of sorting trees at the point of harvest of the log is to categorise and grade logs according to their diameter, length, straightness, diameter eccentricity and visual defects; the logs are placed in categories which reflect log diameter, log size and log grade. The basic assumption is that logs in each category are substantially identical. However, so far as chemical pulping yield is concerned, logs sorted in the above manner often prove to be far from identical, and may vary widely in cellulose content.
[0007] When a batch of logs is being processed by chemical pulping, it is of considerable economic advantage if all the logs have a similar cellulose content, since this will directly affect processing time and the quantities of processing chemicals required.
[0008] There is known to be a relationship between acoustic velocity through a bulk wood unit and its stiffness or modulus of elasticity. U.S. Pat. No. 6,026,689 discloses a system for predicting the modulus of elasticity of a bulk wood unit by generating a stress wave along the length of the unit by striking the unit (e.g. with a hammer), picking up vibrational signals from a standing stress wave in the unit, and using this information to calculate the speed of the stress wave in the unit, and hence the predicted modulus of elasticity for that unit.
[0009] It also is known that there is a relationship between the modulus or elasticity of a bulk wood unit and the microfibril angle, i.e. the angle of inclination of the stiff bundles of cellulose chains (microfibrils) which are embedded within the cell walls of the wood tissue. Generally, the microfibril angle is taken to refer to the helical inclination of the cellulose in the S 2 layer of the cell wall. (Page, DH, E-Hosseiny F, Winkler K and Lancaster AF 1977 ‘Elastic Modules of Single Pulp Fibres’ Tappl 60 (4) V 1-4 and Cave I. D. 1968 ‘The Anisotropic Elasticity of the Plant Cell Wall’ Wood Sciences & Technology 2 (4) 268-78).
[0010] In the paper by R. H. Newman (University of Canterbury Wood Technology Workshop of 1996), there was shown to be an empirical correlation between the modulus of elasticity of wood and its ‘pure’ cellulose content (i.e. excludes hemicellulose), but the two properties were not shown to be derived from or directly dependent upon each other. In the development of the method of the present invention, it was postulated that there may be a direct relationship between the microfibril angle and the cellulose content of wood, although such a direct relationship has not yet been proved.
SCOPE OF THE INVENTION
[0011] An object of the present invention is the provision of a method whereby a batch of logs may be reliably and accurately graded according to their likely yield during chemical pulping under alkaline conditions, by utilising the assumption that there is a sufficient relationship between the microfibril angle of wood and the cellulose content of that wood to permit cellulose content (and hence pulping yield) to be predicted from a measurement of acoustic velocity through the wood.
[0012] The present invention provides a method for sorting a batch of bulk wood units for chemical pulping under alkaline conditions comprising the steps of:
[0013] 1) establishing a reference scale for the timber group to be sorted by:
[0014] a) selecting at random a plurality of sample units of bulk wood from the timber group;
[0015] b) measuring the acoustic velocity through each of said sample units using a predetermined measuring technique;
[0016] c) recording said acoustic velocities and grouping said velocities into two or more velocity bands;
[0017] d) processing all or part of each of said sample units to pulp using a predetermined chemical pulping process;
[0018] e) determining the pulp yield from each sample;
[0019] f) producing a reference scale indicating predicted pulp yield for a range of acoustic velocities;
[0020] 2) measuring the acoustic velocity through each of said bulk wood units in turn, using said predetermined measuring technique;
[0021] 3) comparing said acoustic velocity measurements against the reference scale to predict the chemical pulping yield for each tested unit; and
[0022] 4) dividing the tested units into subgroups according to the predicted chemical pulping yield.
[0023] Preferably, before said acoustic velocity bands are selected, the acoustic velocities from all of said sample units are graphed to show the distribution of acoustic velocity in the total sample, to enable velocity bands to be selected such that a predetermined proportion of bulk wood units fall within each of the selected velocity bands.
[0024] Preferably, each of the batch of bulk wood units would be of the same or a similar species and would have a similar history i.e. each of the bulk wood units would be of a similar age, have been grown under similar conditions, end managed in a similar fashion.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] [0025]FIG. 1 is a flow chart illustrating the method of the present invention;
[0026] [0026]FIG. 2 is a diagram showing of the method of taking an acoustical measurement from a log;
[0027] [0027]FIG. 3 is a distribution curve of the acoustic velocities in the sample units;
[0028] [0028]FIG. 4 is a graph of pulp yield versus Kappa number; and
[0029] [0029]FIG. 5 is a graph of pulp yield versus acoustic velocity,
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0030] [0030]FIG. 1 illustrates the sequence of steps for utilising the present invention.
[0031] In step 1 , each of the batch of bulk wood units is of the same or a similar species, and preferably also has a similar history, as defined above. Whilst it may be possible to treat all bulk wood units of the same tree species as forming part of the single batch i.e. being sufficiently similar to be classified using only a single set of reference tests, it is probable that before bulk wood units can be treated as forming part of a single batch, they must have a similar history. Thus, it is envisaged that separate reference tests will be required for bulk wood units of the same tree species but with a different history.
[0032] The extent to which separate reference tests are required will become apparent in the course of industrial use of the method of the present invention; as data are accumulated from large-scale use, it will become apparent to users of the method whether more or fewer reference tests are required to meet particular conditions.
[0033] In step 2 , sample bulk wood units are selected from the batch, to carry out the detailed testing needed to establish a reference scale. Typically, 100-300 samples would be taken from a batch, assuming that the characteristics of the batch were completely unknown.
[0034] In step 3 , the acoustic velocity of each sample unit is measured, using the standard method represented diagrammatically in FIG. 2. The equipment for, and techniques for measurement of, acoustic velocity through a bulk wood units are known, and therefore are not described in detail. One typical system is shown in FIG. 2, In which a bulk wood unit 20 is supported and is struck on one end 21 by a hammer 22 . The acoustic wave generated in the bulk wood unit by the impact of the hammer 22 travels down the length of the bulk wood unit, is reflected from the far end 23 , and travels back to the end 21 where it is detected by an acoustic sensor 24 . The detected signal is analysed by signal analysis apparatus 25 , which also computes the velocity of the sound. The velocity is calculated from the time taken for the sound wave to travel along the length of a log and back divided by a distance equal to twice the length of a log. The apparatus is controlled by controller 26 .
[0035] There are a number of known types of apparatus available for measuring acoustic velocity, and the above described equipment may be varied in a number of ways:—for example, the velocity may be determined from a single reading taken at the opposite end of the bulk wood unit 21 to the hammer 22 . Further, the hammer 22 may be replaced by any device capable of generating an acoustic wave in the bulk wood unit, e.g. piezoelectric device or a wave from a sound generator.
[0036] In step 4 , the readings of acoustic velocity obtained in step 3 are graphed to give a distribution curve of the type shown in FIG. 3 which shows the distribution of acoustic velocities of a sample batch of 165 pinus radiata logs. The distribution curve shows the acoustic velocity range in which any specified percentage of the test samples fall. Thus, a study of the distribution curve enables the operator to select acoustic velocity bands which will include or exclude a specified percentage of the bulk wood units. The actual figures selected for the acoustic velocity bands will depend upon the operator's requirements:—If the operator wishes to select for chemical pulping only those bulk wood units which are optimum for this purpose, then only a single acoustic velocity may be selected, as discussed hereinafter.
[0037] It will be appreciated that the acoustic velocity bands may be used for grouping of the bulk wood units rather than for simply selecting or rejecting the units. As discussed above, it greatly increases the efficiency of chemical pulping if all of the units being pulped in a particular batch have a similar cellulose content. Thus, the acoustic velocity bands may be used to group together those bulk wood units predicted to have a similar cellulose content. The group or groups of bulk wood units which are predicted to have a relatively high lignin content would be more economically processed for unbleached paper, since the higher the lignin content in the pulp, the more bleaching the pulp requires.
[0038] It will be appreciated that the higher the efficiency of the chemical processing, the less effluent produced. Further, the higher the quality of the pulp produced (i.e. the higher its cellulose content) the less bleaching is required; this also reduces the bleach effluent.
[0039] Alternatively, the operator may wish to select acoustic velocity bands such that a majority of the bulk wood units would be selected for chemical pulping, and only those units which were clearly unsuitable would be rejected. In this case, the upper and lower limits of the acoustic velocity band into which the bulk wood units to be selected would fall, would be set to include a large proportion of the units e,g. a velocity ≧3.0 km per second in the example shown in FIG. 3.
[0040] In step 6 , all or a predetermined proportion of each sample bulk wood unit is pulped, using a standard chemical pulping technique such as the Kraft process.
[0041] Depending upon the requirements and practices of the particular pulpmill, the processing may be carried out using the route shown in steps 7 a - 9 a, or the route shown in steps 7 b - 9 b.
[0042] In the route shown in steps 7 a - 9 a , the sample units are pulped to a standard Kappa number (typically in the range 20-30). This route would be used it the pulpmill requirements were for pulp only of a particular Kappa number. The pulp yield for each sample is then measured at the standard Kappa number, and a graph of pulp yield against acoustic velocity is prepared, giving a reference scale for that Kappa number. A typical graph is shown in FIG. 5, which shows the pulp yield at Kappa 30 against acoustic velocity, and clearly demonstrates the increase in pulp yield as the acoustic velocity increases. From a graph of this type, it is easy for an operator to select a suitable cut-off acoustic velocity for selecting bulk wood units for chemical pulping e.g. FIG. 5 shows that a suitable cut-off velocity would be 3 km per second.
[0043] In the alternative route shown in steps 7 b - 9 b , a series of sub-samples from each pulp sample is processed, each to a different Kappa number. This route is used where the pulp mill requirements are somewhat more flexible, so that it is feasible to select a Kappa number which will optimise the yield.
[0044] The pulp yield for each sub sample is measured, and a graph of yield against Kappa number for each velocity band is prepared, to produce a reference scale of the type shown in FIG. 4. A reference scale of this type can be used by an operator to select the optimum acoustic velocity band depending upon the intended processing conditions for that batch of bulk wood units.
[0045] In the typical results shown in FIG. 4, four velocity bands were selected:—
[0046] Speed 1: velocity≦2.52 km/second.
[0047] Speed 2: velocity≧2.7 km per second but ≦2.8 km per second.
[0048] Speed 3: velocity≧3.1 km per second but ≦3.2 km per second.
[0049] Speed 4: velocity≧3.4 km per second.
[0050] The graph enables the operator to select the velocity band in which the desired level of pulp yield can be achieved for the required Kappa number (e.g. 30).
[0051] As FIG. 4 shows, the four velocity bands selected experimentally in practice group reasonably well into two separate bands, since the results for speed 1 and speed 2 lie close together, and the results for speed 3 and speed 4 also lie close together. It follows that for practical purposes, the results could be grouped into two acoustic bands for Kappa No. 30:—
[0052] The first having a velocity <3 km per second;
[0053] The second having a velocity >3 km per second.
[0054] Of these first and second bands, the second gives a notably superior pulp yield at Kappa number 30. It follows that, in step 10 , where the acoustic velocity through each unit of the batch of bulk wood units is measured, if those units are to be processed to Kappa number 30, then the operator should select for chemical pulping only those bulk wood units having an acoustic velocity greater than 3 km per second, since these are the units which will yield the highest percentage of pulp when processed to Kappa number 30.
[0055] The bulk wood units having an acoustic velocity less than 3 km per second could be diverted to other uses e.g. mechanical pulping, or could be used for chemical pulping in applications where an unbleached pulp is required.
[0056] However, if the bulk wood units are to be processed to a higher Kappa number e.g. a Kappa number 40 then the operator might decide to lower the acoustic velocity cut-off for selection to include the speed 2 group i.e. to select for chemical pulping bulk wood units which have an acoustic velocity greater than 2.7 km per second, since the drop in pulp yield from the speed ¾ groups to the speed 2 group at this higher Kappa number is relatively small.
[0057] The reference scale of the type shown In FIG. 4 also may be reworked for any specified Kappa number to give a pulp yield/acoustic velocity graph of the type shown in FIG. 5.
[0058] In the steps described above, pulp yield is measured in the standard manner i.e. the percentage of dry pulp achieved from the dry matter of the bulk wood units.
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A method of selecting bulk wood units for chemical pulping in alkaline conditions which consists of establishing a reference scale by selecting a test sample, measuring the acoustic velocity through each sample units, selecting acoustic velocity bands from the sample results, processing the sample units using known chemical pulping processes, measuring the percentage pulp yield, and then using the measured pulp yields and acoustic velocities to produce a reference scale; measuring the acoustic velocity through each of the units, comparing the velocity measurement for each unit against the reference scale, and then dividing the tested units into subgroups according to the predicted yield in chemical pulping.
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BACKGROUND OF THE INVENTION
The present invention relates generally to methods and apparatus in paper machines and, more particularly, to methods and apparatus in the head box of a paper machine for controlling the distortion of fibre orientation in the paper web.
It is known that the speed of the discharge flow of the pulp suspension from the head box must be uniform in the transverse direction of the paper machine. It is also known that if the transverse speed of the pulp suspension flow discharging from the head box is unduly high, the quality of the paper produced may be detrimentally affected. In particular, an unduly high transverse speed in the discharge flow of the pulp suspension results in increased lateral wave formation at the lateral portions of the web. However, paper production is normally subject to requirements that the paper produced be homogeneous over the entire width of the web with respect to grammage, formation and strength properties so that as little as possible of the web edges must be cut off.
In order to meet these requirements, it has been suggested to remove a small portion of the pulp suspension flow through both of the side walls of the discharge channel of the head box before the suspension flow is discharged onto the forming wire. See, for example, Finnish Pat. No. 43.812 (U.S. Pat. No. 3,434,923) of Beloit Corporation. Another contrary solution has been suggested wherein an additional flow of water is passed through the side wall of the head box and in this connection reference is made to Finnish Pat. No. 30,095 (U.S. Pat. No. 2,956,623) of Valmet Oy.
The above-described requirements imposed on paper production have been increased and new requirements for the uniformity in the structure of fine paper have resulted from the recent development of certain printing methods, such as sheet-heating copying developed by Xerox and continuous-formedheating copying. These increased requirements are essentially due to the rapid and intensive heating of the sheet that takes place during the printing process. These new printing methods impose the particular requirement that the main axes of the directional distribution or orientation of the fibre network in the paper should coincide with the directions of the main axes of the paper and that the orientation should be symmetrical with respect to these axes.
Sufficient satisfaction of the particular requirement described above over the entire width of the web has not been possible in practice by means of the above-described prior art suggestions nor by means of any other known construction of the paper machine head box. For example, areas are usually present in the web which are not acceptable in view of the requirement described above. Paper produced by conventional methods are generally subject to the deficiencies of diagonal bending of the sheets or "falling" of a stack of forms.
Studies conducted by applicants' assignee have shown that it is possible to obtain the required symmetry of fibre orientation by ensuring that the transverse speed of the pulp suspension being discharged from the head box does not exceed about 2 to 3 cm/s. Since the transverse flow of pulp suspension is produced in the discharge channel of the head box as the uneven main flow profile is attenuated, the majority of effort must be directed to obtaining uniformity of the speed profile in the direction of pulp suspension flow after the turbulence generator. Even if it were possible to construct the distribution system of the head box in the correct manner and to construct turbulence generators so precisely that the transverse speed requirements are met, such constructions would be so costly in manufacture as to be commercially unprofitable.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide new and improved methods and apparatus for controlling distortion of fibre orientation in a paper web.
Another object of the present invention is to provide new and improved methods and apparatus by which it is possible to control the profile of the distortion of fibre orientation at the head box of the paper machine so that slight lack of precision in the manufacture of the head box can be tolerated.
Briefly, in accordance with the present invention, these and other objects are attained by a method including the steps of passing by-pass flows of pulp suspension into and through respective lateral passages situated at lateral sides in the flow channel of the head box substantially in the region of the turbulence generator thereof, and adjusting at least one of the magnitude and mutual relationship of the pulp suspension by-pass flows to produce a transverse flow in the pulp suspension which is discharged from the head box having a speed which compensates for the distortion in the fibre orientation.
In accordance with the apparatus of the invention, a pair of lateral passages are provided situated at lateral sides of the flow channel of the head box through which by-pass flows of pulp suspension are passed. Means are provided for adjusting at least one of the magnitude and mutual relationship of the pulp suspension by-pass flows to produce a transverse flow in the pulp suspension discharged from the head box having a speed which compensates for the distortion in the fibre orientation.
The adjusting means comprise a pair of adjusting members, each of which is movably mounted in connection with openings, grooves, recesses, or the like provided in a respective one of the lateral side walls of the head box. The inner side of each adjusting member defines an outer side of a respective lateral passage. Means are provided for adjusting the position of each of the adjusting members to adjust the by-pass flows in the lateral passages to control the distortion of the fibre orientation.
In accordance with the invention, it is possible to provide either external by-pass flows in the lateral passages taken, for example, from the distribution beam of the head box, and/or the by-pass flows through the lateral passages can be obtained from the lateral portions of the pulp suspension flow channel which are arranged so as to be adjustable to change the flow resistance or choking in the lateral passages. In the latter case, in order to provide a sufficient range for adjustment, the lateral passages are dimensioned so that the flow resistance presented by them is substantially lower than the flow resistance of the turbulence generator situated between the lateral passages per unit area of the flow channel.
The invention is based on a system wherein the flows in both of the lateral areas of the head box can be controlled within an area having a width of a few centimeters so that the flow discharged from the turbulence generator into the discharge channel of the head box can be adjusted over a sufficiently wide range.
The operation of the method of the invention is based on the theory of narrowing discharge channel flow which has been experimentally verified. The principle under which the invention operates can be described, somewhat simplified, as follows. If the pulp suspension flow within one lateral area of the discharge channel of the head box is increased in excess of the average flow, a constant transverse flow directed towards the opposite lateral edge is produced in the pulp suspension within the discharge channel and, additionally, on the forming wire. The maximum value of the transverse flow is obtained at the lateral edge of the area in which the flow is increased and the value decreases from this area in a uniform manner towards a zero value in the direction of the other edge of the discharge channel. If the supply of pulp suspension is increased in an equal magnitude at the other edge an opposite transverse flow symmetrical to the first one is obtained. These opposite transverse flows have an additive effect and result in the transverse flow profile having a maximum value at each lateral edge towards the center while the transverse flow at the middle of the machine is zero as the substantially equal and opposite transverse speeds cancel or compensate for each other. Correspondingly, measurements of the paper produced indicate that maximum values of different directions are obtained for the distortion of orientation at the edges and a symmetry of orientation at the middle of the web. Therefore, the graph of the distortion of orientation is an inclined straight line which intersects a zero value at the middle of the web. If for some reason the graph representing distortion of orientation has an inclination of equal magnitude but reverse in direction prior to a corrective adjustment in accordance with the invention, the adjustment in accordance with the invention will eliminate the distortion. Correspondingly, the correction of an orientation distortion whose graph inclines in the same direction requires both of the lateral flows to be reduced by a corresponding amount rather than increased.
It is seen from the foregoing that a diagonal distortion profile of the fibre orientation can be corrected in accordance with the principle of the invention by either increasing or reducing the pulp suspension flows within the lateral areas of the discharge channel of the head box.
If one of the lateral by-pass flows is increased while the other lateral by-pass flow is reduced to the same extent, the transverse flow effects will be in the same direction so that when such effects are added, a transverse speed component of constant magnitude is produced across the web. Further, if a transverse flow of constant speed but of opposite direction in the web exists prior to an adjustment in accordance with the invention, the corrective adjustment will eliminate the orientation distortion of constant magnitude. In order to align a fibre orientation which is evenly distorted in an opposite direction, the directions of the changes of the flow are reversed within the adjustment areas.
Thus, a uniform distortion profile of the fibre orientation can only be corrected by means of the invention by changing the magnitude and direction of the lateral by-pass flows through the head box.
By suitably combining the two adjustment operations described above, the graph representative of the distortion of fibre orientation can be both rotated with respect to a center point and vertically shifted both upwardly and downwardly so that it is therefore possible to practically completely correct any distortion error arising from non-uniform flow at or near the edge of the head box, which comprises most of the cases in practice. If the source of distortion error is not at the edge of the head box, complete correction of distortion cannot be achieved through adjustments in accordance with the invention. For example, if the source of error results from a uniform diagonal speed profile of the pulp suspension flow, a graph of the orientation distortion will comprise either an upwardly or downwardly opening parabola, whose ordinates at the edges are zero. By means of the adjustments described above, the maximum value at the middle of the web can be reduced to one-half of the original value in which case an equal but opposite distortion is produced at the edges. The maximum error, however, is reduced to one half of its original value.
The width of each lateral adjustment zone will depend upon the magnitude of the profile errors that must be corrected. An excessively narrow adjustment zone implies that the necessary change in flow speed is so high that a detrimentally high step is produced in the discharge channel.
The effect of such a disturbance may extend further within the area of the finished web and manifest itself, for example, in the grammage profile. On the other hand, the adjustment area should not be extended into the area of the readycut final product since it is difficult to control all of the required properties of the paper within the adjustment area at the same time. In practice, the width of the adjustment zone will generally be in the range of between about 20 to 100 mm in both edges.
The prior art solutions described above do not meet the requirements imposed on the finished paper for at least two reasons. Firstly, lateral flow is not passed through openings situated at the trailing edge of the turbulence generator into the discharge channel which is important in the prevention of the formation of transverse flow. Secondly, the range over which the prior art solution has any effect extends only in the immediate proximity of the lateral side wall and indeed the objective of the prior art solution is to reduce lateral friction. Accordingly, the range of effect is considerably narrower as compared to the present invention.
In comparing the present invention to a prior art solution in which it is attempted to minimize the distortion of fibre orientation through appropriate sizing of the openings in the grid plates at the inlet side of the turbulence generator of the head box which open into lateral passages of the turbulence generator, an important advantage of the present invention is readily seen. In particular, in accordance with the prior art solution, it is frequently necessary to change the grid plate in order to obtain the correct flow in the lateral passages of the turbulence generator. In accordance with the invention, however, adjustment means are provided for by-pass flow pipes so that it is possible to quickly obtain the correct values for the by-pass flows through the lateral passages. Compensation for the distortion of the flow orientation in accordance with the present invention can be accomplished in an automatic manner, if desired, such as by connecting the adjustment means to an automatic control system already operating in conjunction with the paper machine.
DESCRIPTION OF THE DRAWINGS
A more complete appreciation of the present invention and many of the attendant advantages thereof will be readily understood by reference to the following detailed description when considered in connection with the accompanying drawings in which:
FIG. 1 is a side elevation view in section of a head box in which apparatus for performing the method in accordance with the invention is illustrated schematically and in block diagram form;
FIG. 2 is a partial view of the turbulence generator of the head box of FIG. 1 in the direction designated A;
FIG. 3 is a schematic top plan view of the head box of FIG. 1;
FIG. 4 is a side elevation view in section of the lip portion of a head box of a paper machine in accordance with and the embodiment of the invention;
FIG. 5 is a section view taken along line 5--5 of FIG. 4;
FIG. 6 is a view similar to FIG. 5 illustrating another embodiment of the invention; and
FIG. 7 is a partial front section view of the head box illustrated in FIG. 6 taken through the turbulence generator.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings wherein like reference characters designate identical or corresponding parts throughout the several views, and more particularly to FIGS. 1-3, a pulp suspension jet J is fed from the head box shown in FIG. 1 onto the forming wire 11 which runs over a breast roll 10. The discharge channel or slice 15 of the head box is defined by the top wall of the lower lip beam 12 and the bottom wall of the upper lip beam 13. The upper lip beam can be adjusted by conventional position adjustment mechanisms 14. The discharge channel 15 of the head box is preceded in the direction of feed F by a turbulence generator 16 which in the illustrated embodiment comprises flow pipes of rectangular cross section arranged in rows which are offset so that vertically adjacent flow pipes are staggered with respect to each other. The flow pipes communicate at their entry ends with respective circular openings formed in a grid plate 17, the circular cross section being changed to rectangular at the outlet side of the turbulence generator.
Referring to FIGS. 2 and 3, lateral passages 26a and 26b are situated at lateral sides in the flow channel of the head box in the region of the turbulence generator. The lateral passages 26a and 26b have polygonal cross sections seen in FIG. 2. As described in greater detail below, by-pass flows F a and F b of pulp suspension are passed into and through the lateral passages 26a and 26b.
The head box includes an equalization chamber 18 preceding the grid plate 17. An air tank 18a is situated above the equalization chamber 18 in communication therewith and serves to equalize and dampen pressure pulsations in the pulp suspension flow. The pulp suspension is fed from a distribution beam 20 whose longitudinal direction extends transversely to the direction of suspension flow within the head box through a system of distribution pipes 19 into the equalization chamber 18. In FIG. 3, the pulp suspension flow entering the distribution beam 20 is designated F in and the portion of the flow which entirely by-passes the head box is designated F out . Of the total flow passing into the head box, F in -F out , the main headbox flow F 1 enters the head box through the set of distribution pipes 19.
In accordance with the illustrated embodiment of the invention, by-pass pipes 22a and 22b directly fluidly communicate the distribution beam 20 and respective lateral passages 26a and 26b, i.e., the by-pass pipes 22a and 22b by-pass the set of distribution pipes 19 and equalization chamber 18 and communicate directly with both of the lateral passages 26a and 26b lateral of the turbulence generator 16. The by-pass pipes 22a and 22b are joined to the distribution pipe 20 at connections 21a and 22b which are respectively situated at or laterally outside of the side walls 27a and 27b of the head box in the width direction thereof. The by-pass pipes 22a and 22b are connected to the respective lateral passages 26a and 26b by means of extensions 24a and 24b.
The by-pass pipes 22a, 24a and 22b, 24b are provided with respective control valves 23a and 23b (FIG. 1) and are dimensioned so that by-pass flows of pulp suspension F a and F b are produced by means of the normal difference in pressure in the head box without the need for additional pumps. It is understood that pumps may be provided when necessary to obtain sufficiently large flows F a and F b . The by-pass pipes 22a, 22b and 24a, 24b are passed through openings 25a and 25b provided in the plane side walls 28 of lateral passages 26a and 26b so that the by-pass flow F a and F b can be introduced into the lateral passages 26a and 26b in a smooth fashion. In the embodiment of the invention illustrated in FIGS. 1-3, the inlet ends of the lateral passages 26a and 26b, i.e., the ends situated at the grid plate 17, are completely closed so that the pulp suspension flows F a and F b in the lateral passages are obtained solely from the by-pass pipes 22a, 24a and 22b, 24b. However, in certain cases, the by-pass flows F a and F b are obtained from the pulp suspension flowing from the by-pass pipes combined with pulp suspension coming from the equalization chamber 18 through the openings in the grid plate 17. In such a case, the openings in the grid plate are dimensioned so that the flow resistance presented thereby is sufficiently high relative to the flow resistance of the by-pass flow passages 26a and 26b that a sufficiently large range of adjustment of the by-pass flows F a and F b is obtained.
The lateral passages 26a and 26b into which the adjustable by-pass flows are passed in accordance with FIGS. 1-3 extend over the entire height of the turbulence generator 16, i.e., between the top wall 30 and the bottom wall 31. In certain cases, the by-pass feed may be of a lesser height. In addition to the walls 30 and 31, the lateral passages 26a and 26b are defined by respective plane vertical walls 28 and by opposed, stepped walls 29, the configuration of the latter being determined by the staggered nature of the flow passages of the turbulence generator. The flow passages of the turbulence generator are staggered in the manner shown in FIG. 2 in order to prevent formation of vertical disturbances in the pulp suspension flow as is known.
In accordance with the embodiment shown in FIGS. 1-3, the pulp suspension flows are passed from the distribution beam 20 or the like through connections 21a and 21b into by-pass pipes 22a and 22b respectively which are provided with control valves 23a and 23b respectively. The control valves 23a and 23b may be manually controlled to adjust the quantity and/or mutual relationship of the by-pass flows F a and F b . The settings of valves 23a and 23b can be pre-determined experimentally for obtaining the best possible compensation of the distortion of fibre orientation. Alternatively or in addition, the by-pass flows F a and F b can be adjusted by means of valves 23a and 23b or by equivalent means in automatic manner. For example, referring to FIG. 1, the fibre orientation and its distortion can be measured from the web being produced in an on-line manner by apparatus designated 32 which then sends a signal to a control unit and actuating motor, designated 33, by means of which the valves 23a and 23b are adjusted.
Reference will now be had to FIGS. 4-7 wherein additional embodiments of the invention are illustrated.
In the embodiments shown in FIGS. 4-7, turbulence generator 16 comprises a plurality of tubular flow passages 23 arranged in side-by-side fashion both vertically and horizontally. As seen in FIG. 4, the turbulence generator 16 is mounted between walls 119 of the equalization chamber 120 within a groove 121 provided at the joint between chamber wall 119 and the lower wall 112 of the discharge chamber or slice. The turbulence generator 16 may, for example, be formed from a massive member in which a plurality of through-bores are formed and through which the pulp suspension flows. The pulp suspension flow is fed from the distribution beam of the head box through a set of distribution pipes (not shown) into the equalization chamber 120 from where it flows through flow passages 123 as flows F in the turbulence generator 16 into the discharge channel 15. The magnitude of the slice s can be selectively modified by adjusting a profile bar 115 and/or by pivotting the upper lip beam 116 around its articulated joint 117 which connects the lip beam 116 to the upper frame 118.
Lateral passages 26 are provided at respective lateral sides of the turbulence generator 16, partially defined by respective vertical side walls 125 of the flow channel of the head box. By-pass flows F o of pulp suspension are introduced into the lateral passages 26 while by-passing the turbulence generator 16. In the embodiments illustrated in FIGS. 4-7, the by-pass flows F o are obtained from the equalization chamber 120 of the head box, pass through respective lateral passages 26 from where they are discharged into the discharge channel 15. Both of the by-pass flows F o are adjustable in accordance with the invention to provide a control for the distortion of the fibre orientation in accordance with the principles discussed above.
In order to adjust the by-pass flows F o , adjustment means 130 (FIG. 5), 140 (FIGS. 6 and 7) are provided which are movably mounted in openings formed in the side walls of the head box so as to adjust the cross section of the lateral passages. Thus, in the embodiments of FIGS. 4-7, the means for adjusting the magnitude and/or mutual relationship of the pulp suspension by-pass flows through the lateral passages comprise a pair of adjusting members 131;141, each of which is movably mounted on a respective one of the lateral side walls of the head box and having an inner side which defines an outer side portion of the respective lateral passage.
Referring to FIG. 5, the adjusting members 131 each comprise, in a horizontal section, a sector-shaped member having a plane inner side 133a and an outer side 130b shaped as a part of a circular cylinder. The adjusting member 131 is pivotally mounted at its narrow edge to a respective one of the side walls 125 at a vertical joint 132 so that the member 131 can rotate about joint 132. A fluid seal 127 is provided in the opening 128 of wall 125 at side 130b. Means for moving each of the adjusting members 131 are provided in the form of an adjusting screw 135 connected to the adjusting member 131 by means of a link pin 136. Adjusting screw 135 is provided with a crank 137 by means of which manual adjustment of the position of adjusting member 131 is accomplished. The adjusting screw 135 passes through a threaded member 138 attached to the side wall 125 by a support arm 134.
Still referring to FIG. 5, the adjusting member 131 can be moved inwardly to an inner position, shown in phantom at 131', wherein the flow section of the lateral passage 26 is substantially reduced to choke the lateral flow F o . It is understood that both adjusting members 131 of both lateral passages 26 are similarly adjusted in the manner described above.
Referring to FIGS. 6 and 7, the adjusting means 140 comprise slideable adjusting members 141, each of which is situated in a rectangular opening 128 in a respective side wall 125 and surrounded by fluid seals 127a, 127b and 129a, 129b. The slideable adjusting members 141 situated in both of the lateral walls 125, are adjustably moved by means of a screw mechanism 135-138, described above in connection with the embodiment of FIG. 5, to adjust the flow sections of both of the lateral passages 26. In the embodiments of FIGS. 4-7, the lateral passages 26 preferably extend over the entire height of the head box flow channel 120. The inner fully choked position of the slideable adjusting members 141 are shown in phantom in FIGS. 6 and 7 and designated 141'.
As seen from FIGS. 4-7, in the unchoked state, i.e., wherein the adjusting members are in their outward positions, the flow resistances of the lateral passages 26 are substantially lower than the flow resistance of the adjoining turbulence generator 16 per unit of area of the pulp suspension flow channel. In this manner, it is ensured that while in the unchoked condition, the speed of the lateral by-pass flows F o passing through the lateral passages 26 is higher than the speed of the flows F passing through the channels 123 of the turbulence generator 16. By adjusting the speed of the lateral flows F o by means of the adjusting members 131, 141, the distortion of the fibre orientation is controlled.
It will be understood that in accordance with the invention, the adjusting means of the invention for the lateral passages 26 or for corresponding flow sections, and choking devices for the lateral flows F o , can take forms other than as shown in the figures as described herein. The by-pass flow adjusting means may in accordance with the invention, for example, be connected with an automatic system including devices by means of which the fibre orientation of the web being produced is measured in an on-line fashion. The adjusting means may include adjustment units and actuating motors which are in themselves known by means of which the position of the adjusting members or "valves" 131, 141 are changed in order to control the distortion of the fibre orientation in the web.
Obviously, numerous 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 claims appended hereto, the invention may be practiced otherwise than as specifically disclosed herein.
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Method and apparatus in the head box of a paper machine for controlling the distortion of fibre orientation in the paper web comprise an arrangement wherein by-pass flows of pulp suspension are passed through opposite passages lateral of the turbulence generator preceding the slice portion or discharge channel of the head box. The magnitude and/or the mutual relationship of the by-pass flows is adjusted to control the distortion of the fibre orientation in that the by-pass flows produce a transverse flow in the discharge flow of the pulp suspension from the head box, the speed of which compensates for the distortion of the fibre orientation.
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FIELD OF THE INVENTION
The invention relates to suspension systems for tracked vehicles. A suspension system according to the present invention uses an interconnected pressurized fluid support system to suspend the superstructure of a tracked vehicle above the tracks of the tracked vehicle. The invention is particularly useful on farm equipment, such as combine harvesters, tractors, trailers, or the like.
BACKGROUND OF THE INVENTION
Tracked vehicles normally have an elastomeric or rubber belt mounted around a rear drive wheel and a front idler wheel. In general, tracked vehicles have better traction, than wheeled vehicles, and are thus less likely to get stuck.
Another important advantage of tracked vehicles over wheeled vehicles is that they provide reduced ground pressure per unit area of ground contact. In other words, tracked vehicles have better flotation over the ground on which they are moving. Improved flotation is especially important in farming applications because improved flotation means less ground compaction, which is important for maximizing crop yields. When ground becomes overly compacted, crop yields decline and expensive ripping (i.e., deep plowing) may be needed to sufficiently de-compact the ground so that crop yields can again be maximized. Tracked vehicles reduce ground compaction, and the associated need for expensive ripping because they impact the ground with lower ground pressure per unit area.
Due to improved traction and flotation, tracked vehicles are also useful when crops must be planted or harvested but the fields are too wet for wheeled vehicles.
A prior art suspension system for tracked farm equipment is depicted schematically in FIG. 1. In such a system, there are two track undercarriages: a right-hand side undercarriage 12 and a left-hand side undercarriage 10. The undercarriages are mirror images of one another and provide support for the superstructure 14, which is a tractor in FIG. 1. Each track undercarriage 10 and 12 has a belt side 16 encircling a rear drive wheel 18, a front idler wheel 20, and one or more pairs of mid-wheels 22. Note that the belts 16 have inner ribs 17 that are received in grooves in the front 20 and rear 18 wheels and also between the pairs of mid-wheels 22. This keeps the belt track 16 properly aligned.
A bogie suspension system 24 incorporating an air spring 26 is also located within the belt 16, and is used to suspend some of the weight of the superstructure 14 above the mid-wheels 22. The two front idler wheels 20 are connected in such a manner that they are fixed in relative location with respect to the superstructure 14. The two rear drive wheels 18, on the other hand, are connected by a pivotable axle (like axle 108 shown in FIG. 3). The rear drive wheels 18 are, thus, movable with respect to the superstructure 14. This is useful for driving over rough terrain. The weight of the superstructure 14 is in part supported by the front 20 and rear 18 wheels. The remainder of the weight is supported by a middle suspension bar 30 that extends between the left-hand side and the right-hand side bogie systems 24.
The bogie system 24 as depicted in FIG. 1 has four pairs of mid-wheels 22. The front two pairs of mid-wheels are connected together with a front minor bogie 32 (shown in phantom), and the rear two pairs of mid-wheels are connected with a rear minor bogie 34 (shown in phantom). The minor bogies 32 and 34 are connected together by a major bogie 36 having an air spring 26 on the side of the major bogie 36 towards the front. The major bogie 36 on the right-hand side is connected to the major bogie 36 on the left-hand side by the middle suspension bar (not shown in FIG. 1). A substantial portion of the weight of the superstructure 14 is supported on the suspension bar, while the remainder is supported on the front 20 and the rear 18 wheels.
Such a tracked vehicle can be turned by speeding up the rotation of one track in relation to the other. This is typically done by driving each drive wheel with a separate motor.
Such a suspension system as described above is known to be used to support other superstructures besides, tractors such as combine harvesters. It is also known to use a similar suspension structure (with or without drive motors) as a removable suspension structure, such as a trailer.
One drawback with the above described suspension system for tracked vehicles is that vehicles using such a suspension system tend to bob or teeter in the for and aft directions when driving across rough terrain. This not only has the effect of possibly bouncing the driver around the cab, but also has the effect of substantially increasing ground compaction when weight distribution along the track becomes unevenly distributed.
Another drawback is that such suspension systems are not easily modified to accept one or more additional pairs of mid-wheels. This means that changing the undercarriage so it can accept a longer or shorter belt track is difficult.
In addition, servicing of present track undercarriages is difficult and time consuming, especially when the belt must be removed.
SUMMARY OF THE INVENTION
The present invention is a suspension system for tracked vehicles using a plurality of interconnected bags containing pressurized fluid. If used properly, the suspension system can reduce bobbing and teetering in the fore and aft directions when a tracked vehicle is moving across rough terrain. The suspension system can also improve weight distribution along the tracks and improve flotation of a vehicle using the suspension system.
In one aspect, the present invention is a system for suspending a vehicle superstructure on one or more belt tracks. The system has a ground engaging belt that encircles a front and a rear wheel. The front wheel is mounted to rotate around an axle, and the rear wheel is also mounted to and rotated around an axle. A bridge spans between the axle of the front wheel and the axle of the rear wheel, and is supported in part by the front and rear axles. The bridge can be coupled to and or supported by the front and rear axles by the use of collars around the axles. The system also has a plurality of moveable support members each of which support the bridge on one or more mid-wheels. The mid-wheels are located between the front and rear wheels. A bag holding pressurized fluid is associated with each support member in such a manner that each bag resists motion of the associated support member towards the bridge. The bags are in fluid communication with each other. In this manner, the weight of the superstructure is supported in part by the bridge.
It is preferred that the system also have a tensioner that puts pressure on the belt track to tighten the belt track around the front and rear wheels. The preferred tensioner includes a tension wheel above the bridge that is encircled by the belt track, a tension wheel support arm pivotally connected to the bridge, and a tension pressure bag that can be pressurized to push the tension wheel away from the bridge, put pressure on the belt track, and increase the tension of the belt track.
In another aspect, the invention contemplates using a system as described above for both a right-hand side and a left-hand side belt track on a vehicle. Such a vehicle could be a combine harvester, a tractor, or even a detachable superstructure in which case the invention would include trailers or the like. For unpowered trailers, the superstructure can be suspended on the superstructure at only one location. For powered vehicles, it is preferred that the superstructure be supported on the suspension system at only two locations: the rear axle, and a front support shaft spanning between the bridges of the right-hand side and the left-hand side suspension systems. Preferably, the front support shaft is connected to the bridges using a pneumatic stabilizing suspension system.
It is an object of the present invention to improve the ride of track vehicles over rough terrain. The present invention can accomplish this object by using interconnected air bags to compensate for uneven terrain, and reduce bobbing and teetering. The reduction in bobbing and teetering also helps to reduce ground compaction. Improving the ride of the vehicle also reduces driver fatigue. In addition, improving the ride reduces costly wear of the superstructure and otherwise improves the performance of the vehicle.
Another object of the present invention is to reduce ground compaction caused by tracked vehicles by allowing vehicles to be easily retrofitted with longer belt tracks. Vehicles can be easily retrofitted with longer belt tracks by moving the front wheels forward, and lengthening the bridge between the front and rear wheels.
Another object is to improve vehicle flotation by distributing vehicle weight more evenly along the belt tracks. This object can be accomplished by adjusting air pressure in the interconnected bags so that the weight is properly distributed along the part of the track engaging the ground.
Another object of the present invention is to make servicing of the belt tracks and/or the belt track undercarriages easier and less time consuming. The present invention can accomplish this object because it uses a tensioner that can be easily deactivated to loosen tension on the belt track. Also, servicing the mid-wheels and associated bogeys can be accomplished without removing the belt track by depressurizing the interconnected air bags.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view with parts in phantom showing a prior art suspension system for a tracked vehicle.
FIG. 2 is a schematic drawing of a suspension system for a tracked vehicle in accordance with the present invention.
FIG. 3 is a rear view of a preferred suspension system in accordance with the present invention.
FIG. 4 is a cross sectional taken along line 4--4 in FIG. 2.
FIG. 5 is a schematic view showing pressurized fluid flow in accordance with the present invention.
FIGS. 6 and 7 are schematic views showing how the suspension system of the present invention can improve the ride of a tracked vehicle in the fore and aft directions over rough terrain.
FIG. 8 is a schematic view showing how the suspension system of the present invention can improve the ride of a tracked vehicle over rough terrain in the lateral directions.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 2, a suspension system 100 in accordance with the present invention supports a superstructure 102 over a left-hand side undercarriage 104 and a right-hand side undercarriage 106 (shown in FIGS. 3, 4 and 8). It is preferred that the undercarriage 106 for a right-hand side belt track 114 be the mirror image of the undercarriage 104 for a left-hand side belt track 112.
The superstructure 102 is preferably supported on the suspension system 100 at a rear axle 108 (see FIG. 4), and a front support shaft 110 (see FIG. 4). The two-point support structure allows the weight of the superstructure 102 to be evenly distributed over the lengths of the belt tracks 112 and 114. This is because of the position of the superstructure 102 can be adjusted with respect to the position of the front support shaft 110 and the rear axle 108, in such a manner that the weight of the superstructure 102 is evenly distributed along the length of the belts 112 and 114.
The left-hand side undercarriage 104 is now described, and should be understood that it is preferred that the right-hand side undercarriage 106 be the same. Still referring to FIG. 2, the belt track 112 encircles a front idler wheel 116, a rear drive wheel 118, a number of mid-wheels 120 connected to a bridge 122 spanning between the front idler wheel 116 and the rear drive wheel 118, and a tensioner 124 also connected to the bridge 122. In general, the weight of the superstructure 102 is preferably supported by the front support shaft 110 and the rear axle 108, and is distributed along the bridge 122 in such a manner that the ground pressure on the underside of the belt track 112 is even along its entire length.
Referring to FIG. 4, each bridge 122 is connected to the rear axle 108 by a collar 126. Each bridge 122 spans forward to the front idler wheel 116 where it is supported around an axle 128 to which the front wheel is mounted by means of a collar 130. It can be seen in the preferred embodiment that the axles 128 for the front idler wheels 116 are separate from one another. It is preferred that these axles 128 are structured in such a manner that the axle 128 keeps the front idler wheels 116 in a fixed position in respect to the superstructure 102.
Note that the bridges 122 can be made longer or shorter by moving the front 116 and rear 118 wheels further apart or closer together. The length of the bridges 122 can be accommodated by adding additional mid-wheels 120, or by spreading the mid-wheels 120 further apart. Such incremental changes in length is more difficult with the prior art suspension systems.
The bridges 122 are preferably made of steel. It is important that the bridges 122 have a width sufficient to mount the various support members and air bags as is discussed below. Each bridge 122 should also have sufficient strength so that it is completely rigid under the loads expected.
The collars 126 and 130 can be fabricated to be integral with the ends of the bridges 122. It is suggested that bearings 131 (shown in FIG. 3) be used in association with the collars 126 and 130 to facilitate the rotation of axles 108 and 128 in the collars 126 and 130. The bearings 131 should have sufficient strength to support loads on the bridge 122, and it is preferred that the collars/bearing configuration be lubricated with grease or some other lubricant.
As described above, part of the weight of the superstructure 102 is supported on the front support shaft 110 and part is supported on the rear axle 128. Referring again to FIG. 2, this weight is distributed through the bridges 122, which are supported in part by the front 116 and rear 118 wheels that press on the front and rear portions of the belt track 112. The remainder of the weight on the bridges 122 is supported by the mid-wheels 120 that are each connected to the bridge 122 by a support member 132.
It is preferred that the mid-wheels 120 actually be pairs of mid-wheels with the gap therebetween through which ribs 136 on the inside of the belt track 112 can pass. Likewise, it is preferred that both the front 116 and the rear 118 wheels have grooves for accepting the ribs 136. Although not shown in FIG. 2, the ribs 136 preferably run the entire length of the belt track as depicted by ribs 17 in FIG. 1.
Each pair of mid-wheels 120 are preferably connected to another pair of mid-wheels 120 with a minor bogie 138. Minor bogies 138 are known to the industry, and a minor bogie of the type used by Caterpillar, Inc., Peoria, Ill., should be suitable for this application. Briefly, the minor bogies 138 are made of steel, and use collars/bearings on both sides to connect around the axles of the pairs of mid-wheels 120. The minor bogies 138 are concave to increase their strength.
The minor bogies 138 are pivotally connected to an associated support member 132 at a pivot 140. The support members 132 are also pivotally connected to the bridge 122 at a pivot 142. The support members 132 and the pivots 140 and 142 should have sufficient strength to support the weight on the mid-wheels 120. The support member 132 and the pivots 140 and 142 are preferably made of steel.
A bag 134 containing pressurized fluid is located between each support member 132 and the bridge 122. It is preferred that the bags 134 hold pressurized air, although other types of compressible or incompressible fluids can be used. The bags 134 are pressurized to push the support members 132 away from the bridge 122 so that weight being distributed along the bridge 122 can be supported in part by the mid-wheels 120. Air bags 134 can be pressurized using a compressed air supply 35 or an air compressor available to operate other pneumatic devices on a vehicle.
Referring to FIG. 5, each of the air bags 134 on a particular bridge 122 are in fluid communication with each other. In FIG. 5, this is accomplished using a conduit 143 that runs between each of the air bags 134 associated with a particular bridge 122. Note that it is preferred that the air bags 134 associated with the right-hand side bridge 122 not be in fluid communication with the air bag 134 of the left-hand side bridge 122, although a system where they are in fluid communication is contemplated by the present invention.
Referring still to FIG. 5, a pressurized air source 135 provides pressurized air to the bags 134 through lines 137. A three-way valve 139 can be located in each line 137. Each three-way valve 139 can be set to a pressurization position to allow pressurized air from the pressurized air source 135 into the air bags 134. When the pressure in the air bags 134 reaches a desired level, each valve 139 can be set from the pressurization position to a closed position to maintain the air pressure within the interconnected air bags 134 and the conduit 143. When it is desired to relieve the air pressure in the interconnected air bags 134, each valve 139 can be set to a pressure release position in which air within the interconnected air bags 134 is released to the atmosphere. Valve means other than a three-way valve 139 can also be suitable for the present invention.
The air bags 134 are preferably made of rubber. Air bags suitable for this application can be purchased from Goodyear. The air bags should be equipped or modified with nipples to receive the conduit 142. The conduit 142 that interconnects the air bags 134 is preferably made of rubber or steel having sufficient strength, and has an internal diameter of about 3/4 inch which allows the free circulation of air between the bags 134.
With such an interconnected air bag system, ground pressure along the tracks can be evenly distributed along the belt tracks even when a belt track encounters a bump. This is because air from the compressed air bag will propagate to the other air bags 134, thus forcing the other air bags 134 to bear more weight. However, the weight is now spread over more mid-wheels 120. Also, as depicted in FIGS. 6 and 7, the interconnected air bag system decreases bobbing or teetering of a tracked vehicle in the fore and aft directions when the vehicle travels over hills or valleys. This is primarily because the air bags 134 can contract (FIG. 6) or expand (FIG. 7) while at the same time bearing a portion of the weight on the bridge 122.
Referring again to FIG. 2, a tensioner 124 is used to increase the tension on the belt 112 around the front 116 and rear 118 wheels so that the belt 112 does not slip. The preferred tensioner 124 is located above the bridge 122 and pushes the belt 112 away from the bridge 122. In particular, the preferred tensioner has a tension wheel 144 located above the bridge 122. The tension wheel 144 preferably has a groove to accept ribs 136 on the inside of the belt 112. The tension wheel 144 is pivotally connected to the bridge 122 by a tension wheel support arm 146. The tension wheel support arm 146 is pivotally connected to the bridge 122 at pivot 147. A tension pressure bag 148 is located between the tension wheel support 146 and the bridge 122. The tension pressure bag 148 can be pressurized, preferably with pressurized air, to push against the tension wheel support arm 146 and push the tension wheel 144 away from the bridge 122.
Referring again to FIG. 5, the tension pressure bags 148 are preferably pressurized with air from the pressurized air source 135 through lines 153. A valve 151 can be located in each line 153 for changing, releasing and maintaining air pressure in each tension pressure bag 148. It should be noted that it is preferred that the tension pressure bags 148 not be in fluid communication with each other or any other air or fluid bags.
Using valves, such as valves 151, air can be quickly released from the tension pressure bag 148, and the tension pressure bag 148 can be quickly charged with compressed air. A pneumatic tensioner 124 such as described above is convenient for servicing the belt track 112, or other aspects of the undercarriage which require the belt track 112 to be removed or loosened.
Referring in particular to FIGS. 3, 4 and 8, the present invention also contemplates compensating for rough terrain that is uneven in lateral directions. FIG. 3 is a drawing similar to FIG. 3 in U.S. Pat. No. 4,838,373 which was assigned to Caterpillar Inc., Peoria, Ill., when it issued. In FIG. 3, the superstructure 102 is mounted to the rear axle 108 at a pivot 150 located in the middle of axle 108. The weight of the superstructure 102 is then distributed along the axle 108 to pivots 152 and 154. The weight at 152 is supported by undercarriage 104, and the weight at 154 is supported by undercarriage 106. As a result of this construction, it can be seen that the rear of the undercarriages 104 and 106 can move independently of one another in the vertical direction with respect to superstructure 102 depending on the terrain.
Note that each drive wheel 118 is driven by an independent drive motor (not shown). The independent drive motors are discussed in U.S. Pat. No. 4,838,373, and in particular are shown in FIG. 3 of that patent. The vehicle can thus be turned by increasing the speed one of the belt tracks 112 or 114 with respect to the other belt track 114 or 112 using the independent drive motors.
In FIG. 8, the front support shaft 110 is shown to be maintained relatively level even though the terrain over which the vehicle is moving is not level in the lateral direction. This is accomplished by using a system of moveable stabilizer members 158 and interconnected stabilizer air bags 160. Referring to FIG. 2, the stabilizer support member 158 is pivotally connected to the top of the bridge 122 at pivot 167, and pivotally connected to the front support shaft 110 at its other end. The stabilizer air bag 160 is pressurized so that it will expand when pressure on that side of the support shaft 110 is significantly reduced. The air bag 160 for the left-hand side is connected to the air bag 160 for the right-hand side by a line 171 (See FIG. 5). In FIG. 5, the interconnected stabilizer air bags 160 are pressurized with air from the air source 135, and a valve 172 is used to control the air pressure in the interconnected stabilizer air bags 160. When the pressure on the front support shaft 110 is sufficient to keep the air bag 160 compressed, the front support shaft 110 resides in a saddle 162 on the bridge 122. But, when the force on the front support shaft 110 over the bridge 122 lessens, the air bag 160 will expand thus maintaining the support shaft 110 in a level position (or at least more nearly level) than without such a system (see FIG. 8).
In operation, a suspension system in accordance with the present invention can be used by pressurizing the air bags in the system. Each air bag system (i.e., each mid-wheel 120 air bag 134 system, front support bar 110 air bag 160 system, and each tensioner 124 air bag 148 system) is pressurized separately. That is, the two tension air bags 148 are each separately pressurized to tighten the belt track 112 and 114. The stabilizer air bags 160 are interconnected to each other and are pressurized together. The set of air bags 134 for the left-hand side undercarriage 104 are interconnected to one another, and are pressurized together. Likewise, the set of air bags 134 for the right-hand side undercarriage 106 are interconnected to one another, and are pressurized together. The stabilizer air bags 160 and the air bags 134 are pressurized an amount to sufficiently support the superstructure. The air pressure in bags 160 or 134 can be adjusted to compensate for the weight of the superstructure 102. In combine harvester applications, for instance, the weight of the superstructure varies during operation because the load increases, Air pressure can be increased as the load increases to properly suspend the system.
Also, as a load accumulates in a combine harvester, the center of gravity moves. For this reason, it is useful to adjust the position of the superstructure 102 with respect to the two-point suspension system so that the load on the belt tracks 112 and 114 can remain balanced. Weight sensors and/or inventory methods can be used to determine whether air pressure or superstructure position should be adjusted, and the amount of any such adjustments.
It is recognized that various equivalents, alternatives, and modifications of the present invention are possible and should fall within the scope of the claims.
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A suspension system for tracked vehicles has a plurality of interconnected air bags that is used to more evenly distribute the weight of the vehicle superstructure over the belt track. The more even weight distribution improves floatation of the vehicle over the ground, and reduces instability and wear of the superstructure. A tensioner with a pressurized air bag can be used to increase the tension on the belt track during vehicle operation. The pressure in the tensioner air bag can be reduced to ease the tension on the belt track for efficient servicing.
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[0001] This application claims the priority benefit of U.S. application Ser. No. 61/791,738, filed Mar. 15, 2013, the disclosure of which is incorporated herein by reference.
INCORPORATION BY REFERENCE
[0002] “Light Therapy Platform System”, U.S. Patent Publication No. US 2013-0066404 A1, published on Mar. 14, 2013, by Tapper et al., the disclosure of which is incorporated herein by reference in its entirety.
FIELD
[0003] The present embodiments relate to devices and methods for delivering light-based skin therapy treatments for improving skin health, and/or relieving subdermal tissue using light-emitting diode (LED) light therapy, although other types of light radiating sources can be used.
BACKGROUND
[0004] Certain light spectrums emitted by LEDs (blue or red) are known to be therapeutic for skin treatment by being beneficial to better factor wound healing or relieving muscular or other subdermal tissue pain. However, there is a need to provide users/patients with a convenient at-home light therapy delivery device such as a wearable bandage that is adjustable or flexible to conform to different sizes and shapes, and that is simple to use without user discomfort. The alternative is visiting a doctor's office to receive treatments.
[0005] Prior known light therapy devices have suffered from problems relating to the exposure of the LEDs and the associated circuitry to power the LEDs to contact by users. More particularly, in an effort to maximize light communication to a patient, the LEDs have been disposed in a manner which allow them to be physically engaged (e.g., touched) by a patient, or even contact a treatment surface, which processes are debilitating to the LEDs as a result of the accumulation of dirt and oil. In addition, any such engagement can be dangerous to patients who are exposed to the sharp or hot edges of the LEDs and the associated circuitry. The exposure of detailed circuitry presents an intimidating and unpleasant experience.
[0006] Another problem with prior known devices is that the LED arrangement is fixed and not adjustable to better correspond to would location, size or shape, or to be better placed relative to pain areas. The LEDs of such devices are not selectively arrangeable in a variety of patterns to better go near particular pain areas of a wound.
[0007] It is desired to provide alternative means of using the benefits of the light therapy in a manner to maximize therapeutic efficiencies in exposure while maintaining ease and convenience of use. For this reason, a variety of light weight, flexible and adjustable embodiments are disclosed within this disclosure incorporating a variety of energy varying applications responsive to user conditions or needs.
SUMMARY
[0008] The present embodiments comprise phototherapy systems and devices comprising a therapeutic lamp platform for radiant lamps such as LEDs which are disposed in an assembly comprising a multi-layer structure wherein the LEDs are guarded from patient contact.
[0009] The present embodiments comprise an adjustable/flexible platform for providing a light-based therapy that is adaptable to the user's receptive surfaces, whether based on size or condition, wherein the light therapy can be applied without limitation of the kind of light and without limitation of the ultimate purpose of the therapy, i.e., beauty, health, pain relief and/or wound healing. Such sources can vary in the form of the radiant energy delivery. Pulsed light (IPL), focused light (lasers) and other methods of manipulating light energy are encompassed within the present embodiments. Other methods of light emission may comprise continuous, pulsed, focused, diffuse, multi wavelength, single wavelength, visible and/or non-visible light wavelengths.
[0010] A present embodiment describes forms such as a shaped/fitted bandage with LED light emitted from LED bulbs or LED strips that are capable of being adjusted to accommodate the variances in the desired treatment area.
[0011] The present disclosure thus describes a fully flexible and adjustable LED device which provides improved usability and light dispersion. Such device comprises light therapy bandage system including a spacing and insulating layer to effectively elevate the lamp radiation from the treatment area (e.g. skin) of the patient's last user. The lamps are recessed relative to the insulating layer and further covered by a sheer mesh layer to protect the user from being able to contact the lamps.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1A is a plan view of one embodiment of a therapeutic lamp platform comprising a lumbar brace;
[0013] FIG. 1B is an opposite plan view of the device of FIG. 1A ;
[0014] FIG. 2 is an exploded view of the device of FIG. 1A and 1B ;
[0015] FIG. 3 is a perspective view of the device of FIG. 1A and 1B on a patient;
[0016] FIG. 4A is a perspective view of another embodiment comprising a knee brace;
[0017] FIG. 4B is an alternative view of the device of 4 A;
[0018] FIG. 4C is an alternative view of the device of 4 A;
[0019] FIG. 4D is an alternative view of the device of 4 A;
[0020] FIG. 5 is an exploded perspective view of the device of FIG. 4A ;
[0021] FIG. 6 is an alternative embodiment of a knee brace;
[0022] FIG. 7 is an exploded view of the device of FIG. 6 ;
[0023] FIG. 8 is another embodiment of a knee brace;
[0024] FIG. 9 is another embodiment of a knee brace;
[0025] FIG. 10 is a top perspective view of one embodiment of the subject bandage system;
[0026] FIG. 11 is a bottom view of the device of FIG. 10 ; and
[0027] FIG. 12 is an exploded view of the device of FIG. 10 .
DETAILED DESCRIPTION
[0028] The subject embodiments relate to a phototherapy system including methods and devices, preferably comprising a wearable device with a removable, portable battery pack for powering therapeutic lamps in the device. The subject devices display numerous benefits including a light platform wherein the platform and the lamps therein are properly positionable relative to a user during use with no human touch. That is, structural componentry of the device not only supports the lamp platform on the user, but functions as a guide for the appropriate disposition of the lamps relative to the treatment areas of the user. The structural assembly of the device precludes sharp or hot surfaces from being engageable by a user as the lamps are recessed relative to an inner reflective surface nearer to and facing the patient treatment surface. Circuit componentry to communicate power to the lamps is also encased within the flexible wall structure. Therapeutic light, shining through wall apertures or mesh, is communicated to the user while the lamps and the circuitry are effectively covered within the layered wall structure. A surface is thus presented to the user that is properly spaced for the desired therapeutic treatments, yet provides improved ventilation so that an aesthetic and appealing device surface is presented to the user that minimizes user discomfort. Other benefits relate to the adjustability of the device in the form of a bandage which forms upon user receipt to match a treatment surface, e.g., back or knee, of the user. The overall assembly is purposefully constructed of relatively light weight and minimized componentry for ease of user use and comfort.
[0029] More particularly, and with reference to FIGS. 1A , 1 B and 2 , the subject embodiments preferably comprise a lumbar brace 10 that can be worn by a patient/user such as shown in FIG. 3 . The brace 10 can be supported and affixed on the user by a hook-and-loop locking fabric at the terminal ends of the brace. Such a brace will typically include heat wraps for lower back and hips 14 on the exterior of the brace 10 opposite of the patient facing surface. The LED platform of the bandage comprises an elastic member 12 on which LED strips 14 are mounted on a support layer 16 that is heat insular and/or reflective. It is important that the layer 16 be flexible and stretchable with the elastic bandage 12 . Note that the wires connecting the LEDs to the battery pouch 18 are of extra length to allow stretching of the dimension between the LED strips. Power is supplied by a battery pack 20 received in battery pack 22 . The LED lights 14 are spaced from direct engagement of the patient by an insular layer 24 which can range from a mesh cloth to a flexible sheet of formable material in which the strips are integrally molded.
[0030] In one embodiment the mesh cloth allows communication of the lamp radiation through to the patient without reflection.
[0031] In another embodiment the flexible formable material 24 can have apertures (not shown) functioning as a window to allow the light to pass through and the remainder can be of a light reflective surface. In this embodiment the LEDs are effectively hidden from the patient, where layer 24 is a mesh cloth that the patient can, of course, see the LEDs tips and the associated circuitry.
[0032] The subject system may also include control systems to vary light intensity, frequency or direction. A portable battery pack is included.
[0033] The subject adjustability may be implemented through “smart” processing and sensor systems for enhanced flexibility/adjustability in the form of adjustable energy output, adjustable wavelengths, priority zones, timers, and the like. The sensors of the sensor systems will enable the subject embodiments to have the ability to evaluate the treatment area and plan a smart treatment, utilizing more or less energy on the priority zones. The subject embodiments can be smart from the standpoint of body treatment area such as knee or back, and of skin type, age, overall severity of problems and have the ability to customize the treatment accordingly.
[0034] In yet another embodiment, the lamps are embedded in a flexible sheet of formable material and are integrally molded as strips within a material sheet.
[0035] With reference to FIGS. 4A , 4 B, 4 C, 4 D and 5 , the LED bandage is shown where the LED strips are arranged in a diamond pattern and the elastic bandage is formed as a unitary sleeve which is pulled over the leg to the knee area. The multi-structural layer of the brace is shown in FIG. 5 to comprise an elastic bandage platform 50 , a first layer reference material that may be constructed of emergency blanket material 52 , LED light strips 54 , and a surface layer 56 to cover the strips 54 .
[0036] With reference to FIGS. 6 and 7 , another alternative embodiment of a knee brace is shown where the elastic bandage is a wraparound of the knee as it is shown in FIG. 6 again in a diamond pattern about the patient's kneecap including the multi-layer structures such as is shown in FIG. 7 .
[0037] FIGS. 8 and 9 show yet other embodiments which can also function as a wraparound knee brace including the same multi-layer structures such as is shown in FIG. 9 .
[0038] In other embodiments the strip pattern can be arranged in different placements as shown in the Figures to better match treatment to the desired patient area. For example, rather than being equally spaced, the strips can be bunched together in a group, or several groups. In which case the bandage material would be constructed of a material that would allow the strips to be selectively moved and then affixed to the material at different locations. Hook-and-loop fastening fabric could accomplish this structural objective.
[0039] FIGS. 10 and 11 show another embodiment wherein the battery energy sources 70 are encased in battery shrouds 72 and received with controller 74 on a primary fabric layer 76 . FIG. 10 shows the top layer of the device away from a user treatment area (not shown). FIG. 11 shows the bottom surface of the device of FIG. 10 wherein the therapeutical lamps of radiation communicate to the treatment area through a plurality of spacer window openings 80 .
[0040] FIG. 12 shows more clearly the component elements of the device. The battery pack 72 and controller 74 are either mechanically attached or heat bonded to the primary fabric layer 82 which can be secured to a patient treatment area through a strap (not shown) received in a buckle 84 and buckle receiver 86 assembly. The therapeutic lamps preferably comprise a plurality of LED strips 90 mounted on a foam and reflective layer 92 in a manner so that the LEDs are aligned with the windows 80 . Power to the LED strips 90 is communicated from the battery 72 via wires (not shown). The foam and reflective layer 92 comprises a heat insulator and spacer so that the LEDs on the strips 90 are recessed relative to the opposite surface of the layer 92 than that on which they are mounted. The strips 90 and layer 92 form a subassembly that in one embodiment is selectively removable and replaceable from and to the device. Layer 92 is highly flexible as are the strips 90 so that the strip 90 and layer 92 subassembly is preferably flexible along a plurality of directions aligned with the areas intermediate the strips for the overall purpose of providing a device which is conformable to properly and comfortably cover a non-flat treatment area. The layer 92 is dimensioned so that the lamps on the LED strips 90 don't break the surface plane of layer 92 on which a reflective layer 94 is attached. Reflective layer 94 preferably comprises some type of flexible foil suitable for reflecting the radiant energy of the lamps. A secondary fabric layer 96 covers the foam and reflective layer 92 with a sheer mesh 98 which allows lamp radiation to be communicated to the treatment area with minimal obstruction. The effect is that of a plurality of expanding cones of radiant energy from the lamps of the LED strips 90 that is communicated through the foam layer 92 for therapeutic treatment of the treatment area.
[0041] The controller 74 is intended to communicate operational aspects of the device to the user in several ways. When the user actuates an on switch an indicator such as a light or beep sounder will let the user know that the device is operating. The controller will time the operation to a predetermined limit such as 10 or 15 minutes. In addition, the controller will count usage or cycle sessions to indicate to the user via a controller display of how many sessions have been run and additionally, to disable the device after the sessions have occurred so many times that the LED efficiency in generating therapeutic radiation has been so diminished that the device should no longer be used. The controller will also deactivate the indicator light after the session has been timed out or may alternatively send another sound beep to the user. Alternatively, the indicator can also provide for indicating battery life or lamp failure.
[0042] It will be appreciated that variants of the above-disclosed and other features and functions, or alternatives thereof, may be combined into many other different systems or applications. Various presently unforeseen or unanticipated alternatives, modifications, variations or improvements therein may be subsequently made by those skilled in the art which are also intended to be encompassed by the following claims.
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The radiant energy bandage system is disclosed including a plurality of therapeutic lamps and a controller for operating the lamps. Batteries power the lamps and are secured to a flexible fabric layer supporting the lamps and the controller. A foam and reflective layer includes a spacer foam and radiant energy reflector. A plurality of spacer windows are aligned with the lamps for communicating lamp radiation therethrough. A sheer mesh fabric layer is supposed to cover the foam and reflective layer.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of PCT application serial number PCT/EP2004/006948, filed Jun. 26, 2004, which claims priority to European Patent Application No. 03 017 009.6, filed Jul. 26, 2003.
TECHNICAL FIELD
[0002] This description relates to a tool holding system for metal-processing machines, such as punches and laser cutting machines and the like.
BACKGROUND
[0003] A machine tool including a punch machine with a die which can be raised and lowered is disclosed in EP 0 417 836 B1. The stroke movement of the die is generated by means of a tool stroke drive which in turn comprises a hydraulic piston-cylinder unit and a wedge gear. The piston-cylinder unit is arranged horizontally and moves a first gear wedge of the wedge gear in the horizontal direction. The first gear wedge has on its side facing upwards a wedge surface angled towards the horizontal. On this wedge surface of the first gear wedge rests a second gear wedge of the wedge gear with a corresponding wedge surface. The second gear wedge supports on its top a die holder and via this the die to be raised or lowered. By means of the wedge gear the horizontally oriented drive movement of the piston-cylinder unit is transformed into a vertical movement of the die. As well as the die, the die holder and the gear wedges of the wedge gear are fitted with orifices passable in the vertical direction, through which for example punching waste occurring at the machining point can leave the working area of the machine.
[0004] Because of the configuration described, the tool stroke drive of the previously known punch machine and hence the punch machine itself are relatively large.
SUMMARY
[0005] According to one aspect, a tool stroke drive includes a spindle gear, of which the at least one spindle runs in the stroke direction. In any case transverse to the stroke direction—and with a corresponding design also in the stroke direction—the tool stroke drive according to the invention is extremely compact. At the same time, a passage is left clear which continues into the orifice of the tool holder in the stroke direction. The accessibility of the working area of the machine tool or of the machining tool through the tool holder is consequently not hindered by the presence of the tool stroke drive. The passage can, for example with the die integrated into the tool holder, serve to discharge punching waste from the working area of the machine tool. If as an alternative to a punch tool a laser cutting head can be attached to the tool holder, the laser beam originating from the beam source can be directed to this through the passage left clear by the spindle gear and/or the rotary drive of the tool stroke drive. Various implementation provide a compact construction of the tool stroke drive and hence a compact construction of the entire machine.
[0006] In some embodiments, the passage continuing into the orifice of the tool holder in the stroke direction is formed by the inner recess of a hollow spindle of the spindle gear and provides a compact configuration. This embodiment is characterized by particular compactness.
[0007] In some embodiments, the spindle drive of machine tools according to the invention can include several spindle-spindle nut units which are arranged about the passage continuing into the orifice of the tool holder. Also in the context of the invention it is conceivable to provide a spindle-spindle nut unit with a hollow spindle forming said passage and in addition arrange at least one further spindle-spindle nut unit at a distance from the passage.
[0008] In some embodiments, multi-spindle solutions are characterized generally by high dynamics. This allows the performance of fast short strokes of the tool holder with high acceleration. In addition, the use of multiple spindle-spindle nut units allows the transmission of particularly large forces. Finally, when several spindle-spindle nut units are used, these can be used as a twist lock for the tool holder or a housing fitted with the tool holder during performance of the strokes. Expensive measures for twist prevention are consequently not required. This circumstance in turn contributes to a compact construction of the entire arrangement.
[0009] Drive ring gears with inner recess are provided in the interests of a compact construction of the rotary drive and hence the entire tool stroke drive. A particularly compact arrangement arises if a drive ring gear drives one or more spindle-spindle nut units without intermediate gear. In this case only a coupling is required between the drive ring gear and the spindle-spindle nut unit or units concerned. Elastic couplings or rigid ones, switchable or non-switchable couplings are conceivable.
[0010] The tool stroke drive becomes particularly compact if the drive ring gear is formed by the rotor of an electric motor serving as a drive motor for the tool stroke drive. In particular if a torque motor is used as an electric motor, high torques can be transmitted to the spindle gear or gears without intermediate gear. In some embodiments, the drive ring gear surrounds the at least one spindle-spindle nut unit to be driven. In some embodiments, the same drive ring gear can be used for common drive of a multiplicity of spindle-spindle nut units.
[0011] The compact tool stroke drive of machine tools according to the invention can be used in particular to drive punches and/or dies. Both working strokes for punch workpiece machining and adjustment strokes for positioning the punching tool concerned can be performed as strokes.
[0012] According to another aspect, a tool holding system includes a tool holder configured to releasably retain a metal-processing tool and defining a tool holder passage extending along a stroke axis, an adjustment drive operable to rotate the tool holder about the stroke axis, and a stroke drive including a spindle operable independent of the adjustment drive to translate the tool holder along the stroke axis. The stroke drive defines a stroke drive passage cooperating with the tool holder passage to define a waste disposal passageway through the tool holding system.
[0013] In various embodiments, the adjustment drive includes a stator and rotor which are concentric with the tool holder passage. The spindle is coupled to the rotor and defines an inner recess cooperating with the stroke drive passage. The stroke drive can also includes a plurality of spindle-spindle nut units mounted for rotation and positioned to commonly engage an inner surface of the spindle. The stroke drive can further include a number of spindle-spindle nut units mounted for rotation and positioned to commonly engage an outer surface of the spindle. The metal-processing tool can include a punch, die or a laser cutting head.
[0014] According to another aspect, a machine for processing a workpiece includes a machine frame including an upper frame leg and a lower frame leg, a workpiece table configured to support a workpiece disposed generally between the upper and lower frame legs, and the tool holding system of claim 1 affixed to the free end of at least one of the upper frame leg and the lower frame leg.
[0015] In some embodiments of the foregoing aspect, a first tool handling system is affixed to the free end of the upper frame leg and a second tool handling system is affixed to free end of the lower frame leg.
[0016] In some embodiments, the metal-processing tool of the first tool handling system includes a punch and the metal-processing tool of the second tool handling system includes a die. In some embodiments, the metal-processing device includes a laser cutting head and the machine for processing a workpiece includes a laser operable to direct a laser beam through the cutting head and the waste disposal passage to the workpiece.
[0017] In some embodiments the adjustment drive includes a stator and rotor which are concentric with the tool holder passage. In some embodiments, the spindle is coupled to the rotor and defines an inner recess cooperating with the stroke drive passage. In still other embodiments, the stroke drive further includes multiple spindle-spindle nut units mounted for rotation and positioned to commonly engage an inner surface of the spindle.
[0018] In some embodiments the stroke drive further includes a plurality of spindle-spindle nut units mounted for rotation and positioned to commonly engage an outer surface of the spindle. In some embodiments, the machine for processing a workpiece includes a workpiece table for supporting a workpiece which includes a controllable flap proximate the metal-processing tool, the flap being moveable to reveal a chute for delivery of workpiece waste to a collection container disposed below the table.
[0019] According to still another aspect, a method of machining a workpiece includes retaining a metal-processing tool on a tool holder, rotating the position of the tool holder about a stroke axis with an adjustment drive, translating the position of the tool holder along the stroke axis with a stroke drive having a spindle operable independent of the adjustment drive, maintaining an access passage through the tool holder and the stroke drive while adjusting the position of the tool holder and processing the workpiece with the metal-processing tool.
[0020] In some embodiments, the metal-processing tool includes a laser cutting head and the method also includes illuminating a laser through the laser cutting head and the access passage. In some embodiments, the method also includes delivering workpiece waste through the access passage during processing the workpiece.
[0021] According to another aspect, a method of machining a workpiece includes retaining a first metal-processing tool on a first tool holder, rotating the position of the first tool holder about a stroke axis with a first adjustment drive, translating the position of the first tool holder along the stroke axis with a first stroke drive including a first spindle operable independent of the first adjustment drive, retaining a second metal-processing tool on a second tool holder, rotating the position of the second tool holder about a stroke axis with a second adjustment drive, translating the position of the second tool holder along the stroke axis with a second stroke drive including a second spindle operable independent of the second adjustment drive, and maintaining a first passage through the first tool holder and the first stroke drive while adjusting the position of the first tool holder.
[0022] According to still another aspect, a machine tool for processing a workpiece positioned in a working area includes a tool holder to support a punch tool and defining an opening proximate the working area of the machine tool, the tool holder configured to rotate about a stroke axis and a tool stroke drive attached to the tool holder at a first end and including a spindle gear mounted for rotation about the stroke axis, a rotary drive coupled to the spindle gear, and at least one spindle-spindle nut unit operably connected with the spindle gear with a spindle, the rotary drive configured to move the tool stroke drive along the stroke axis. The tool holder and stroke drive holder define a continuous central bore.
[0023] The details of one or more embodiments of the invention are set forth in the accompanying drawings and the description below. Other features and advantages of the invention will be apparent from the description and drawings, and from the claims.
DESCRIPTION OF DRAWINGS
[0024] FIG. 1 shows a punch machine with die and punch in highly schematic, partly cut-away overall view,
[0025] FIG. 2 shows a longitudinal section of a stroke drive of a first design for the die in FIG. 1 ,
[0026] FIG. 3 shows a cross-section of the stroke drive according to FIG. 2 with a cut plane running perpendicular to the drawing plane in FIG. 2 and in the direction of line III-III,
[0027] FIG. 4 shows a longitudinal section of a stroke drive of a second design for the die in FIG. 1 ,
[0028] FIG. 5 shows a cross-section of the stroke drive according to FIG. 4 with a cut plane running perpendicular to the drawing plane in FIG. 4 and in the direction of line V-V,
[0029] FIG. 6 shows a longitudinal section of a stroke drive of a first design for the punch in FIG. 1 ,
[0030] FIG. 7 shows a longitudinal section of a stroke drive of a second design for the punch in FIG. 1 .
[0031] FIG. 8 shows a longitudinal section of the stroke drive of FIG. 6 including a laser cutting head, and
[0032] FIG. 9 shows a longitudinal section of the stroke drive of FIG. 7 including a laser cutting head.
[0033] Like reference symbols in the various drawings indicate like elements.
DETAILED DESCRIPTION
[0034] According to FIG. 1 , a punch machine 1 has a C-shaped machine frame 2 with an upper frame leg 3 and a lower frame leg 4 . At the free end of the upper frame leg 3 , a punch 5 can be raised and lowered in a stroke direction 6 indicated by a double arrow. The machine 1 can also include a laser 50 (shown in phantom) in place of or in conjunction with the punch 5 . The stroke movement of the punch 5 is achieved by means of a tool stroke drive described in detail below.
[0035] Opposite the punch 5 at the free end of the lower frame leg 4 is arranged a die 7 . This too can be moved in the stroke direction 6 by means of the tool stroke drive explained in more detail below. Both the punch 5 and the die 7 are rotationally adjustable in the direction of a double arrow 8 about a rotary axis running in the stroke direction 6 . Both the rotational adjustment and the stroke movement of the punch 5 and the die 7 are numerically controlled.
[0036] Below the die 7 in the inside of the lower frame leg 4 is provided a collection container 9 for punching waste. Finished parts produced by means of the punch 5 and die 7 are discharged out of the working area of the punch machine 1 via a flap 12 integrated into a workpiece table 10 and swivellable to and from in the direction of a double arrow 11 .
[0037] In the example shown, a plate 13 is to be processed with the punch machine 1 , and is positioned in the known manner in relation to the punch 5 and the die 7 by means of a coordinate guide 14 accommodated in the gap between the upper frame leg 3 and the lower frame leg 4 .
[0038] A tool holding system 100 is shown in detail in FIGS. 2 and 3 as tool stroke drive 15 and includes a spindle gear 16 with a spindle-spindle nut unit 17 and a rotary drive 18 provided for this. Parts of the spindle-spindle nut unit 17 are a spindle 19 formed as a hollow spindle and a spindle nut 20 . The spindle 19 runs with an axis 21 in the stroke direction 6 . It is mounted rotatable about the axis 21 on a housing 22 of the tool stroke drive 15 and fixed in the direction of axis 21 . In its inside, it has an inner recess 23 open at both axial ends.
[0039] The rotary drive 18 for the spindle-spindle nut unit 17 is an electric motor. A torque motor 24 serves as a drive motor and is mounted with a stator 25 on the housing 22 of the tool stroke drive 15 . A rotor 26 of the torque motor 24 revolves about the axis 21 of the spindle 19 and is rigidly coupled to this at an outer flange of the spindle 19 . A housing of the torque motor 24 , evident in FIG. 2 , is not shown in FIG. 3 for the sake of clarity.
[0040] The spindle nut 20 of the spindle-spindle nut unit 17 is drive-connected with a tool holder 27 for the die 7 . A corresponding form-fit connection 28 between the spindle nut 20 and the tool holder 27 acts in the direction of the axis 21 of the spindle 19 and hence in the stroke direction 6 . The spindle 19 revolving about axis 21 is prevented from carrying with it the tool holder 27 and spindle nut 20 by a twist lock of the tool holder 27 not shown in detail. A rotary adjustment movement of the tool holder 27 about the axis 21 of the spindle 19 can however be executed by means of an adjustment motor 29 . The adjustment motor 29 serves to adjust the die 7 in the direction of the double arrow 8 in FIG. 1 . On rotary adjustment of the tool holder 27 or the die 7 , the twist lock of the tool holder 27 is disabled.
[0041] By means of the tool stroke drive 15 , the die 7 can be raised and lowered in the stroke direction 6 . FIG. 2 shows the die 7 in its upper end position. The die 7 assumes this position during punching of the plate 13 . If after punching, the plate 13 is to be moved by means of the coordinate guide 14 in relation to the punch 5 and die 7 , the die 7 is lowered by means of the tool stroke drive 15 . This prevents the plate 13 , during its subsequent movement by means of the coordinate guide 14 , on its underside coming into contact with the die 7 and consequently scratches being formed on the underside of the plate 13 . In addition it is conceivable to use the tool stroke drive 15 to perform the working strokes necessary for the punch machining of the plate 13 . In this case the relative movement between the punch 5 and the die 7 is generated by stroke movement of the die 7 when the punch 5 is stationary in the stroke direction 6 .
[0042] A tool holding system 200 is shown in FIGS. 4 and 5 for lifting and lowering the die 7 in the form of a tool stroke drive 30 includes a spindle gear 31 with a total of eight spindle-spindle nut units 32 and a rotary drive 33 .
[0043] Each of the spindle-spindle nut units 32 has a spindle 34 and a spindle nut 35 sitting thereon. Axes 36 of the spindles 34 run in the stroke direction 6 . On a housing 37 of the tool stroke drive 30 , the spindles 34 are mounted rotatable about their axes 36 and fixed in the axial direction. Each spindle 34 has an outer collar 38 with outer toothing.
[0044] A torque motor 39 with a stator 40 and a rotor 41 serves for common rotation of the spindles 34 . The rotor 41 revolves about an axis extending in the stroke direction 6 and engages with an inner toothing 42 on the outer toothings of the outer collars 38 on the spindles 34 . Like the rotor 26 of the torque motor 24 in FIGS. 2 and 3 , the rotor 41 of the torque motor 39 forms a drive ring gear with inner recess.
[0045] Via a form-fit connection 43 , the spindle nuts 35 of the spindle-spindle nut units 32 are actively connected in the stroke direction 6 with the tool holder 27 for the die 7 . An adjustment motor 44 ensures the rotary adjustment in the direction of the double arrow 8 in FIG. 1 of the tool holder 27 which can be raised and lowered by means of the tool stroke drive 30 .
[0046] An orifice 45 in the inside of the tool holder 27 aligns according to FIGS. 2 and 3 with the passage-forming inner recess 23 in the spindle 19 provided there, in the situation in FIGS. 4 and 5 it aligns with a passage in the form of a clear space 46 about which are arranged the spindle-spindle nut units 32 and which is surrounded by the torque motor 39 . Punching waste generated on machining the plate 13 can leave the working area of the punch machine 1 under the effect of gravity through the orifice 45 of the tool holder 27 and the inner recess 23 of the spindle 19 or the clear space 46 between the spindle-spindle nut units 32 .
[0047] Like the tool stroke drive 15 in FIGS. 2 and 3 , the tool stroke drive 30 in FIGS. 4 and 5 can perform both an adjustment movement and a working stroke of the die 7 .
[0048] A tool holding system 300 including a tool stroke drive 47 is shown in FIG. 6 and a tool holding system 400 including a tool stroke drive 48 is shown in FIG. 7 serve to move the punch 5 in the stroke direction 6 . In its construction, the tool stroke drive 47 for the punch 5 corresponds to the tool stroke drive 15 for the die 7 . The tool stroke drive 48 for the punch 5 is structured substantially the same as the tool stroke drive 30 for the die 7 . The same reference numerals are used for the components of the tool stroke drives 47 , 48 as for the corresponding components of the tool stroke drives 15 , 30 .
[0049] FIG. 8 show a laser cutter head 450 fitted to the tool holding system 300 of FIG. 6 instead of the punch 5 and FIG. 9 shows the laser cutter head 450 fitted to the tool holding system 400 of FIG. 7 instead of the punch 5 . In these implementations, the laser beam from laser 50 ( FIG. 1 ) is directed through the inner recess 23 ( FIG. 8 ) or the space 46 ( FIG. 9 ) and the opening 45 in the laser cutting head 450 .
[0050] A number of embodiments of the invention have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the invention. Accordingly, other embodiments are within the scope of the following claims.
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A tool holding system includes a tool holder configured to releasably retain a metal-processing tool and defining a tool holder passage extending along a stroke axis, an adjustment drive operable to rotate the tool holder about the stroke axis, and a stroke drive comprising a spindle operable independent of the adjustment drive to translate the tool holder along the stroke axis. The stroke drive defines a stroke drive passage cooperating with the tool holder passage to define a waste disposal passageway through the tool holding system.
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CROSS REFERENCE TO RELATED APPLICATION
This is a National Phase Application of PCT Application No. PCT/IL98/00581 which in turn is based on Israeli Application No. 122396 filed Nov. 29, 1998, the priority of which is claimed herein.
BACKGROUND OF THE INVENTION
This invention relates to methods of heating and/or homogenizing of liquid products in a steam-liquid injector. By liquid products (hereinafter: products) are meant liquids with different degrees of viscosity, with or without solid particles (solid phase) dispersed in them. By a steam-liquid injector is meant an injector which uses steam as a process medium and liquid as injected medium.
The prior art methods of heating and/or homogenizing of products in a steam-liquid injector include the following steps:
feeding steam and a product into a mixing chamber—through a steam nozzle and a product nozzle accordingly;
forming in the mixing chamber a two-phase steam-liquid flow by mixing the product with steam;
compressing the two-phase steam-liquid flow and condensing steam in the product.
Examples of the use of this method and devices based thereon can be found in the following patents:
[1] WO 89/10184, also published as EP 0399041, describes an emulsifier based on a passive steam-liquid injector;
[2] SU 1472052 describes a method of liquid foodstuff heating in a steam-liquid injector;
[3] SU 1281761 describes a water-heating steam-liquid injector.
[4] SU 1507299 describes a pasteurization method for a liquid whole milk substitute in a passive supersonic steam-liquid injector,
[5] U.S. Pat. No. 5,205,648 and [6] U.S. Pat. No. 5,275,486 <<Method and Device for Acting upon Fluids by Means of a Shock Wave>> describe, as an instance of application, heating and homogenizing of liquid foodstuffs in a steam-liquid injector, wherein product and steam are fed to the mixing chamber at a subsonic speed, creating a two-phase steam-liquid mixture; in the process the mixture is first sped up to the sonic and then to a supersonic speed and, due to a shock wave, transformed into a single-phase liquid flow traveling at a subsonic speed.
[7] U.S. Pat. No. 5,544,961 <<Two-Phase Supersonic Flow System>> describes, as an instance of application, heating and homogenizing of liquid foodstuffs in a steam-liquid injector, with product fed to the mixing chamber at a subsonic speed and steam fed at a supersonic speed, creating a two-phase steam-liquid mixture traveling at a supersonic speed; in the process the two-phase steam-liquid flow, due to a shock wave, is transformed into a single-phase liquid flow traveling at a subsonic speed.
[7] U.S. Pat. No. 5,544,961 <<Two-Phase Supersonic Flow System>> describes, as an instance of application, heating and homogenizing of liquid foodstuffs in a steam-liquid injector, with product fed to the mixing chamber at a subsonic speed and steam fed at a supersonic speed, creating two-phase steam-liquid mixture traveling at a supersonic speed; in the process the two-phase steam-liquid flow, due to a shock wave, is transformed into a single-phase liquid flow traveling at a subsonic speed.
Some distinctive features of the method and device suggested by the above patent provide for a more stable operation of the injector, a higher shock wave and a higher degree of sterility and homogeneity of the product.
From the points of the essence of the present invention, the number of common features and the objects in view, its closest prototype is the method and device described in an article [8] under the title <<The Principle and the Use of a New Multifunction Direct Steam Technology (Ultrasonic Device) in Food and Dairy Industry>> by M. Rogenhofer, E. Hauss and V. Fissenko, published in <<Magazine for Food and Dairy Industry>> # 13/114, Mar. 25, 1993).
[8] [M. Rogenhofer, E. Hauss, V. Fisenko <<Aufbau und Wizkungsweise einer neuen multifunktionalen Uberschall-Direktdampf-Technologie (Transsonic-Gerat) fur den Milch-und-Lebensmittelbereich>>].
According to the authors of the above article, the injector described in their article was based on U.S. Pat. No. 5,205,648 [5] and U.S. Pat. No. 5,275,486 [6].
Based on testing operating conditions given in the article, it can be presumed that under some regimes (according to steam pressures forward of the injector and inside the mixing chamber) the steam was fed to the mixing chamber at a supersonic speed. In other words, in such cases the injector operated according to U.S. Pat No. 5,544,961 [7]. This enables us to consider the results according to several patents simultaneously.
The test data reported in the above article demonstrate that the required homogenizing standards have not been achieved whereas the pasteurization quality corresponds to that achieved on conventional equipment at an appropriate temperature. From FIG. 5 and information contained in the article [8], it can be seen that the stability of the injector's operation decreases sharply with the increase in the injection index, i.e. with reduction of the product's temperature difference between the inlet and the outlet of the injector. In all the above analogs and prototypes all the essential features, both of methods and devices, are related to conditions of steam feeding to the mixing chamber, proportions between the dimensions of the steam nozzle channel and the mixing chamber, and the effect of these parameters on the injector's operation. The device's longitudinal section given in FIG. 2 . in the article.[8] and description of its operation demonstrate that the product nozzle's critical section area is sufficiently large to allow a relatively low speed of product at the point where it is mixed with The steam. The fact that the device works as a passive injector suggests a low speed of product. Likewise, in other designs or design and calculation instructions for injectors no importance is attached to the flow speed in the mixing area. For instance: [9] Y.Y. Sokolov and N. M. Zinger, <<Stream Devices>>, Moscow, <<Energhia>>, 1970, pp. 234-251.
The stability of the injector's operation, especially at the moment of start and in transient condition, remains one of the main problems of the prior art injector systems.
Accordingly, they require highly skilled maintenance staff especially start up men. As a result, the injectors are perceived as unreliable and unpredictable devices which restricts their application despite their many advantages
OBJECTS AND SUMMARY OF THE INVENTION
The aim of the present invention is to improve the quality of products processed by the injector Quality attribute of foodstuffs and pharmaceutical products, for instance, are sterility, homogeneity, reduced thermal melting of proteins, conservation of vitamins, biological activity, etc. The other aims of the present invention include: increasing the stability of the injector's operation, increasing its injection index and regulating the intensity of the shock wave.
The stated aim can be achieved by the following method:
steam and liquid product are fed into the mixing chamber of the injector through a steam nozzle and a product nozzle correspondingly, in said chamber, two-phase steam-liquid flow is formed by mixing the product with steam; this flow is subjected to compression causing condensation of the steam in the product; the product is accelerated at entry to the mixing chamber to a maximum permissible speed matching processing operating conditions while not exceeding the speed at which the static pressure of the flow matches the saturation pressure at an input temperature of the product, the maximum speed, according to the liquid flow speed curve in the injector channel before steam feeding, being observed at the output cross-sectional area of the product nozzle.
The above operation sequence relates to the general case. The preferred options of embodiment of the suggested method are as follows:
steam is fed to the mixing chamber at the sonic or a supersonic speed;
steam is fed to the mixing chamber with temperature equal to or lower than final product heating temperature, but remaining above the input temperature of the product. The preferred temperature is calculated by the following formula: Tst = Tin + Tout - Tin 2 ,
where Tst is steam temperature at the mixing chamber inlet Tin is product temperature at the injector inlet Tout final product heating temperature;
transmission of the two-phase steam-liquid flow formed in the mixing chamber at a speed equal or exceeding the local sonic speed;
subjection of said flow to shock wave, compression jump, condensation jump (later on - to shock wave);
creation at the injector outlet of regulated backpressure, thereby enabling regulation of intensity of the shock wave and its location in the channel of the injector;
partial heat and/or mass abstraction from the supersonic steam-liquid flow;
feeding the product to the mixing chamber in the form of a thin sheet with thickness within 0.15-2.5 mm;
feeding steam to the mixing chamber only on one side of said sheet of product;
feeding steam to the mixing chamber on both sides of said sheet of product;
feeding the product through product nozzle placed along the injector axis, whereas steam is fed through steam nozzle placed concentrically to the product nozzle.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The main distinctive feature of the method of the invention is the increase in speed of product fed to the mixing chamber, namely:
the product is accelerated at entry to a maximum permissible speed matching processing operating conditions while not exceeding the speed at which the static pressure of the flow matches the saturation pressure at an input temperature of the product, the maximum speed, according to the liquid flow speed curve in the injector channel before steam feeding, being observed at the output cross-sectional area of the product nozzle.
These features, separately and in the aggregate, provide for new good properties listed below.
Firstly, a new injector has been created, based on a new conception which includes methods of operation of two prior art injectors: steam-liquid injector which uses steam as a process medium and liquid as injected medium (See [9] pp.); steam-liquid injector which uses liquid as a process medium and steam as injected medium (See [9] pp ). The new method of injector operation combines advantages of steam-liquid injectors (good operating characteristic, especially of those with supersonic steam flow and two-phase steam-liquid mixtures) and liquid-steam injectors (easy to handle, reliable start stable performance). In addition, the new injector based on the new method is free from imperfections of both of the above types of injectors.
Secondly, increase in product flow speed at entry to the mixing chamber while retaining the same flow rate of the product, will reduce the thickness of the product sheet contacting with steam, Thus improving heat- and mass interchange. As a result, Reynolds number (Re) increases, leading to increase in turbulization of the flow and higher probability of the full contact between product mass and steam. This, in its turn, insures forming of a more homogeneous and finer dispersed two-phase steam-liquid flow, thereby improving the injector performance. Thirdly, kinetic energy of the flow after mixing increases as square speed of the flow fed to the mixing chamber (according to formulas 1-6 on p. 14 [9]). This leads to reduction of the shock loss at the time of mixing and increases the injector's coefficient of efficiency. (See formulas: 1-7, 1-8, 1-9, 1-10 and 1-11 on p. 14 [9]). As a result, the stability of the injector's operation, its operating characteristic and homogeneity of the product improve.
Fourthly, when the product flow at the mixing chamber nozzle reaches a speed at which the static pressure of the flow nearly matches the saturation pressure at the input temperature of the product, it becomes possible to substantially increase the injection index (U) - up to and over 100. This becomes possible because even slight heating of a product (for instance, by 4-7° C.), as a result of energy impulse exchange between steam and product, makes the mixing chamber pressure equal to or slightly below that of the saturation (cavitation) pressure. As a result, condensation of the working steam ceases, and steam fed to the mixing chamber serves to form a two-phase steam-liquid flow. This allows a significant speed gradient between the product and steam, without steam condensing along a large part of the mixing chamber, thereby providing better dispersion and homogenizing of the product. This, in its turn, insures forming of a more homogeneous and finer dispersed two-phase steam-liquid flow which reflects on the injector's operating characteristics. In addition,.according to [9] (p.14), as the injection index (U) increases, so does the injector's coefficient of efficiency.
Fifthly, the product flow speed at the mixing chamber nozzle does not exceed the speed at which static pressure of the flow matches the saturation pressure at the input temperature of the product. Exceeding this speed would increase power consumption, causing deterioration of operating conditions and in some cases disabling the injector.
Six. The fact that the maximum speed, according to the liquid flow speed curve in the injector channel steam feeding, is observed at the output cross-sectional area of the product nozzle makes it easier to start the injector and insures its stable operation.
The first preferred option of embodiment of the suggested method involves feeding of steam to the mixing chamber at the sonic or a supersonic speed which ensures a number of advantages.
Speed gradient between the product and steam increases, thereby improving homogeneity of the product. In addition, according to Weber formula, the higher speed of steam, the finer is breaking of liquid drops in the steam flow. This also leads to forming of a more homogeneous and finer dispersed two-phase steam-liquid flow improving the injector performance and, consequently, to a decrease in sonic speed in this particular medium which, in its turn, (as will be demonstrated below) increases the intensity of shock wave. As experiments have demonstrated, the features listed above increase the stability of the injector's operation as compared with the prior art models and improve homogeneity of the product. As steam pressure at the injector input grows, so do the above parameters.
The second preferred option of embodiment of the method of the invention involves feeding of steam to the mixing chamber with temperatures equal to or lower than final product heating temperature, but remaining above input temperature of the product. The preferred temperature is calculated by the following formula: Tst = Tin + Tout - Tin 2 ,
where Tst is steam temperature at the mixing chamber inlet Tin is product temperature at the injector inlet
Tout final product heating temperature. This reduces the <<burning-in>> of the product and thermal melting of proteins, conserves vitamins and biological activity of the substance and retains natural color, smell and taste of the product Depression of Tst below Tin is not only inadvisable but hazardous as well, because due to the absence of condensation, pressure in the mixing chamber increases, thereby <<upsetting>> the injector.
The third preferred option of embodiment of the suggested method involves transmission of the two-phase steam-liquid flow formed in the mixing chamber at a speed equal or exceeding the local sonic speed and subjection of said flow to shock wave.
The above features allow to create a more homogeneous and finer dispersed two-phase steam-liquid flow characterized by reduced local sonic speed (a). On the other hand, an increase in speed of the product flow at entry to the mixing chamber increases proportionally an absolute value of the two-phase steam-liquid flow speed. As a result, the Mach number M = W a ,
i.e. ratio of the absolute flow speed (W) to the local sonic speed (a), increases. The shock wave intensity is in direct proportion to the square of the Mach number (See).
Another factor having impact on the shock wave intensity is β index. β = Vst Vmix ,
where Vst is volume of steam in the two-phase mixture and Vmix is volume of the two-phase mixture equal to a sum of volumes of steam and liquid contained in the mixture.
As indicated above, it is possible to regulate the intensity and degree of condensation of steam in the mixing chamber at the expense of the product flow speed. This provides another tool for regulating intensity of the shock wave through the β index over a wide range of injection indexes.
The fourth preferred option of embodiment of the suggested method involves forming at the injector outlet of regulated backpressure, thereby enabling regulation of intensity of the shock wave and its location in the channel of the injector. This feature in combination with the above method of β index regulation and with injection index held constant, provides for a new property giving an additional tool for regulating intensity of the shock wave.
The fifth preferred option of embodiment of the suggested method involves a partial heat and/or mass abstraction from the supersonic steam-liquid flow, allowing to increase speed and kinetic energy of the two-phase steam-liquid flow. This feature, in combination with those listed above, further improves operating characteristic of the injector and allows to regulate intensity of the shock wave.
The sixth preferred option of embodiment of the suggested method involves feeding the product to the mixing chamber in the form of a thin sheet with thickness within 0.15-2.5 mm. The thinner the product sheet contacting with steam in the mixing chamber, the better heat- and mass interchange between the product and steam.
This also improves turbulization of the flow and increases probability of the full contact between the product mass and steam and of shift flows between them. However, reducing the product sheet thickness below 0.15 mm would require an unjustified increase in product pressure at entry to the injector. In such cases the product is usually fed to the mixing chamber in <<cavitation condition>>, which is unacceptable. On the other hand, as experiments have demonstrated, increasing the product sheet thickness beyond 2.5 mm, leads to the loss of good properties provided by the present invention. Actual dimensions of the product sheet are determined on the basis of input and output parameters of the product (viscosity, flow rate, and temperature, on the one hand, and targeted dispersion and homogeneity levels, on the other hand).
The seventh preferred option of embodiment of the method of the invention (See FIG. 1) involves feeding steam to the mixing chamber only on one side of the product sheet, whereas the other side of the sheet is in contact with the wall of the injector channel. This option would be appropriate for low viscosity products on low capacity injectors with low injection index. It is distinguished by its mechanical simplicity.
The eighth preferred option of embodiment of the method of the invention (See FIG. 2) involves feeding steam to the mixing chamber on both sides of the product sheet. This option would be appropriate for high viscosity products on high capacity injectors. In such cases, contact area between the product and steam is at least twice as large, which eliminates slowing down of the product as a result of dragging against the walls in the forward part of the mixing chamber channel.
The ninth preferred option of embodiment of the suggested method (See FIG. 3) involves feeding the product through product nozzle placed along the injector axis, whereas steam is fed through a annular steam nozzle placed concentrically to the product nozzle. This design allows to process liquid products having solid particles (solid phase) dispersed in them (e.g. soups, pulps, salsa sauce, etc.) This version allows to homogenize liquid phase while providing the maximum preservation of the solid phase and heating of the whole product.
FIG. 1 schematically represents an axial section of the injector for embodiment of the seventh preferred option of the method of the invention.
FIG. 2 schematically represents an axial section of the injector for embodiment of the eighth preferred option of the method of the invention.
FIG. 3 schematically represents an axial section of the injector for embodiment of the ninth preferred option of the method of the invention.
FIG. 4 schematically represents a speed curve along the injector channel before steam feeding.
Injector represented in FIG. 1 comprises body 1 enclosing steam nozzle 2 , mixing chamber 3 , comprising, as a rule, input snout (convergent tube) ( 4 ), cylindrical part 5 and diffuser 6 . The product is fed to the injector through nipple 7 . The product is fed to mixing chamber 3 through product nozzle 8 formed by the external wall of steam nozzle 2 and the internal wall of mixing chamber 3 . Nozzle 2 represented in FIG. 1, is a supersonic steam nozzle which is used in most of the preferred options of embodiment of the method of the invention listed above. However, in the general case a subsonic steam nozzle may also be used.
At the output of the injector, a tap 9 is placed for regulating the intensity and location of shock wave in the mixing chamber. The thickness of the product sheet fed to mixing chamber 3 is determined by critical section area of nozzle 8 which is regulated by adjusting nut 10 and/or spacer 11 .
Injector represented in FIG. 2 comprises body 15 enclosing internal steam nozzle 16 , shaped separating cartridge 17 , mixing chamber 18 comprising, as a rule, input snout (convergent tube) 19 , cylindrical part 20 and diffuser 21 . The product is fed to the injector through nipple 22 . The product is fed to the mixing chamber 18 through product nozzle 23 formed by the external wall of nozzle 16 and the internal wall of separating cartridge 17 . This version of the injector includes external (regarding the product sheet) steam nozzle 24 , formed by the external wall of cartridge 17 and the internal wall of mixing chamber 18 . Steam to external steam nozzle 24 is fed through nipple 25 . In device represented in FIG. 2 both steam nozzles, 16 and 24 , are supersonic which is not obligatory in the general case.
At the output of the injector, tap 26 is placed for regulating the intensity and location of shock wave in mixing chamber 18 . The thickness of the product sheet fed to mixing chamber 18 is determined by critical section area of nozzle 23 which is regulated by adjusting nut 27 and/or spacer 28 . This version of the injector allows to regulate critical section area of external steam nozzle 24 by adjusting nut 29 and/or spacer 30 .
Injector represented in FIG. 3 comprises body 33 enclosing product nozzle 34 , mixing chamber 35 comprising as a rule, input snout (convergent tube) 36 , cylindrical part 37 and diffuser 38 . Steam is fed to the injector through nipple 39 , then to mixing chamber 35 through steam nozzle 40 . Steam nozzle 40 is formed by the external wall of nozzle 34 and the internal wall of separating cartridge 17 . This version of the injector includes external (regarding the product sheet) steam nozzle 24 , formed by the external wall of cartridge 17 and an internal wall of mixing chamber 18 . Steam to external steam nozzle 24 is fed through nipple 25 . In device represented in FIG. 2 both steam nozzles, 16 and 24 , are supersonic which is not obligatory in the general case. Critical section area of nozzle 8 may be regulated by adjusting nut 41 and/or spacer 42 . At the output of the injector, tap 43 is placed for regulating the intensity and location of shock wave in mixing chamber 35 .
FIG. 4 represents the product speed curve W at different characteristic parts of the injector channel before steam feeding. This curve is practically identical for all three embodiments listed above (FIG. 1 - 3 ). Therefore, it relates to all three of them simultaneously. Characteristic sections are marked with Roman numerals as follows:
I. input section of the product nozzle;
II. output (critical) section of the product nozzle, which coincides with section of product entry into the mixing chamber;
III. output section of the input snout part of the mixing chamber which coincides with the head of its cylindrical part;
IV. output section of the cylindrical part of the mixing chamber which coincides with its diffuser part;
V. output section of the diffuser part of the mixing chamber which coincides with the head of the product output conduit.
Injector represented in FIG. 1 operates as follows:
Product is fed through nipple 7 and product nozzle 8 to mixing chamber 3 of the injector. Speed of the product flow at section 11 (See FIG. 4) is determined according to targeted quality parameters of the product (homogeneity, dispersion rate, sterility, etc.) and to its input parameters (temperature, viscosity, flow rate, etc.).
By means of adjusting nut 10 and/spacer 11 , the appropriate size of the product nozzle critical section is set which determines the thickness of product sheet to be fed to mixing chamber 3 . According to the present invention, maximum speed of the product flow and, correspondingly, minimum static pressure before steam feeding occur at output section of product nozzle 8 . Therefore, the injector becomes <<(compensated)>> up to creation of vacuum in steam nozzle 2 . This makes starting up easier and allows to make the process automatic. Steam is fed to the injector through nozzle 2 . The above mode of operation insures stable performance of the injector, even when working with recuperated steam at pressure equal to -0.4 Bar (relative vacuum). Steam is mixed with product, thereby forming a two-phase steam-liquid mixture. Speed and level of steam condensation in the product depends not on only on temperature difference but on condensation conditions as well (turbulization of the flow, heat-exchange surface, dimension of condensation, etc.). The invention, depending on a stated aim, allows to achieve two diametrically opposed effects. On the one hand, by means of increase in speed and reduction of thickness of the product sheet at the mixing chamber input, increase in heat-exchange surface and turbulization of the flow is achieved leading to intensification of mixing and heat-and-mass exchange between steam and the product.
This allows to increase the injector capacity and amount of product heating and extend the injection index range on he minimum side. On the other hand, when the flow speed is such that the product fed to the mixing chamber is on the verge of boiling, the speed and intensity of heat exchange decrease and incoming steam is used for producing a finely dispersed homogeneous two-phase steam-liquid mixture as described in more detail above. This makes it possible, even at a high injection index (U=100 and above), to form a supersonic two-phase steam-liquid flow with a subsequent shock wave, which, as is well known, allows to improve the quality of the product. Intensity and location of the shock wave in the injector channel is regulated by tap 9 placed at the output flow conduit. According to theory, the Mach number, as indicated above, is M = W a
According to the method of the invention, speed W of the two-phase steam-liquid mixture increases whereas sonic speed α in this medium drops. This allows to regulate the intensity of the shock wave (which varies as the square of Mach number) in a wider range, as compared to the prior art methods. The speed of the two-phase steam-liquid mixture increases as kinetic energy of the steam flow. Injector represented in FIG. 2 operates in much the same way as injector according to FIG. 1 . The main distinction is the external steam nozzle 24 with regulated critical section area which makes it possible to regulate the rate of the steam flow through the nozzle. Due to this feature, contact area between the product and steam is at least doubled, thereby eliminating slowing down of the product caused by dragging against the walls in the forward part of the mixing chamber channel 18 . This feature is of particular interest in case of processing high viscosity products and in high capacity injectors.
Injector represented in FIG. 2 operates in the following manner: the product is fed to mixing chamber 35 through product nozzle 34 while steam is fed through a steam nozzle placed concentrically to product nozzle 40 . This design allows to process liquid products having solid particles (solid phase) dispersed in them. Homogenizing involves mainly liquid phase, thereby providing maximum preservation of the solid phase while heating the whole product.
Injector designs represented in FIGS. 1-3 are examples rather than only possible versions of embodiment of the suggested method.
Although only preferred embodiments are specifically illustrated and described herein, it will be appreciated that many modifications and variations of the present invention are possible in light of the above teachings and within the purview of the appended claims without department from the spirit and intended scope of the invention.
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A method of heating and/or homogenizing of various liquid food products by means of a steam-liquid injector ( 1 ) is disclosed. The method complies feeding of steam and a liquid product into a mixing chamber ( 3 ) through corresponding nozzles ( 2, 4 ) and then accelerating the flow of the product to a maximum speed depending on particular processing operating parameters. The acceleration is carried out without exceeding the speed at which the static pressure of the flow matches the saturation pressure of the product at the input temperature. The steam and liquid product are mixed within the mixing chamber ( 3 ) and then compressed to obtain condensation of steam within the product.
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TECHNOLOGICAL FIELD
[0001] The present disclosure is directed to a sleeve configured for use in a non-contacting gas seal and toward a gas seal including the sleeve, and, more specifically, toward a sleeve configured for use in a non-contacting gas seal that includes a bore configured to carry gas from a high pressure side of the sleeve to a radially outer side of the sleeve and to a gas seal including the sleeve.
BACKGROUND
[0002] Various devices are known for forming a seal between a sleeve fixedly mounted on a rotatable shaft and a housing or other structure surrounding the shaft. One type of seal, sometimes referred to as a non-contact circumferential shaft seal, or non-contact gas seal, is effective in controlling leakage. Such seals include one or more seal rings with circumferential inner faces that are spaced a small distance away from the sleeve. Such seals may be formed from compacted and sintered carbon graphite to provide heat and wear resistance, and they are often formed as a plurality of inter-connectable ring segments to facilitate installation around the sleeve. The seal rings are held in place by a suitable retaining device and may include a biasing device, such as a circumferential or garter spring, for holding the seal segments together.
[0003] It is desirable to make the gap between the sleeve and seal ring as small as practicable while substantially preventing the sleeve from contacting the seal ring. To this end, it is known to provide cutouts or pads on the radially inner face of the seal ring in order to generate lift relative to the sleeve and maintain a cushion of gas that helps keep the seal ring away from the sleeve. Various arrangements are also known for routing gas around the outer walls of the seal ring to keep the seal ring in a particular axial location and to maintain a radial spacing from the sleeve.
SUMMARY
[0004] The present disclosure provides an improved gas seal and arrangement for maintaining a radial spacing between a seal ring and a sleeve mounted on a rotatable shaft inside the sleeve. To this end, a first aspect of the disclosure comprises a sleeve mountable on a rotatable shaft that is configured to form a non-contacting seal with a seal ring surrounding and radially spaced from the sleeve. The sleeve includes a radially inner surface configured to be mounted on the rotatable shaft, a radially outer surface, an axially inner surface between the radially inner surface and the radially outer surface, and an axially outer surface between the radially inner surface and the radially outer surface. The sleeve also includes a bore configured to provide fluid communication between gas at the axially inner surface of the sleeve and the radially outer surface of the sleeve.
[0005] Another aspect of the disclosure comprises a non-contacting gas seal that includes the sleeve described above, and a seal ring having a radially inner side extending around the radially outer surface of the sleeve, a radially outer side, an axially inner side and an axially outer side.
[0006] A further aspect of the disclosure comprises a sleeve mountable on a rotatable shaft and configured to form a non-contacting seal with a seal ring radially spaced from the sleeve. The sleeve includes a radially inner surface configured to be mounted on the rotatable shaft, a radially outer surface, an axially inner surface between the radially inner surface and the radially outer surface, and an axially outer surface between the radially inner surface and the radially outer surface. The sleeve also includes pressure generating means for increasing a pressure between the sleeve and the seal ring radially spaced from the sleeve.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] These and other aspects and features of the present disclosure will be better understood after a reading of the following detailed description together with the attached drawings.
[0008] FIG. 1 is an exploded perspective view of a seal that includes a sleeve mountable on a rotatable shaft and a seal ring that surrounds the sleeve.
[0009] FIG. 2 is a perspective view of the seal ring of FIG. 1 .
[0010] FIG. 3 is a perspective view of the sleeve of FIG. 1 .
[0011] FIG. 4 is a partial sectional view of the sleeve of FIG. 3 taken along line IV-IV in FIG. 3 .
[0012] FIG. 5 is side elevational view of the sleeve of FIG. 1 .
[0013] FIG. 6 is a top plan view of the sleeve of FIG. 1 .
DETAILED DESCRIPTION
[0014] Referring now to the drawings, wherein the showings are for the purpose of illustrating presently preferred embodiments of the disclosure only and not for limiting same, FIG. 1 shows a non-contact gas seal 10 comprising a sleeve 12 and a seal ring 14 . The sleeve 12 is configured to be mounted on a rotatable shaft (not illustrated), and the sleeve 12 includes a radially inner surface 16 , a radially outer surface 18 , an axially inner surface 20 and an axially outer surface 22 . The terms “inner” and “outer” are used herein with reference to the high pressure space that is to be sealed by the gas seal 10 ; the “inner” side of the gas seal 10 is the high pressure side of the gas seal, the inside of a compressor, for example, and the outer side of the gas seal 10 is a housing of the compressor or the environment around the device in which the gas seal 10 is installed. These terms are used for ease of reference, and the “inner” side of the seal is the side intended to face a higher pressure environment even if in some cases that high pressure environment might not be described as being “inside” something else.
[0015] The axially inner surface 20 includes a plurality of recesses 24 that extend into the axially inner surface 20 from the radially outer surface 18 . Each of these recesses includes a bottom 26 which faces in a generally axial direction and may or may not be parallel to the axially inner surface 20 , and a side wall 28 that extends from the bottom 26 to the axially inner surface 20 . The side wall 28 has a first portion 30 that is linear and a second portion 32 that is curved, and the side wall 28 meets the bottom 26 at a junction 34 . The shape of the side wall 28 is configured to increase a pressure in the recess 24 when the sleeve 12 rotates. Therefore, other recess shapes could be used without exceeding the scope of the present disclosure.
[0016] The radially outer surface 18 of the sleeve 12 includes a circumferential groove 36 that extends completely around the sleeve 12 . The groove may be discontinuous in other embodiments. A bore 38 extends from the bottom 26 of each of the recesses 24 to a location on the radially outer surface 18 of the sleeve 12 . In the present embodiment, the second end of the bore 38 is located in the groove 36 . Moreover, as will be appreciated from FIGS. 4 and 6 , the bore 38 preferably tapers in the direction from the axially inner surface 20 to the radially outer surface 18 . While a tapered bore 38 is presently preferred, it may be possible to use a constant-diameter bore in other embodiments. The bore 38 has a first end 40 near the junction 34 of the recess bottom 26 and the second, curved portion 32 of the recess side wall 28 and a second end 42 in the groove 36 . The second end 42 of the bore 38 is offset from the first end 40 of the bore in axial, radial and circumferential directions, and the bore 38 thus extends at an angle to the axis of rotation of the sleeve (i.e., it is not parallel or perpendicular to the axis of rotation). In some embodiments, the groove 36 and/or the recesses 24 may be omitted such that the bore 38 will extend from the axially inner surface 20 to the radially outer surface 18 . Also, as used herein, the bottoms 26 of the recesses 24 may also be considered to be part of the axially inner surface 20 .
[0017] Turning now to the seal ring 14 illustrated in FIGS. 1 and 2 , the seal ring 14 includes a radially inner side 46 , a radially outer side 48 , an axially inner side 50 and an axially outer side 52 . The seal ring 14 itself is formed from three (or more) separate seal ring segments 14 a, 14 b and 14 c which segments allow for the radially installation of the seal ring 14 in a housing (not illustrated) or around the sleeve 12 . The radially inner side 46 and the axially outer side 52 also include cutouts 54 that contribute to hydrostatic and/or hydrodynamic balancing of the seal ring 14 relative to the sleeve 12 . A bore 56 extends from the radially inner side 46 of the seal ring 14 to the axially outer side 52 of the seal ring 14 . A first end 58 of the bore 56 is located between a pair of adjacent cutouts 54 in the radially inner side 46 of the seal ring 14 and a second end 60 of the bore 56 is located in or between a pair of the cutouts 54 in the axially outer side 52 . The bore 56 is generally axially centered on radially inner side 46 and radially centered on the axially outer side 52 and may be straight or curved but, for ease of manufacture, may also comprise a first radial portion leading away from the first end 58 and a second axial portion leading away from the axially outer side 52 which first and second portions meet at a right angle inside the seal ring.
[0018] The operation of the gas seal 10 is now described. The sleeve 12 is installed on a rotatable shaft (not illustrated) and the seal ring 14 is installed in a housing (not illustrated) around the sleeve 12 so that a very small space (on the order of 2 to 8 micrometers) exists between the sleeve 12 and the seal ring 14 . Pressure is increased on the side of the gas seal 10 where the axially inner surface 20 of the sleeve 12 and the axially inner side 50 of the seal ring 14 are located, and even if the sleeve 12 is not rotating relative to the seal ring 14 , gas escapes through the gap between the sleeve 12 and the seal ring 14 and also through the bore 38 . When the shaft and sleeve 12 begin to rotate, the rotation of the sleeve 12 in combination with the angle made by the bore 38 relative to the axis of rotation, forces high pressure gas into the bore 38 . The taper of the bore 38 increases the pressure of the gas in the bore 38 , and a relatively high pressure jet of gas exits the second end 42 of the bore 38 between the radially outer surface 18 of the sleeve and the radially inner side 46 of the seal ring 14 . When the groove 36 is present, the groove 36 may help to distribute the gas around the circumference of the sleeve 12 and/or equalize the radially outward pressure produced by the plurality of bore second ends 42 in the groove 36 . This outward flow of high pressure gas helps form a buffer between the sleeve 12 and the seal ring 14 and helps to maintain the position of the seal ring 14 relative to the sleeve 12 .
[0019] The second ends 42 of the bores 38 in the axially outer surface 22 of the sleeve 12 are axially aligned with the first ends 58 of the bores 56 in the axially inner side 50 of the seal ring 14 , and thus some of the gas exiting the second ends 42 of the bores 38 will enter the first ends 58 of the bores 56 and exit the second ends 60 of the bores 56 in the axially outer side 52 of the seal ring 14 . The bores 56 in the seal ring 14 generally have a larger diameter than the diameter of the bore 38 in the sleeve 12 .
[0020] The diameter of the bore 38 in the sleeve and the amount of its taper and the angle that the bore 38 makes relative to the axis of rotation of the sleeve 12 can be adjusted based on the application in which the gas seal 10 is being used, i.e., based on the pressure difference expected between the high and low pressure sides of the gas seal 10 and on the speed at which the sleeve 12 is expected to rotate relative to the seal ring or gas being compressed. Likewise, the gap between the sleeve 12 and the seal ring 14 and the depth and width of the groove 38 and the diameter of the bore 56 in the seal ring 14 can be selected based on the particular application.
[0021] The present invention has been described herein in terms of a presently preferred embodiment. However, modifications and additions to this embodiment will become apparent to persons of ordinary skill in the art upon a reading of the foregoing disclosure. It is intended that all such modification sand additions form a part of the present invention to the extent they fall within the scope of the several claims appended hereto.
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A sleeve mountable on a rotatable shaft and configured to form a non-contacting seal with a seal ring surrounding and radially spaced from the sleeve, the sleeve including a radially inner surface configured to be mounted on the rotatable shaft, a radially outer surface, an axially inner surface between the radially inner surface and the radially outer surface, an axially outer surface between the radially inner surface and the radially outer surface and a bore configured to provide fluid communication between gas at the axially inner surface of the sleeve and the radially outer surface of the sleeve.
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BACKGROUND AND SUMMARY OF THE INVENTION
The invention relates to a flow regulator for maintaining a stable rate of flow of a fluid in a flow channel, comprising a flow-actuated element which is movable under the influence of a pressure drop in the fluid flow, and a throttle valve for regulating the fluid flow under the influence of said element.
A typical field of use for such a regulator is in connection with hydraulic pumps for unloading cargo tanks for oil or the like on e.g. a tanker, wherein the pumps are connected to and driven from a ring conduit transporting hydraulic liquid under a very high pressure, more specifically about 300 bars (30 000 kPa). Such applications utilize pumps of very large power, on the order of megawatts. In front of each pump a flow regulator is used for ensuring a stable liquid supply for the operation of the pumps in order to prevent them from "running riot" when they are about to empty the reservoir and start sucking air. Such a situation with overspeed of the pump will result in damage thereof in the course of a very short time.
Different types of regulators have been developed for this purpose. Such regulators operate to restrict or throttle the supply of hydraulic liquid as soon as changes occur in the operating conditions which may have a tendency to increase the liquid supply in the flow channel to the pump motor. The known types of flow regulators are, however, encumbered with problems in that they are complicated and in that they absorb a considerable amount of energy under normal operating conditions (i.e. with a little throttling of the liquid flow). This is a consequence of the fact that a considerable pressure drop has to be established across these known regulators in order to produce the forces used for stabilizing the through-put. With a conduit pressure of about 300 bars, it may for example be the question of a pressure drop of about 10 bars for each regulator. This in reality involves an energy loss of the order of 30 kW, which results in a substantial heating of the oil; something which in turn requires artificial cooling. It is obvious that this is economically unfavorable and also renders as the system structure more complicated.
Thus, it is an object of the invention to provide a flow regulator which is able to operate with a substantially reduced pressure drop in the flow channel in relation to the known regulators.
A further object is to provide such a flow regulator giving a more sensitive regulation with a short response time and a smoother response than what is achieved with the regulators according to the prior art.
The above-mentioned objects are achieved with a flow regulator of the introductorily stated type which, according to the invention, is characterized in that the flow-actuated element constitutes a control element for a servo means comprising a pilot valve for controlling the movement of a drive means coupled to a valve body in the throttle valve, and which, by means of the servo means, is arranged to be moved in a smooth manner independently of sudden changes in the fluid flow, the control element being arranged to be moved in the flow direction only when the rate of flow exceeds a preselected level.
In the flow regulator according to the invention, the flow-actuated element operates as a control element in a servo control of the throttle valve. By means of this technique there is achieved an efficient stabilization of the fluid flow with a very moderate pressure drop across the regulator. It is estimated that the pressure drop may be reduced to approximately 1 bar; i.e. to 1/10 of the pressure drop required in the regulators according to the prior art. The servo control absorbs some energy, but this is quite inconsequential compared to the energy lost in the existing solutions.
The flow regulator according to the invention distinguishes itself in that it has a small energy demand under normal operating conditions, and in that it maintains a stable flow level even if sudden changes in the operating conditions occur. By, inter alia, designing the throttle valve such that an efficient balancing of the pressure influencing the valve body in the throttle valve is obtained, the flow control functions well with a very moderate use of servo. Thus, by means of the utilized technique, a very "smooth" and precise flow regulation has been achieved, even with a fluid pressure of up to 300 bars.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be further described below in connection with an exemplary embodiment with reference to the drawings, wherein
FIG. 1 shows a longitudinally sectioned view of a flow regulator according to the invention; and
FIGS. 2 and 3 show enlarged sectional views of the servo means with the pilot valve in FIG. 1 in two different operational positions.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In the following, the flow regulator according to the invention will be described in connection with the regulation of a liquid flow, but it is emphasized that the solution is suitable for any fluid.
As appears from FIG. 1, the shown embodiment of the flow regulator comprises a body 1 containing a flow channel 2 and in which the regulator elements are built in as shown next to the flow channel. In the flow channel 2, there is provided a pressure-drop producing means in the form of an orifice 3 for the generation of a flow-dependent force for actuating or influencing the flow-actuated element of the regulator. In the illustrated embodiment, this element is a piston 4 which is movable in a cylindrical cavity which is divided by the piston into a first chamber 5 and a second chamber 6. The first chamber 5 is connected to the channel 2 through a port 7 upstream of the orifice 3, and the second chamber 6 is connected to the channel 2 through a port 8 downstream of the orifice 3. Thus, the pressure in the chamber 6 is reduced in relation to the pressure in the chamber 5 with a value corresponding to the pressure drop which is generated across the orifice 3 and which in turn is dependent on the rate of flow (the flow level) in the channel 2. Thus, the piston 4 is influenced by a force seeking to move the piston in the flow direction. However, the piston 4 is also influenced by a suitably prestressed spring 9 counteracting the first-mentioned force on the piston 4, so that the liquid flow has to exceed a certain level before the piston 4 is moved in the flow direction. The arrangement in connection with the spring 9 will be further described later.
The regulator comprises a throttle valve 10 for regulating the liquid flow in the channel 2 under the influence of the piston 4, the piston constituting a control element for a servo means 11 for controlling movement of a drive means 12 for operating the throttle valve.
As shown in FIG. 1, the drive means 12 is arranged in the second chamber 6 and comprises a piston housing 13 which is fixedly mounted in the body 1, and a drive piston 14 which, together with the piston housing, defines a third chamber 15 on the side of the piston 14 facing away from the throttle valve 10. The piston housing 13 is formed from a cup-shaped body which is outwardly open on the side of the drive piston 14 facing the throttle valve 10, so that the piston at this side is influenced by the pressure in the second chamber 6. On its opposite side the piston 14 is influenced by the force from a suitably prestressed drive spring 16 and by the pressure from liquid which has been supplied to the third chamber 15 by means of the pilot valve 17 of the servo means 11. The piston 14 is fixedly connected through a piston rod 18 to a valve body 19 in the throttle valve 10.
The pilot valve 17 of the servo means 11 comprises a center shaft 20 arranged on the control element piston 4 and consisting of a pair of members 21, 22 extending at opposite sides of the piston, and a guiding sleeve 23 arranged for the center shaft 20 which is connected to the drive piston 14 and extends outside of the third chamber 15 towards the piston 4. The center shaft 20 on its surface is provided with a number of longitudinally extending channels 24 which, at one end, communicate with the second chamber 6 through first ports 25 through the wall of the guiding sleeve 23, and which, at their other end, can be brought into communication with the third chamber 15 through second ports 26 in the wall of the guiding sleeve. Further, the center shaft 20 comprises a transverse passage 27 which can be brought into communication with the second ports 26 of the guiding sleeve 23 when these are shut off from the channels 24, and which communicates with a passage 28 extending through the center shaft 20 in the longitudinal direction thereof and communicates with an outlet 29 for the escape of liquid from the third chamber 15. This outlet may open into the external ambient pressure of 1 atmosphere.
The longitudinal passage 28 of the center shaft 20 extends as shown throughout the center shaft and opens at opposite ends thereof, so that it is pressure-balanced in the axial direction.
The control function of the pilot valve consists in that it controls liquid to or from the third chamber 15 in such a manner that the drive piston 14 at any time is forced to follow the movement of the control element piston 4 and therewith the movement of the center shaft 20. As will be understood, the drive piston 14 is moved in one or the other direction when the resulting force from the drive spring 16 and the liquid pressure in the third chamber 15 exceeds or becomes less than the force influence on the piston because of the pressure in the second chamber 6.
By the servo means one achieves that the drive piston 14 is moved in a smooth manner even if a sudden pressure change occurs in the liquid flow in the channel 2, consequently a sudden movement of the flow-actuated piston 4 will result in movement of the drive piston 14 only when the chamber 15 is filled or emptied sufficiently for achieving the necessary differential pressure across the piston 14.
The operating principle of the pilot valve is further in FIGS. 2 and 3 wherein the shown arrows indicate the liquid flow in the servo mechanism. FIG. 2 shows the liquid flow when the piston 4 and the center shaft 20 are moved downwards and the chamber 15 is filled with liquid so that the drive piston 14 is moved correspondingly downwards, and FIG. 3 shows the liquid flow when the piston 4 is moved upwards and the chamber 15 is emptied of liquid so that the drive piston 14 is moved correspondingly upwards.
As shown in FIG. 1, the upper part 22 of the center shaft 20 at the outlet 29 is introduced into a cavity 30 in a closing body 31 which in a manner not further shown, is adjustable in the longitudinal direction of the center shaft in the body 1. The cavity 30 has an outlet opening 32 which is directed towards the piston 4 and is defined by a collar 33 which is arranged to cooperate with an annular seat 34 around the center shaft. The outlet 29 thereby may be closed in connection with shutting-off of the throttle valve 10, as described below.
The above-mentioned prestressing spring 9 for preadjustment of the flow level through the regulator is, as shown, restrained between the outlet end of the closing body 31 and a support member 35 at the end of the center shaft 20, so that the prestressing force of the spring 9 is reduced by movement of the closing body 31 in the direction towards the seat 34.
The throttle valve 10 of the regulator comprises a housing 36 having a cylindrical cavity 37 wherein the valve body 19 is slidably arranged in a sealing manner. In the shown embodiment, a sealing ring 38 is arranged between the valve body 19 and the adjacent housing wall. However, this sealing ring may be omitted with an accurate adaptation and polishing of the sliding surfaces. The cavity 37 merges into the outlet opening 39 of the regulator, the downstream end of the cavity communicating with the flow channel 2 through a number of radial ports 40 symmetrically arranged in the peripheral wall of the housing 36, and through an annular space 41 arranged in the body 1 around the housing 36.
As shown, the valve body 19 is provided with through-going axial channels 42 for equalizing the pressure difference between the end surfaces of the valve body. By the axial movement of the valve body there is obtained a stepless and not very force-demanding change of the effective flow cross-section through the radially arranged ports 40. When the flow regulator is completely closed, the lower edge of the valve body 19 is pressed against a seat 43 in the valve housing 36. This seat is disposed at a certain distance from the ports 40 for minimizing pressure effects when the valve body 19 causes a considerable throttling of the liquid flow.
The through-put of the regulator may be adjusted to a desired level by establishing a given prestressing of the spring 9. The prestressing of the spring is dependent on the position of the closing body 31 which in this context may also be designated "control cylinder". This may be positioned by manual or pneumatic control according to known technique. In FIG. 1, the control cylinder is raised to its uppermost position whereby the regulator is adjusted to maximum through-put. Further, it may be assumed that the liquid flow through the system corresponds to the set level. The force trying to press the piston 4 downwards, then is equal to and oppositely directed in relation to the tension of the spring. In this situation the throttle valve body 19 is maintained in a position allowing full through-put or through-flow via the ports 40 of the throttle valve 10.
If the external conditions change and the liquid flow starts increasing, the piston 4 immediately will be pressed downwards and quickly see to it that the throttle valve 10 enters into operation and thereby maintains the flow level. An important property of the illustrated embodiment is that the piston 4 is not influenced by forces which may create instability in the liquid regulation. Thus, importance is attached to balancing undesired pressure effects on the center shaft. All ports therefore are symmetrically placed and, as mentioned, the through passage of the center shaft provides for eliminating undesired axial forces.
When the control cylinder 31 is positioned in its lowermost position, the collar 33 rests sealingly against the seat 34, so that the outlet 29 is closed. In this situation liquid can not be discharged from the chamber 15, and this is filled gradually with liquid until the spring 16 has pressed the throttle valve body 19 downwards against the seat 43, so that the throttle valve is closed.
In the illustrated embodiment, the valve body 19 is disposed at the inside of the ports 40 in the valve housing 36. In an alternative embodiment (not shown) the valve body may be disposed at the outside of the ports, but this would entail an undesired dimensional increase of the movable parts. It is also conceivable to place the flow-actuated piston 4 in the liquid flow in the flow channel, and thereby avoid the special pressure-drop generating means 3. It has been found, however, that this gives a somewhat poorer stability.
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A flow regulator for maintaining a stable rate of flow of a fluid in a flow channel (2), comprising a flow-actuating element (4) which is movable under the influence of a pressure drop in the fluid flow, and a throttle valve (10) for regulating the fluid flow under the influence of said element (4). The fluid-actuated element (4) constitutes a control element for a servo means (11) comprising a pilot valve (17) for controlling the movement of a drive means (12) coupled to a valve body (19) in the throttle valve (10), and which, by means of the servo means (11), is arranged to be moved in a smooth manner independently of sudden changes in the fluid flow. The control element is influenced by a prestressed spring (9) acting in the opposite direction to the flow direction, so that the control element (4) is moved in the flow direction only when the rate of flow exceeds a preselected level.
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FIELD OF THE INVENTION
This invention relates to a system for cleaning or sanitizing industrial filling equipment. The system has a movable arm spray manifold means coupled with at least one stationary arm spray manifold means.
BACKGROUND OF THE INVENTION
Industrial equipment for filling containers such as bottles or cans in beverage or brewery plants contain a difficult to clean filling area. Generally a filling valve is positioned above the container to empty contents from a rotating filling source. After filling, the container moves from the filling station towards a crowning or capper area and the next container to be filled is positioned under the filler valve to receive the contents from the machine. Over time, the filling station may become soiled with the filling contents and potentially broken glass or metal filings may also accumulate in the filling area.
In the past, a stationary arm spray manifold attached to a vertical stanchion was used to spray detergent or sanitizing agents onto the filling station to clean or sanitize it. The problem with the stationary arm spray manifolds is that the direction of detergent or sanitizing spray could not be easily changed to clean the interior portion of the filling valve directly above the containers to be filled. Since cleaning the reverse side of the valve is virtually impossible, to clean this portion, historically, the production line was stopped and the area was manually cleaned.
The present invention addresses the problem of cleaning the entire filling station automatically. In particular, detergent or sanitizing spray is directed to all points of the filling station without the need to manually clean beneath or behind the filling valve of the station.
It is thus an object of the present invention to provide a cleaning apparatus for cleaning or sanitizing the filling station, in particular, the filling valve of the filling station of an industrial filling machine. The apparatus has a movable arm spray manifold which may be mounted or coupled with a housing and is used to position the spray arm below the filling valve to direct a cleaning or sanitizing spray upward toward an interior area and reverse side of the filling valve. The movable manifold is then used to move the spray arm away from the filling station so that the filling production can resume with little interruption.
In a preferred embodiment, the apparatus is coupled with at least one stationary arm spray manifold to form a cleaning or sanitizing system which directs a sanitizing or cleaning spray onto both exterior and interior portions of the filling station.
A method for using the apparatus alone or in the cleaning system is also described.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is schematic top plan of a beverage filling production line including the movable apparatus of the invention.
FIG. 2 is an overview of the system of the invention including the movable arm spray apparatus coupled with two stationary spray arm manifolds.
FIG. 3 is a cross sectional view of the filling station and cleaning system of FIG. 1.
FIG. 4 is a cross sectional view of the mounting clamp shown in FIG. 2.
FIG. 5 is a cross sectional view of the system shown in FIG. 2.
FIG. 6 is a side elevation view of the spray arms of the system.
FIG. 7 is a top view of the movable spray arm manifold of the invention in two possible positions.
FIG. 8 is a side elevational view of the movable arm including a water coupling
FIG. 9 is a top view of the movable spray arm indicating a second means of extending the arm.
FIG. 10 is a front view of the v-bolt of FIGS. 8-9.
FIG. 11 is a side elevational view illustrating a slide means for extending the movable arm.
FIG. 12 is a top view of the spray arm manifold.
FIG. 13 is a side view of the spray arm manifold.
FIG. 14 is a cross sectional view of the stanchion base.
FIG. 15 is a side view of the stanchion base.
FIG. 16 is a top view of the slide member illustrated in FIG. 9.
FIG. 17 is a side view of the slide member of the movable spray arm.
FIG. 18 is a front view of the movable spray arm.
FIG. 19 is a side view of the movable spray arm having both lateral and top positioned nozzles.
FIG. 20 is a side view of the movable spray arm of FIG. 19.
FIG. 21 is a front view of the movable spray arm of FIG. 20.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The present invention pertains to a cleaning apparatus and system for cleaning or sanitizing industrial filling equipment.
Filling equipment used in industrial or institutional settings fill containers with liquid or semi-liquid materials. In particular, such equipment is generally found in beverage or brewery plants. A conventional filling equipment 10 used in a beverage or brewery plant is schematically illustrated in FIG. 1.
In such a system, the containers, generally bottles or cans to be filled travel on a continuous track from an infeed station 4 around a filler or star wheel 2 and are filled with the liquid or semi-liquid material from one or more filler valves. Once filled the containers continue on the track to a discharge star 6 and then to a capper or seamer station 8 tog receive closures. The closure may be seamed in a seamer area. Once the container is sealed, the track passes out of the closure area to a capper or seamer discharge star wheel 12.
As illustrated in FIG. 3, a filler valve 3 is generally positioned above rests 7 on the track so the container can be positioned to receive its contents. As the containers travel on the continuous track, the contents to be filled may spill and overflow or the containers may break or tip. Over time, the filling station becomes soiled with the contents to be filled.
Cleaning the interior of the filler valve or valve 3 and the surrounding area has proven difficult in the prior art. To address this problem and as illustrated in FIG. 2, a movable spray arm assembly 30 is provided. The spray arm assembly 30 is mounted onto a vertical stanchion 16 preferably by means of a vertical pipe clamp 54, most preferably having a proximity sensor. A movable arm 31 of the assembly 30 contains a plurality of nozzles 24 through which detergent active or a sanitizing agent may be sprayed.
To clean the filler valve or valves 3, the movable spray arm may be positioned with the nozzles 24 directed upward toward the filler valve 3 to clean and sanitize the valve.
It should be understood that the spray arm assembly 30 may be positioned in the filling area by any conventional means known in the art. In a preferred embodiment illustrated in FIGS. 7-11 the spray arm 31 is extended by a pneumatic air assembly wherein the arm 31 is connected via a cylinder 40 and ultimately connected to the vertical stanchion via a vertical pipe clamp having a proximity sensor 54 and swing bracket 46. The sensor uses a magnetic field as a safety feature to prevent the arm 31 from swinging into a loading filler valve 3. By means of the pneumatic air assembly a swing arm 50 positions the movable spray arm 31 to place the nozzles 24 directly under the filler valve 3.
In addition to a horizontal positioning the swing arm 50 positions the movable spray arm 31 telescopically by providing a slide means 68, as illustrated in FIG. 7. The slide means 68 contains a slide groove 69 (see FIG. 11) which enables the spray arm 31 to move away or toward a vertical stanchion 16 when the pneumatic air cylinder 40 is activated. Any means of activating the pneumatic air assembly known in the art is suitable for the invention.
The vertical stanchion 16 is stabilized by a base plate 18 as particularly shown in FIGS. 14 and 15.
A coupling 26 is connected to a curved portion of the swing arm 50 as illustrated in FIGS. 8 and 11. The coupling connects to a detergent or sanitizing composition source whose proportions and pressure are controlled by any conventional means known in the art such as a programmable logic controller (PLC), housed in a control panel 60 and connected to the spray arm assembly 30 by conventional means.
Preferably, the detergent is supplied in a foam whose viscosity is determined by the ratio of water, air and detergent active combined as programmed in the control panel 60. Preferably, the detergent liquid contains from about 0.8 to about 4% detergent active and the balance being water. The detergent liquid is expanded as a foam with air at a ratio of preferably about 8 to 1 air to detergent. This optimum detergent foam provides about 20 gallons per minute of detergent active to clean the filling station.
The height of the detergent or sanitizing spray is determined by the position of the nozzles 24 relative to the filler valve or valves 3 in combination with applied pressure programmed in the control panel 60. Preferably, the foam spray is sprayed from the spray arm 31 at a pressure of about 30 to 80 lbs. per minute, preferably about 60 lbs. per minute.
Any conventional sanitizing active known in the art may be used in the invention to provide the sanitizing agent.
In another preferred embodiment of the inventive apparatus, a linear motion device 70, preferably an electrical version of the pneumatic cylinder 40 is used to position the spray arm 31 as shown in FIGS. 16-18.
In still another preferred embodiment the nozzles 24 of the spray arm 31 are located laterally along the axis of the spray arm 31 to provide a larger clearance space between the rests 7 on the track and the opening of the filler valves 3 as illustrated in FIGS. 19-20.
Another preferred embodiment of the apparatus is a robotic arm which may be used to position the nozzles as known in the art to spray the detergent or sanitizing agent on the filler valves.
It should be understood that any means known in the art to move the movable arm spray into position under the filler valve is within the scope of the invention.
A system 20 of combining the movable spray arm 31 with at least one stationary spray manifold arm 14 to provide a cleaning or sanitizing system of both the interior or exterior of the filling station is also within the scope of the invention. In a preferable embodiment as shown in FIG. 2 and 3, the movable spray arm 31 is coupled with two stationary spray arms 14 to direct detergent or sanitizing active to substantially all of the filling station areas for cleaning or sanitizing. The stationary spray arms 14 are preferably attached to the vertical stanchion 16 via a brace 36 and stanchion clamps 32 and the detergent or sanitizing agent is connected to the arms 14 via a water inlet 38. Arm nozzles 33 provide a means of spraying the agents onto the filling star 2 of the filling station. Caps 22 are preferably used to cap the arms 14 to prevent liquid spillage.
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An apparatus and a system for cleaning or sanitizing industrial filling equipment is described. The apparatus is a movable arm spray manifold which is used to position a spray manifold below a filling valve of a filling machine and a clean interior portion of the filling station. The system may couple the movable arm spray manifold with one or more stationary arm spray manifolds to provide a cleaning system for the filling station. A method of using both the apparatus and filling system of the invention is also described
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This is a division of application Ser. No. 08/606,706, filed Feb. 26, 1996, now U.S. Pat. No. 5,884,699, such prior application being incorporated by reference herein in its entirety.
BACKGROUND OF THE INVENTION
The present invention relates generally to retrievable packers for use in subterranean wellbores and, in a preferred embodiment thereof, more particularly provides a retrievable packer which may be torqued through, and which has high strength and a reduced cross-sectional area.
Retrievable packers are typically conveyed into a subterranean wellbore suspended from a service tool which is, in turn, suspended from tubing extending to the earth's surface. Such packers are generally utilized for two main purposes--to provide a releasable anchor for preventing longitudinal movement relative to the wellbore, and to provide a releasable annular seal between portions of the wellbore above and below the packer.
When the wellbore is lined with tubular protective casing, the anchor function of a packer is usually performed by hardened jaw-like gripping members known as "slips" which, contrary to their name, act to prevent slippage of the packer within the casing. The slips are typically designed to extend radially outward from the packer and, when extended, bite into the casing's inner surface. In this manner, the packer's slips permit forces to be applied to the packer without resulting in movement of the packer within the wellbore. A type of slip known as a "bidirectional" slip permits both tensile and compressive forces to be applied to the packer without producing longitudinal movement of the packer relative to the casing.
The sealing function of the packer is typically performed by multiple ring-shaped "rubbers" located in axially compressible annular recesses formed on the packer's exterior surface. When compressed, the recesses force the rubbers radially outward to seal against the inner surface of the casing. Generally, the axial compression of the recess coincides with the radially outward extension of the slips to thereby "set" the packer in the casing.
It will be appreciated from the foregoing that complex mechanical and/or hydraulic mechanisms are required to efficiently achieve the main functions of the packer. The mechanisms necessarily are located in cross-sectional areas between the inner and outer surfaces of the packer. In recent years it has become increasingly important to compress those mechanisms into smaller and smaller cross-sectional areas of packers to provide for increased flow area through the packers. For example, in some fracturing, acidizing, and gravel packing operations, and combinations thereof, it is highly desirable to utilize a packer having a large flow area therethrough, while simultaneously having the ability to seal against high pressures and resist movement due to high loads applied to the packer.
In past packer designs, as with most engineering designs, trade-offs were typically made in an effort to optimize the designs for intended uses of the packers. In general, a packer which had increased anchoring or pressure sealing capabilities would consequently have a reduced flow area. Conversely, a packer which had a large flow area would usually be restricted in its anchoring and sealing capabilities. These past packer designs are, therefore, unsuitable for use in those operations requiring large flow area, high pressure sealing, and anchoring against high loads.
Another desirable characteristic of retrievable packers is the ability to apply torque through the packer while running in or out of the wellbore. Such torque may be used to enable the packer to pass an obstruction in the casing, operate other equipment, etc. At times, it is also desirable for the packer to be rotated within the casing when torque is applied to the packer and for the packer to rotate as a unit, that is, with all, or substantially all, portions of the packer rotating together.
Mechanisms for permitting torque-through of a packer and for preventing relative rotation of packer portions, as with the anchoring and sealing mechanisms discussed above, are necessarily located in the cross-sectional area of the packer. Therefore, in the past, these features of a packer design typically resulted in decreased flow area, reduced anchoring ability, reduced sealing ability, or a combination thereof.
From the foregoing, it can be seen that it would be quite desirable to provide a packer which efficiently utilizes its cross-sectional area to thereby simultaneously achieve a large flow area, high resistance to axial and radial forces applied thereto, high pressure sealing capability, the ability to torque through the packer, and the ability to prevent relative rotation of portions of the packer. It is accordingly an object of the present invention to provide such a packer.
SUMMARY OF THE INVENTION
In carrying out the principles of the present invention, in accordance with an embodiment thereof, a packer is provided which is a retrievable torque-through packer, utilization of which permits high rates of flow therethrough. The packer's cross-sectional area includes mechanisms which anchor the packer against high loads, seal against high pressures, and prevent relative rotation of portions of the packer.
According to a preferred embodiment of the present invention, in which a variety of unique features thereof are cooperatively combined, a packer is provided which includes a tubular mandrel, casing slips disposed on the mandrel's exterior surface, rubbers disposed on the mandrel's exterior surface, upper and lower compression members for axially compressing the rubbers, upper and lower wedges for radially extending the casing slips, a mandrel slip between the upper compression member and the mandrel, a C-ring release mechanism for releasing the lower wedge for axial displacement relative to the mandrel, a ring in the form of a tubular clutch radially between the casing slips and the mandrel, and a split ring radially between the upper wedge and the mandrel.
The casing slips are barrel-type bidirectional slips with a series of circumferentially spaced apart slots formed thereon. The clutch prevents rotation of the casing slips relative to the mandrel while the packer is being run into the well. It has a series of circumferentially spaced apart projections formed thereon for engaging the slots on the casing slips. The clutch also has a sloping upper surface for engaging the casing slips and radially inwardly biasing them when the packer is retrieved after having been set.
The mandrel has two axially extending slots on its exterior surface. The upper wedge carries a pin which extends into one of the slots to prevent relative rotation between the mandrel and the upper wedge. The pin also extends into one of the slots on the casing slips to prevent relative rotation between the upper wedge and the casing slips. The lower wedge carries a key which extends into the other one of the slots on the mandrel. The key prevents relative rotation of the lower wedge relative to the mandrel.
Portions of the mandrel which are subjected to radially inwardly directed loads have threads or axially spaced apart teeth formed thereon in order to distribute the loads across the exterior surface of the mandrel to thereby help prevent collapse of the mandrel. In this way, the mandrel may be designed with a relatively thin cross-section and have a relatively large flow passage therethrough. Series of threads or angled teeth more efficiently utilize the available packer cross-section by eliminating large ramping surfaces conventionally found on packers.
An example of the utilization of threads and axially spaced apart teeth to distribute loads and efficiently compress the packer's cross-section may be found in the mandrel slip. The mandrel slip uses small internal teeth to grip the mandrel exterior surface. External threads on the mandrel slip and mating internal threads on the upper compression member evenly distribute inwardly directed force across the external surface of the mandrel slip, thereby distributing the force across the external surface of the mandrel.
The release mechanism is utilized to release the packer after it has been set. A C-ring is disposed on the mandrel axially downward from a housing and has internal threads which engage threads on the exterior surface of the mandrel. The C-ring also has axially spaced apart external surfaces which are in contact with axially spaced apart internal surfaces on a release sleeve. Such multiple mating surfaces reduce the amount of displacement required to release the C-ring for radially outward flexing to disengage the threads.
The features listed above are among those provided by the disclosed preferred embodiment of the present invention. Other features will become apparent upon consideration of the detailed description set forth hereinbelow. It will be readily appreciated by one of ordinary skill in the art that these features may be utilized individually or in any combination in a packer embodying principles of the present invention.
The use of the disclosed packer does not require flow area to be sacrificed to achieve other capabilities. Modern fracturing, acidizing, gravel packing, and combined operations are, thus, enhanced by use of a packer embodying principles of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A-1E are quarter-sectional views of successive axial portions of a packer embodying principles of the present invention, the packer being configured for running into a subterranean well, FIG. 1E being an enlarged view of a portion of the packer;
FIG. 2 is an enlarged scale cross-sectional view through the packer, taken along line 2--2 of FIG. 1C;
FIG. 3 is an enlarged scale cross-sectional view through the packer, taken along line 3--3 of FIG. 1C;
FIG. 4 is an enlarged scale cross-sectional view through the packer, taken along line 4--4 of FIG. 1C;
FIGS. 5A-5D are quarter-sectional views of successive axial portions of the packer, illustrating a configuration thereof wherein the packer is set in casing within the well;
FIGS. 6A-6D are quarter-sectional views of successive axial portions of the packer, illustrating a partially released configuration thereof; and
FIGS. 7A-7D are quarter-sectional views of successive axial portions of the packer, illustrating a fully released configuration thereof.
DETAILED DESCRIPTION
Illustrated in FIGS. 1A-1D is a packer 10 which embodies principles of the present invention. The packer 10 is shown in a configuration in which the packer is run into a subterranean well. In the following detailed description of the embodiments of the present invention representatively illustrated in the accompanying figures, directional terms such as "upper", "lower", "upward", "downward", etc. are used in relation to the illustrated packer 10 as it is depicted in the accompanying figures. It is to be understood that the packer 10 may be utilized in vertical, horizontal, inverted, or inclined orientations without deviating from the principles of the present invention. For convenience of illustration, FIGS. 1A-1D show the packer 10 in axial portions, but it is to be understood that the packer is a continuous assembly, lower end 12 of FIG. 1A being continuous with upper end 14 of FIG. 1B, lower end 16 of FIG. 1B being continuous with upper end 18 of FIG. 1C, and lower end 20 of FIG. 1C being continuous with upper end 22 of FIG. 1D.
Referring specifically now to FIG. 1A, the packer 10 includes an upper portion 24 which facilitates setting the packer in casing 146 in a wellbore 148 (see FIGS. 5A-5D). A tubular upper adaptor 26 and tubular top sub 28 enable attachment of the packer 10 to a conventional service tool (not shown) which applies a tensile force to the top sub and a compressive force to the upper adaptor to set the packer. A downwardly extending and externally threaded portion of the service tool threads into internal threads 30 on the top sub 28 and an external shoulder on the service tool axially contacts the upper adaptor 26. When it is desired to set the packer 10, the downwardly extending and externally threaded portion of the service tool pulls axially upward on the top sub 28, thereby applying the tensile force to the top sub, and the external shoulder on the service tool pushes axially downward on the upper adaptor 26, thereby applying the equal and opposite compressive force to the upper adaptor 26. It will be readily appreciated that other methods may be utilized to apply a tensile force to the top sub 28 and a compressive force to the upper adaptor 26 without departing from the principles of the present invention. For example, service tools are frequently used for setting packers, which service tools do not have provisions for threading into internal threads 30, but utilize a shear pin 34 for releasably applying a tensile force to the top sub 28.
Upper adaptor 26 is threadedly attached to a tubular upper housing 32 which coaxially and externally overlaps the top sub 28. Shear pins 34 and 36 are installed laterally through the upper housing 32 and into the top sub 28. Pin 36 prevents inadvertent setting of the packer 10 by preventing axial movement of the top sub 28 relative to the upper housing 32 until sufficient force has been applied to the top sub and upper adaptor 26 to shear the pin 36. Thus, when the packer 10 sets, top sub 28 moves axially upward relative to the upper housing 32, shearing pin 36.
Pin 34 is driven through the top sub 28 and into the service tool (not shown) to prevent rotational movement of the service tool relative to the top sub. Pin 36 prevents rotational movement of the top sub 28 relative to the upper housing 32. Torque may also be applied to the top sub 28 from the service tool by means of eight circumferentially spaced apart slotted openings 37 (only two of which are visible in FIG. 1A) in order to rotate the packer 10. Rotation of the packer 10 is desirable in certain circumstances, such as when an obstruction or debris is encountered as the packer is being run into the well. Since it is also beneficial for external portions of the packer 10 to rotate in those circumstances, the packer includes specially designed features, more fully described hereinbelow, which enable the external portions to rotate when torque is applied to the top sub 28 from the service tool.
Referring specifically now to FIG. 1B, packer 10 also includes a sealing portion 38 which operates to effect an annular seal between the packer and the casing 146 when the packer is set (see FIGS. 5A-5D). A tubular mandrel 40 is threadedly attached to the top sub 28 and extends downwardly therefrom. The tubular mandrel 40 has a generally smooth exterior surface 42 onto which three rings 44 are externally and slidingly disposed. The rings 44 are known to those skilled in the art as packer "rubbers" and may be made of a suitable elastomeric material for the temperatures and pressures which may be experienced while the packer 10 is set in the well. Axially straddling the rubbers 44 are two partially conical protective sleeves 46 which partially outwardly overlap the rubbers. The sleeves 46 provide a measure of protection against abrasion of the rubbers 44 as the packer 10 is being run into the well and protect against extrusion of the rubbers 44 radially intermediate the packer and casing 146 when the packer is set (see FIGS. 5A-5D).
A tubular upper compression member 48 is threadedly attached to the upper housing 32 and extends axially downward therefrom. The upper compression member 48 slidingly engages the exterior surface 42 of the mandrel 40, such that when the packer 10 is set and the mandrel 40 moves axially upward with the top sub 28 relative to the upper housing 32, the upper compression member will move axially downward relative to the mandrel and contact the upper one of the sleeves 46 to thereby compress the rubbers 44 between the upper compression member and a tubular lower compression member 50. The lower compression member 50 also slidingly engages the exterior surface 42 of the mandrel 40, such that the upper and lower compression members 48 and 50 axially straddle the rubbers 44 and protective sleeves 46.
Anti-extrusion rings 52 and 54 are carried on upper and lower compression members 48 and 50, respectively, and slidingly engage the exterior surface 42 of the mandrel 40. When the packer 10 is set, the anti-extrusion rings 52 and 54 prevent extrusion of the rubbers 44 radially intermediate the upper and lower compression members 48 and 50, respectively. Applicants prefer for anti-extrusion rings 52 and 54 to be conventional radially inwardly biased spiral rings so that no radial gap exists between the rings and the exterior surface 42 of the mandrel 40.
A specially designed tubular mandrel slip 56 is contained radially intermediate the upper compression member 48 and the mandrel 40. The mandrel slip 56 prevents axially downward movement of the mandrel 40 relative to the upper compression member 48, thereby maintaining compression of the rubbers 44 between the compression members 48 and 50 after the packer 10 has been set. A pin 58, installed laterally through the upper compression member 48 and into one of a series of circumferentially spaced apart slots 60 extending partially axially through the mandrel slip 56, prevents rotation of the mandrel slip relative to the upper compression member. Although only one axially downwardly extending slot 60 is visible in FIG. 1B, mandrel slip 56 includes multiple slots 60 which circumferentially alternate between axially upwardly and axially downwardly extending orientations to provide flexibility to the mandrel slip. Another axially extending slot 62, not visible in FIG. 1B (see FIG. 7B), extends completely axially through the mandrel slip 56 and permits the mandrel slip to be radially inwardly compressed.
Mandrel slip 56 includes a series of axially spaced apart circumferentially formed teeth 64 for gripping the exterior surface 42 of the mandrel 40. An enlarged view of the mandrel slip 56 is shown in FIG. 1E. Preferably, the teeth 64 are hardened so that they bite into the surface 42. Teeth 64 may be separately formed or, preferably, may be spirally formed as threads having a pitch of approximately 0.06 inch., For unidirectional gripping of the mandrel 40 (i.e., preventing axially downward, but not axially upward, movement of the mandrel 40 relative to the upper compression member 48), the teeth 64 are axially upwardly angled.
Mandrel slip 56 is radially inwardly biased to grip the exterior surface 42 of the mandrel 40 by ramping contact between external threads 66 formed on the mandrel slip and cooperatively shaped internal threads 68 formed on the upper compression member 48. For radially inward biasing of the mandrel slip 56 when the mandrel slip is biased axially downward, the external threads 66 are preferably radially inclined on their downwardly facing flanks and the cooperatively shaped internal threads are preferably radially inclined on their upwardly facing flanks. Note that the mandrel slip 56 will be biased axially downward, and will, thus, be radially inwardly biased, when teeth 64 are in gripping engagement with the external surface 42 of the mandrel 40 and the mandrel is axially downwardly biased relative to the upper compression member 48 (e.g., when the packer 10 is set). To provide an initial downwardly biasing force to thereby initially radially inwardly bias the mandrel slip 56, a conventional wavy spring 70 is axially compressed between the mandrel slip and a spacer ring 72 disposed axially intermediate the upper housing 32 and the upper compression member 48. Adjacent the spacer 72 is a port 74 which extends laterally through the upper compression member 48 and provides fluid communication between the wellbore 148 and the top sub 28, so that a vacuum is not created between the top sub and the upper compression member when the top sub moves axially upward as the packer 10 is set.
Axially spaced apart teeth 64 and axially extending threads 66 and 68 act to distribute forces resulting from the compression of the rubbers 44, and from the radially outward ramping of the casing slips described hereinbelow, over the external surface 42 of the mandrel 40. In this way, the mandrel slip 56 helps to prevent collapse of the mandrel 40, permitting the mandrel to have a large inner diameter 76 for flow of fluids therethrough.
Referring specifically now to FIG. 1C, packer 10 includes a casing slip portion 78 for anchoring the packer against axial movement relative to the casing 146 (see FIG. 5C). When the packer 10 is set, casing slips 80 extend radially outward and axially spaced apart hardened circumferential teeth 82 bite into the casing 146. The radially outward movement of the casing slips 80 is due to ramping engagement of the slips with a tubular upper wedge 84 and a tubular lower wedge 86, which, together, axially straddle the casing slips.
The casing slips 80 are of the bidirectional type known to those skilled in the art as "barrel-type" slips, meaning that they are formed from a single piece of tubular material in which a series of circumferentially spaced apart, alternately upwardly and downwardly axially extending, slots 88 have been formed. Due to the resulting material removal, the casing slips 80 are flexible and may be radially outwardly expanded and inwardly compressed. Teeth 82 are preferably externally formed on axially opposite ends of the casing slips 80, such that when the casing slips are radially outwardly extended, the teeth 82 are radially inwardly supported by the upper and lower wedges 84 and 86.
The casing slips 80 are in sliding engagement with the external surface 42 of the mandrel 40. A ring in the form of a tubular clutch 90 is disposed radially intermediate the casing slips 80 and the mandrel 40 in an undercut 92 formed on the casing slips, and is attached to the mandrel with fasteners 96 which extend laterally through the clutch and into the mandrel. The clutch 90 has a series of circumferentially spaced apart and axially downwardly extending projections 94 formed thereon which, when inserted in the slots 88 of the casing slips 80, prevent rotation of the casing slips relative to the mandrel 40. While the packer 10 is being run into the well, the clutch 90 prevents axially upward movement of the casing slips 80 relative to the mandrel 40. The clutch 90 also has an axially upwardly and radially outwardly sloping upper end surface 98 which, when it is desired to release the packer 10 after it has been set, engages a cooperatively shaped downwardly facing surface formed on the casing slips 80 (see FIG. 7C) to help radially inwardly retract the casing slips as will be described in further detail hereinbelow.
Upper wedge 84 is threadedly attached to the lower compression member 50 and radially outwardly overlies the mandrel 40. Upper wedge 84 is releasably secured against axial movement relative to the mandrel 40 by two shear pins 102, only one of which is visible in FIG. 1C. Shear pins 102 extend laterally through the upper wedge 84 and into a split ring 104. Split ring 104 is radially outwardly and threadedly attached to the mandrel 40 and is axially split (see FIG. 7B) to permit it to be radially outwardly expanded for installation onto the mandrel. In this way, the mandrel 40 does not need to be undercut to provide for installation of the split ring 104, permitting the mandrel to maintain its exterior surface 42 and, thus, does not require a decrease in the inner diameter 76 in this portion 78 of the packer 10. The threaded attachment of the split ring 104 to the mandrel 40 axially distributes forces applied to the split ring over the exterior surface 42 of the mandrel 40, contributing to the strength of the mandrel. The split ring 104 prevents axially upward movement of the upper wedge 84 relative to the mandrel 40 while the packer 10 is being run into the well. After the packer 10 has been set and released, the split ring 104 is in contact with the lower compression member 50 and thereby prevents axially downward displacement of the lower compression member relative to the mandrel 40 (see FIG. 7B).
When the packer 10 is set, a downwardly facing exterior conical surface 106 formed on the lower end of the upper wedge 84 rampingly contacts the casing slips 80, thereby radially outwardly biasing the casing slips. Two shear pins 108 (only one of which is visible in FIG. 1C) extend laterally through the upper wedge 84 and into two of the slots 88 on the casing slips 80. The shear pins 108 prevent rotation of the casing slips 80 relative to the upper wedge 84. Each of shear pins 108 also extend laterally into one of two axially extending slots 110 (only one of which is visible in FIG. 1C) formed on the exterior surface 42 of the mandrel 40. The shear pins 108, thus, also prevent rotation of the upper wedge 84 relative to the mandrel 40, but permit axially downward movement of the upper wedge relative to the mandrel.
While the packer 10 is being run into the well, a radially outwardly and axially downwardly sloping shoulder 109 formed on the exterior surface 42 of the mandrel 40 engages a complementarily shaped sloping surface 111 (see FIG. 5C) formed on the casing slips 80 to radially inwardly bias the casing slips and prevent axially upward displacement of the casing slips relative to the mandrel 40.
Referring additionally now to FIG. 2, a cross-sectional view of the packer 10 taken along line 2--2 of FIG. 1C is shown. In this view the manner in which the casing slips 80, the upper wedge 84, and the mandrel 40 are interconnected may be more clearly seen. Ten shear pins 112 extend radially through the casing slips 80 and into the upper wedge 84 conical surface 106. Shear pins 112 releasably secure the casing slips 80 against axial movement relative to the upper wedge 84 until the packer 10 is set, thereby preventing inadvertent setting if the packer is picked up while it is being run into the well.
Referring additionally now to FIG. 3, a cross-sectional view of the packer 10 taken along line 3--3 of FIG. 1C is shown. In this view the manner in which the projections 94 on the clutch 90 engage the slots 88 of the casing slips 80 may be clearly seen.
Referring again to FIG. 1C, lower wedge 86 has an upwardly facing external conical upper end surface 114 formed thereon. When the packer 10 is set, the conical surface 114 rampingly engages the casing slips 80, thereby radially outwardly biasing the casing slips.
A tubular housing 118 is threadedly and coaxially attached to the lower wedge 86 and extends downwardly therefrom. A stop ring 119 is formed on the housing 118 and extends downwardly therefrom radially adjacent the outer surface 42 of the mandrel 40. Two axially upwardly extending slots 116 (only one of which is visible in FIG. 1C) are formed on the lower wedge 86. A key 120 is disposed in each of the slots 116 axially intermediate the lower wedge 86 and the housing 118. Each key 120 extends laterally into an axially extending keyway 122 (only one of which is visible in FIG. 1C) formed on the mandrel 40 exterior surface 42. In this manner, the lower wedge 86 is prevented from rotational movement relative to the mandrel 40. Note, however, that keys 120 do not prevent axially upward movement of the mandrel 40 relative to the lower wedge 86.
Referring additionally now to FIG. 4, a cross-sectional view of the packer 10 taken through line 4--4 of FIG. 1C is shown. In this view, the manner in which keys 120 engage slots 116 and keyways 122 may be clearly seen.
Referring specifically now to FIG. 1D, the packer 10 includes a release portion 124 which, after the packer has been set (see FIGS. 5A-5D), may be utilized to release the packer for retrieval from the well. A tubular outer housing 126 is threadedly and coaxially attached to the housing 118 and extends downwardly therefrom. The outer housing 126 radially outwardly overlaps a C-ring 128 which contacts the stop ring 119 formed on the housing 118 and which has a C shaped cross-section, due to slot 121 axially and radially formed therethrough, enabling it to radially outwardly expand.
C-ring 128 is specially designed to distribute forces applied thereto axially along the exterior surface 42 of the mandrel 40. C-ring 128 grippingly engages the exterior surface 42 of the mandrel 40 with a series of internal and axially spaced apart circumferential teeth 130 which, preferably, are threads. Teeth 130 engage cooperatively shaped teeth 131 formed on exterior surface 42. Thus, when C-ring 128 is radially inwardly retained, stop ring 119 axially contacting the C-ring, axial movement of the housing 118 relative to the mandrel 40 is prevented. Forces tending to displace the housing 118 axially downward relative to the mandrel 40, such as those forces maintaining the casing slips 80 radially outwardly biting into the casing 146 (see FIG. 5C), are distributed by the teeth 130 axially along the exterior surface 42 of the mandrel 40, thus helping to prevent collapse of the mandrel.
C-ring 128 is radially inwardly retained by radial contact between three external and axially spaced apart projections 132 formed on the C-ring, and three internal and axially spaced apart cooperatively shaped projections 134 formed on a tubular release sleeve 136. Release sleeve projections 134 radially outwardly overlap the projections 132 until it is desired to release the housing 118 for axially downward movement relative to the mandrel 40. Release sleeve projections 134 are disposed radially intermediate the outer housing 126 and the C-ring 128.
Release sleeve 136 is releasably secured against axial movement relative to outer housing 126 by four shear screws 138 (only two of which are visible in FIG. 1D) which extend laterally through the outer housing and into the release sleeve 136. When it is desired to release the packer 10 after it has been set, release sleeve 136 is shifted axially upward relative to the outer housing 126 by applying an axially upward force to radially inwardly extending portion 142 formed on the release sleeve, thereby shearing shear screws 138 and displacing projections 134 so that they no longer radially inwardly retain projections 132. C-ring 128 is then permitted to flex radially outward, releasing the housing 118 for axially downward displacement relative to the mandrel 40.
The utilization of multiple axially spaced apart projections 132 and 134 permits a shorter axial displacement of the release sleeve 136 to release C-ring 128 for the amount of contact surface area between them than would be required if only one projection were utilized on the release sleeve and C-ring. Multiple projections 132 and 134 also act to more evenly distribute forces applied to the C-ring 128 axially across the exterior surface 42 of the mandrel 40, thereby helping to prevent collapse of the mandrel.
Radially outwardly extending portion 140 formed on the exterior surface 42 of the mandrel 40 prevents axially upward movement of the housing 118 relative to the mandrel 40, thereby preventing the lower wedge 86 from displacing axially upward and inadvertently setting the packer 10 while it is being run into the well. After the packer 10 has been released, the radially outwardly extending portion 140 contacts the lower wedge 86 adjacent the slots 116 and thereby prevents the lower wedge, housing 118, C-ring 128, outer housing 126, and release sleeve 136 from detaching from the mandrel 40 as the packer is retrieved (see FIG. 7D).
A tubular lower adaptor 144 is threadedly and coaxially attached to the outer housing 126 and extends downwardly therefrom. Lower adaptor 144 permits tubing or other equipment (not shown) to be suspended from the packer 10. When the packer 10 is set in the casing 146 (see FIGS. 5A-5D), the tubing or other equipment attached to the lower adaptor 144 is also anchored against axial displacement relative to the casing 146.
Circumferential seals 146 and 148 are internally disposed on the release sleeve 136 and sealingly engage the mandrel 40 and the lower adaptor 144, respectively. Seals 146 and 148 thereby prevent fluid passage radially intermediate the release sleeve 136 and each of the mandrel 40 and lower adaptor 144, respectively.
Threaded connections T between components of the packer 10 described above are preferably of the type known to those skilled in the art as right hand threads, to permit right hand rotation of the packer as it is being run into the well, if necessary to pass obstructions, etc., without permitting relative rotation between the threadedly connected components. It is to be understood, however, that if this feature of the packer 10 is not desired, the threaded connections T may be differently configured. Additionally, if it is desired to permit left hand rotation of the packer 10 as it is being run into the well, left hand threads may be utilized for the threaded connections T. Where the hereinabove described threaded connection is unrelated to rotation of the packer 10 as a unit, it may be left or right handed without departing from the principles of the present invention.
Thus has been described the packer 10 which uniquely provides for a mandrel 40 having a relatively large inner diameter 76, permitting relatively large flow rates of fluids therethrough. Such relatively large inner diameter 76 is permitted by, for example, the various features of the packer 10 which act to prevent collapse of the mandrel 40 as described hereinabove. Additionally, features of the packer 10 described hereinabove act to maintain relatively large compressive forces on the rubbers 44 without damage to the mandrel 40, permitting the packer to withstand relatively large differential pressures when set in casing 146 within the wellbore 148 (see FIGS. 5A-5D). Furthermore, the packer 10 includes features described hereinabove which act to maintain relatively large radially outwardly biasing forces on the casing slips 80 without damage to the mandrel 40, permitting the packer to withstand relatively large differential pressures and also permitting the packer to anchor relatively large loads against axial displacement relative to the casing 146. Still further, features of the disclosed packer 10 described hereinabove prevent relative rotation of components of the packer, permitting the packer to be rotated as a unit and torqued through while it is being run into the well.
Referring additionally now to FIGS. 5A-5D, the packer 10 is shown set in casing 146 which lines the wellbore 148. As representatively illustrated in FIGS. 5A-5D, the packer 10 is anchored to the casing 146, preventing relative axial movement therebetween, the teeth 82 on the casing slips 80 biting into the casing. A seal has been effected radially intermediate the packer 10 and the casing 146, preventing fluid flow therebetween, the rubbers 44 being axially compressed and radially outwardly extended so that they sealingly contact the casing.
Referring specifically now to FIG. 5A, the upper portion 24 of the packer 10 is shown. The service tool (not shown) has forced the upper housing 32 axially downward relative to the top sub 28. As will be described further hereinbelow, such axially downward movement of the upper housing 32 activates the sealing and anchoring functions of the packer 10. Note that shear pin 36 has sheared, sufficient axially upward force having been applied to the top sub 28 and axially downward force having been applied to the upper adaptor 26 to cause the shear pin 36 to shear.
Referring specifically now to FIG. 5B, the sealing portion 38 of the packer 10 is shown. The mandrel 40 has been displaced axially upward relative to the upper housing 32, the mandrel being attached to the top sub 28. Mandrel slip 56 is grippingly engaging the mandrel 40, teeth 64 biting into the exterior surface 42 of the mandrel, preventing the mandrel from moving axially downward relative to the upper housing 32.
The axially downward movement of the upper housing 32 relative to the mandrel 40 has axially compressed the rubbers 44 between the upper and lower compression members 48 and 50. Protective sleeves 46 have been deformed such that they now extend radially outward to the casing 146, helping to prevent extrusion of the rubbers 44 radially intermediate the packer 10 and the casing. Anti-extrusion rings 52 and 54 prevent extrusion of the rubbers 44 radially intermediate the upper and lower compression members 48 and 50, respectively, and the mandrel 40.
Referring specifically now to FIG. 5C, the casing slip portion 78 of the packer 10 is shown. The axially downward movement of the upper housing 32 relative to the mandrel 40 has forced the upper wedge 84 axially downward, shearing shear pin 102. The axially downward movement of the upper wedge 84 has forced the conical surface 106 to rampingly engage the casing slips 80, forcing the casing slips axially downward and radially outward, the conical surface 114 on the lower wedge 86 also rampingly engaging the casing slips.
Note that the clutch 90, as viewed in FIG. 5C, no longer engages the casing slips 80, the projections 94 having moved axially upward relative to the slots 88 on the casing slips.
Referring specifically now to FIG. 5D, the release portion 124 of the packer 10 is shown. In this view it can be seen that the housing 118, C-ring 128, release sleeve 136, outer housing 126, and lower adaptor 114 have not moved relative to the mandrel 40. Thus, when the packer 10 is set, the release portion 124 of the packer 10 may remain unchanged.
Referring additionally now to FIGS. 6A-6D, the packer 10 is shown partially released, after having been set as shown in FIGS. 5A-5D and previously described hereinabove. The rubbers 44 are no longer axially compressed or radially outwardly extended and, thus, are no longer in sealing engagement with the casing 146. The casing slips 80 are no longer radially outwardly extended and, thus, no longer anchor the packer 10 to the casing 146.
Referring specifically now to FIG. 6D, the release sleeve 136 has been shifted axially upward relative to the housing 118, shearing shear screws 138, and permitting C-ring 128 to flex radially outward. Such radially outward flexing of the C-ring 128 permits the teeth 130 and 131 to disengage, thereby permitting the mandrel 40 to move axially upward relative to the housing 118. Note that the radially enlarged portion 140 on the mandrel 40 no longer axially contacts the stop ring 119. Note, also, that only a relatively short axially upward movement of the release sleeve 136 is required to disengage the multiple spaced apart radial projections 132 and 134 on the C-ring 128 and release sleeve, respectively.
Referring specifically now to FIG. 6C, the casing slips portion 78 of the packer 10 is shown. The axially upward movement of the mandrel 40 relative to the housing 118 permits the lower wedge 86 to move axially downward relative to the mandrel 40, and relative to the casing slips 80, thereby permitting the casing slips to radially inwardly retract. Teeth 82 no longer bite into the casing 146. Note that the keys 120 have axially downwardly displaced in the keyways 122, and that the clutch 90 has axially upwardly displaced relative to the casing slips 80. Note, also, that the split ring 104 now axially contacts the lower compression member 50.
Referring specifically now to FIG. 6B, the sealing portion 38 of the packer 10 is shown. The lower compression member 50 has been displaced axially downward relative to the mandrel 40 and the upper compression member 48, thereby permitting the rubbers 44 to axially expand. The protective sleeves 46 remain deformed and radially outwardly contact the casing 146, but due to their flexibility, do not prevent the packer 10 from being axially displaced relative to the casing, nor do they effect a seal to an appreciable extent. Note that, even though the forces acting to compress the rubbers 44 and radially outwardly extend the casing slips 80 have been released, the mandrel slip 56 still grippingly engages the mandrel 40, preventing axially downward movement of the mandrel relative to the upper housing 32.
Referring specifically now to FIG. 6A, the upper portion 24 of the packer 10 is shown. Mandrel 40 has been permitted to move axially upward relative to the upper housing 32 as described hereinabove, and the top sub 28 now contacts a radially inwardly extending shoulder 150 formed on the upper housing, thereby preventing further axially upward movement of the mandrel relative to the upper housing.
Referring additionally now to FIGS. 7A-7D, the packer 10 is shown fully released and is now configured for retrieval from the well. The packer 10 is retrieved by the service tool (not shown) which is threaded into the threads 30 on the top sub 28 as described hereinabove. An axially upward force is thereby applied to the top sub 28 to withdraw the packer 10 from the well.
Referring specifically now to FIG. 7A, the top sub 28 is in axial contact with the shoulder 150 on the upper housing 32. Therefore, an axially upward force applied to the top sub 28 by the service tool will also act to axially upwardly displace the upper housing 32. Thus, the upper adaptor 26, upper housing 32, top sub 28, and mandrel 40 are axially upwardly displaced when the axially upward force is applied to the top sub.
Referring specifically now to FIG. 7B, the upper compression member 48, being attached to the upper housing 32, is also axially upwardly displaced, preventing the rubbers 44 from being inadvertently compressed while the packer 10 is retrieved from the well. As described hereinabove the split ring 104 is in axial contact with the lower compression member 50 on the mandrel 40. Thus, when the mandrel 40 is axially upwardly displaced, the lower compression member 50 is also axially upwardly displaced.
Referring specifically now to FIG. 7C, the upper wedge 84, being attached to the lower compression member 50 is also axially upwardly displaced when the mandrel 40 is axially upwardly displaced. The conical surface 106 no longer rampingly contacts the casing slips 80, and the casing slips are permitted to completely radially inwardly retract. Sloping upper end surface 98 on the clutch 90 now axially contacts the sloping surface 100 on the casing slips 80, thereby maintaining a radially inwardly biasing force on the casing slips as the packer 10 is retrieved from the well. Axial contact between the casing slips 80 and the clutch 90 also axially upwardly displaces the casing slips as the mandrel 40 is axially upwardly displaced, thereby preventing inadvertent setting of the casing slips as the packer 10 is retrieved from the well. Radially outwardly extending portion 140 on the mandrel 40 axially contacts the lower wedge 86 adjacent slots 116, thereby axially upwardly displacing the lower wedge, along with the housing 118 which is attached thereto, as the mandrel is axially upwardly displaced.
Referring specifically now to FIG. 7D, the mandrel 40 has been displaced axially upward relative to the housing 118, the teeth 131 on the mandrel no longer being in engagement with the teeth 130 on the C-ring 128. Note that, as the housing 118 is axially upwardly displaced, the lower housing 126, C-ring 128, release sleeve 136, and lower adaptor 144 are also axially upwardly displaced.
The foregoing detailed description is to be clearly understood as being given by way of illustration and example only, the spirit and scope of the present invention being limited solely by the appended claims.
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A packer for use in subterranean wellbores provides efficient utilization of its cross-sectional area with mechanisms therein for anchoring, sealing, and torquing through the packer. In a preferred embodiment, a retrievable packer has a tubular mandrel, rubbers disposed on the mandrel, upper and lower compression members axially straddling the rubbers, a barrel-type casing slip, upper and lower wedges axially straddling the casing slip, a release mechanism, and a series of threaded load-distributing components which help to prevent collapse of the mandrel.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention relates to a circuit board adapted to a fan and a fan structure, and, more particularly, to a circuit board that possesses an enhanced efficiency in heat dissipation and a fan structure provided with the same.
[0003] 2. Description of the Related Art
[0004] Generally, a conventional fan is operated by a circuit board to drive a motor for activating a hub and fan blades thereof to generate airflow at a certain speed. Accordingly, the heat generated by a heat-generating device provided with the fan can be dissipated by the airflow.
[0005] However, after the fan is operated for a certain period of time, the efficiency in heat dissipation of the fan will deteriorate because during operation the electronic components of the fan also generate heat which cannot be readily dispersed away from the fan structure.
[0006] Usually, the integrated circuit of the cooling fan used in a notebook computer operates in a single-phase bipolar mode. In this case, regardless of the amount of operable current of the integrated circuit, since the current flows directly into the integrated circuit, it always results in considerable heat. When the heat cannot be dispersed efficiently, it will accumulate and thus causes problems such as overheating and shutdown of the notebook computer.
BRIEF SUMMARY OF THE INVENTION
[0007] In view of the aforementioned problems, an object of the invention is to provide a circuit board adapted to a fan for improving the efficiency in heat dissipation and increasing the operable current range of the electronic components mounted thereon.
[0008] Another object of the invention is to provide a fan structure using the aforementioned circuit board for extending the lifetime of a fan.
[0009] To achieve the objects, the invention provides a circuit board adapted to a fan comprising a circuit region and a heat-dissipative film. The circuit region is located on one surface of the circuit board and includes a plurality of pads for mounting at least one heat-generating component thereon. The heat-dissipative film is coated on an edge portion of the same surface as the circuit region is located on and is in contact with the heat-generating component.
[0010] Preferably, the circuit region is surrounded by the heat-dissipative film, and the heat-dissipative film is formed with a plurality of openings. Besides, the heat-dissipative film is a coating film made of heat-conducting material; specifically, the heat-conducting material is selected from the group consisting of copper, aluminum, iron, and an alloy thereof.
[0011] Moreover, the circuit board of the invention may further include a heat sink located on a second surface opposite to the aforementioned surface of the circuit board. Besides, another circuit region may be provided on the second surface of the circuit board. The heat sink is connected to the heat-dissipative film via the openings. The heat sink is formed by coating a heat-conducting material on an edge portion of the second surface; specifically, the heat-conducting material is selected from the group consisting of copper, aluminum, iron, and an alloy thereof.
[0012] Furthermore, the circuit board may be provided with a protrusion on which the heat-generating component and/or the heat-dissipative film may be formed. Besides, the protrusion may have a cutout which extends over the length of the heat-generating component.
[0013] In addition, the invention also provides a fan structure that includes a hub, a motor located inside the hub, a plurality of fan blades connected to the hub, and a circuit board connected to the motor. Specifically, the fan structure is characterized by the circuit board, which comprises a circuit region and a heat-dissipative film. In more detail, the circuit region is located on one surface of the circuit board and has at least one heat-generating component mounted thereon. The heat-dissipative film is coated on an edge portion of the same surface as the circuit region located on and is in contact with the heat-generating component.
[0014] The circuit board of the invention is provided with the heat-dissipative film and optionally the heat sink, thus the heat generated by the heat-generating component can be readily dissipated by the heat-dissipative film or the heat sink, so that it is possible to dramatically enhance the efficiency in heat dissipation.
[0015] Also, according to the fan structure of the invention, the heat-dissipative film and/or the heat sink may extend outside the circumference of the hub, thus the heat dissipated from the heat-dissipative film and/or the heat sink can be further dispersed by an airflow generated by the fan. Therefore, it is possible not only for the circuit board to have an enhanced efficiency in heat dissipation and therefore an increased operable current range of the electronic components mounted thereon, but also for the fan provided with the same to have a prolonged lifetime.
[0016] Still further, in the case that the protrusion of the circuit board is protruded outwardly with respect to the hub, since the heat-generating component provided on the protrusion is exposed to the airflow of the fan, the heat of the heat-generating component can be dispersed rapidly. Therefore, it is possible not only for the circuit board to enhance its efficiency in heat dissipation and therefore to increase the operable current range of the electronic components mounted thereon, but also for the fan provided with the circuit board to have a prolonged lifetime.
[0017] Other aspects and advantages of the invention will become apparent from the following detailed description in conjunction with the accompanying drawings, which illustrate by way of example the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] [0018]FIG. 1 is a schematic diagram showing the circuit board according to the first embodiment of the invention.
[0019] [0019]FIG. 2 is a schematic diagram showing the fan provided with the circuit board of the invention.
[0020] [0020]FIG. 3 is a schematic diagram showing the circuit board according to the second embodiment of the invention.
[0021] [0021]FIG. 4A is a schematic diagram showing the heat sink linked with the circuit board of the invention.
[0022] [0022]FIG. 4B is a cross-sectional view taken along the line A-A′ of FIG. 4A.
[0023] [0023]FIG. 5 is a schematic diagram showing the circuit board according to the third embodiment of the invention.
[0024] [0024]FIG. 6 is a schematic diagram showing the circuit board according to the fourth embodiment of the invention.
[0025] [0025]FIG. 7 is a schematic diagram showing the circuit board according to the fifth embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0026] [0026]FIG. 1 is a schematic diagram showing the circuit board according to the first embodiment of the invention, and FIG. 2 is a schematic diagram showing a fan provided with the circuit board. As shown in FIGS. 1 and 2, a fan structure 200 of the invention includes a hub 202 , a motor (not shown) located inside the hub 202 , a plurality of fan blades 204 connected to the hub 202 , and a circuit board 100 connected to the motor.
[0027] The hub 202 is coupled to the motor so as to rotate synchronously with the motor and drive the fan blades 204 to rotate accordingly. When the fan blades 204 rotate, an airflow flowing through the fan structure 200 is generated.
[0028] It should be understood that the various shapes and materials of the hub 202 , motor, and the fan blades 204 can be chosen to meet the actual requirements. It will be obvious, 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, the specific details have been omitted to avoid misinterpretation of the present invention.
[0029] The circuit board 100 comprises a circuit region 102 and a heat-dissipative film 106 , wherein the heat-dissipative film 106 is located on the edge of the circuit board 100 . The circuit region 102 includes circuits, semiconductor devices, integrated circuits and related components for driving the motor connected to the circuit board. Some of the components, such as the integrated circuit and semiconductor devices, can be grouped into a heat-generating component 104 .
[0030] To be specific, the heat-dissipative film 106 is in contact with the heat-generating component 104 for dissipating the heat generated by the heat-generating component 104 . Moreover, the heat of the heat-dissipative film 106 can be readily dispersed by means of airflow generated in the fan structure 200 . The heat-dissipative film 106 , for example, is a coating film made of heat-conducting material, wherein the heat-conducting material is selected from the group consisting of copper, aluminum, iron, and an alloy thereof.
[0031] Moreover, the heat-dissipative film 106 is provided to surround the circuit region 102 . The heat-dissipative film 106 can also be located on any region of the circuit board 100 other than on the circuit region 102 . Besides, the heat-dissipative film 106 may extend outside the circumference of the hub 202 as shown in FIG. 2, or may be limited to inside the circumference of the hub 202 . When the heat-dissipative film 106 extends outside the circumference of the hub 202 so that the heat-dissipative film 106 is located in the air passage of the fan structure 200 , the airflow passing by the heat-dissipative film 106 can readily disperse the heat dissipated from the heat-dissipative film 106 . Therefore, it is possible not only for the circuit board 100 to have an enhanced efficiency in heat dissipation and therefore an increased operable current range of the electronic components mounted thereon, but also for the fan structure 200 provided with the circuit board 100 to have a prolonged lifetime.
[0032] As shown in FIG. 3, the heat-dissipative film 106 of a circuit board 300 is formed with a plurality of openings 108 . Preferably, the openings 108 are symmetrically arranged. According to the second embodiment of the invention, the openings 108 of the heat-dissipative film 106 are formed in order to serve as a portion of the air passage in the operating fan structure 200 , thus the heat dissipated from the heat-dissipative film 106 can be readily dispersed by the airflow passing through the openings 108 . Therefore, it is possible not only for the circuit board 300 to have an enhanced efficiency in heat dissipation and therefore an increased operable current range of the electronic components mounted thereon, but also for the fan structure 200 provided with the circuit board 300 to have a prolonged lifetime.
[0033] Moreover, according to the structure of the circuit board 100 , a heat sink (not shown) is further formed on the surface opposite to the surface of the circuit board 100 provided with the heat-dissipative film 106 . The heat sink is connected to the heat-dissipative film 106 via a plurality of protruding portions of the heat sink, wherein the airflow passing through a plurality of through holes or the openings 108 thereof as shown in FIG. 3, so that the total area for heat dissipation of the heat-dissipative film 106 can be increased. The heat sink, for example, can be a sheet or a coating film made of heat-conducting material, which is selected from the group consisting of copper, aluminum, iron, and an alloy thereof.
[0034] Also, various shapes of the heat sink may be chosen to meet the actual requirements, such as a shape corresponding to the outline of the circuit board 100 or any other shapes. In addition, if another circuit region (not shown) is formed on the other surface of the circuit board, the heat sink can be located at any region of the circuit board 100 other than the circuit region.
[0035] Alternatively, as shown in FIGS. 4A and 4B, the heat sink 302 is engaged with the circuit board 300 by sheet-metal working and connected with the heat-dissipative film 106 . For instance, a fastening portion 304 is formed on the heat sink 302 , and then the heat sink 302 is directly engaged with the circuit board 300 via clamping or fastening and then connected to the heat-dissipative film 106 through the fastening portion 304 .
[0036] Moreover, as shown in FIG. 5, the circuit board 400 is provided with a protrusion 110 , wherein a heat-generating component 104 is located on the protrusion 110 . In this embodiment, either only the protrusion 110 of the circuit board 400 extends outside the circumference of the hub 202 or both of the protrusion 110 and the heat-dissipative film 106 extend outside the circumference of the hub 202 . Even in the case where only the protrusion 110 extends outside the circumference of the hub 202 , because the protrusion 110 is located directly in the air passage of the fan structure 200 , it is possible to dissipate the heat generated by the heat-generating component 104 by the airflow passing past the protrusion 110 . Therefore, it is possible not only for the circuit board 400 to have an enhanced efficiency in heat dissipation and therefore an increased operable current range of the electronic components mounted thereon, but also for the fan structure 200 provided with the circuit board 400 to have a prolonged lifetime.
[0037] Alternatively, the heat-dissipative film 112 on the circuit board 500 is formed on the protrusion 110 as shown in FIG. 6, or the heat-generating component 104 is mounted on the protrusion 110 of the circuit board 500 alone. In this case, the heat generated by the heat-generating component 104 can still be dispersed by the air flowing past the protrusion 110 . Therefore, it is possible not only for the circuit board 500 to have an enhanced efficiency in heat dissipation and therefore an increased operable current range of the electronic components mounted thereon, but also for the fan structure 200 provided with the circuit board 500 to have a prolonged lifetime.
[0038] Furthermore, in order to enhance the efficiency in heat dissipation of the circuit board 500 , a cutout 114 is formed through the protrusion 110 of a circuit board 600 as shown in FIG. 7 to extend over the length of the heat-generating component 104 . In this case, a portion of the heat-generating component 104 is exposed to the air passage via the cutout 114 . Therefore, according to this embodiment, the heat-generating component 104 is almost entirely exposed to the air passage, thus the heat-generating component 104 has a greater contact area with the airflow. Hence, the heat generated by the heat-generating component 104 is readily dispersed by the air flowing past the protrusion 110 . Therefore, it is possible not only for the circuit board 600 to have an enhanced efficiency in heat dissipation and therefore an increased operable current range of the electronic components mounted thereon, but also for the fan structure 200 provided with the circuit board 600 to have a prolonged lifetime.
[0039] In conclusion, the circuit board of the invention is provided with a heat-dissipative film and/or a heat sink and thus the heat generated by the heat-generating component can be readily dispersed. Therefore, the efficiency in heat dissipation of the circuit board can be greatly enhanced.
[0040] Also, according to the fan structure of the invention, the heat-dissipative film may extend outside the circumference of the hub, thus the heat generated by the heat-generating component and dissipated to the heat-dissipative film and/or the heat sink can be readily dispersed by the airflow. Therefore, not only is the efficiency in heat dissipation and therefore the operable current range of the electronic components mounted thereon enhanced, but also the fan structure provided with the circuit board will have a prolonged lifetime.
[0041] Moreover, in the case where the protrusion of the circuit board extends outside the circumference of the hub, the heat generated by the operating fan can be readily dispersed because the heat-generating component is exposed to the airflow. Therefore, not only is the efficiency in heat dissipation and therefore the operable current range of the electronic components mounted thereon enhanced, but also the fan structure provided with the circuit board will have a prolonged lifetime.
[0042] Although the foregoing invention has been described in some detail for purposes of clarity and ease of understanding, it is apparent that certain changes and modifications may be practiced within the scope of the appended claims. Accordingly, the present embodiments are to be considered as illustrative and not restrictive, and the invention is not to be limited to the details given herein, but may be modified within the scope and equivalents of the appended claims.
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A circuit board adapted to a fan comprises a circuit region and a heat-dissipative film. The circuit region is provided on a first surface of the circuit board and comprises at least one heat-generating component thereon. The heat-dissipative film is coated on an edge portion of the first surface and is in contact with the heat-generating component. A plurality of openings through the heat-dissipative film, a protrusion of the circuit board, a cutout in the protrusion to expose the heat-generating component to airflow, etc., have been disclosed and claimed for enhancing the efficiency in heat dissipation. A heat sink may also be provided on a second surface opposite to the first surface of the circuit board. The heat sink is connected to the heat-dissipative film to help dissipate the heat generated by the operation of the fan.
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TECHNICAL FIELD
[0001] This invention relates generally to disposable inhalers for substances in powder form intended for inhalation. Specifically it refers to a so-called DPI, “Dry Powder Inhaler” operated by the user's own respiration. Single-dose inhalers are as multidose inhalers, designed to alleviate disease caused by asthma or other problems that prevent normal respiration. New applications that are especially suitable for single-dose disposable inhalers are the relief of migraine, flu vaccination, etc.
TECHNICAL BACKGROUND
[0002] On the market today there are a large number of different inhalers for substances in powder form, most of which are so-called multi-dose inhalers. The inhalers currently marketed are relatively complex in their design. Known disposable inhalers consist of relatively many parts which makes them complicated and thus expensive to manufacture and also expensive to buy for the end user.
[0003] A large proportion of asthmatics have less severe problems, for example, only at high pollen levels or on occasional contact with animal fur. These patients may need to make only a few inhalations per year, hence, a disposable inhaler is a much more economical option than a multidose inhaler. In poorer countries, such as in the Third World, tablets are often sold one by one to customers cannot afford to buy more than one at a time. The cost is crucial and multi-dose inhalers are too expensive. Migraine medication is another application for inhalers since the therapeutic effect is achieved significantly faster through the lungs. A tablet must first be dissolved in the gastric content and then pass out through the stomach wall to reach the bloodstream.
[0004] At vaccination the drug/syringe must always be managed by a registered nurse. The shortage of registered nurses in developing countries is large and disposable syringes are not cheap. An instructor with no medical training can, using the present invention, instruct users how to perform the inhalation, thus one becomes independent of the shortage of nurses for treatment.
[0005] Most of the disposable inhalers on the market today, such as the Boeringer Ingelheim Handihaler® and Aptars Twister®, consist of one inhalation device that adds a capsule that is punctured after which the user inhales the dose. The way the capsule is punctuated carries a risk that the dose in the capsule may become contaminated by the punctured tool. In addition, the actual device in which the capsule is added to be punctured is relatively expensive to manufacture. The present invention eliminates the expensive injection molded plastic inhalation device, which greatly reduces the cost of production and also removes the risk of contaminating the dose. Disposable inhalers exists that are patented (but not yet on the market), such as, for example, U.S. Pat. No. 6,286,507B1, U.S. Pat. No. 6,105,574, US20130025593A1 and WO2012/004485. They are all relatively expensive to manufacture and/or difficult to manage or have one, for the end-user, unsafe construction. U.S. Pat. No. 6,286,507B1 and U.S. Pat. No. 6,105,574 show two different single dose disposable inhalers where an upper part and a lower part are assembled and in between them form an air channel. In the lower part there is a recess for positioning of the medical powder. The powder is contained in the recess with the use of a tape. A portion of the tape is sticking out of one end of the air channel. The user can grab the protruding part of the tape and pull it from the recess and thus expose the dose for inhalation. U.S. Pat. No. 6,286,507B1 describes specifically one alternative design where a flat metal part is arranged with a recess for the powder. The recess has a hole at the bottom and two parts of tape encloses the powder, a tape from the top, and another tape from below. The two parts of the tape are merged so that the user can grab and remove them in a single operation exposing the powder. U.S. Pat. No. 6,105,574 describes specifically that a deformation in the lower part should contact the user's lower lip causing the air outlet channel to be placed approximately 30 mm into the oral cavity. That makes the air outlet channel to a higher degree, to be located on top of the tongue instead of air beam hitting straight on your tongue which is common in traditional inhalers. The amount of powder that sticks on the tip of the tongue is reduced accordingly. The powder that sticks in the cavity of the mouth is swallowed to a high degree with the saliva and hence its clinical effect is lost. The method to enclose the powder in a recess inside the air channel has the disadvantage that the air channel is open. This means that foreign objects, particles from the contents of pockets or purses where the inhaler is stored, falls into the air channel. Since it is medically unacceptable for foreign particles to be inhaled, the air channel must be protected in an appropriate manner. Inhalers must be approved by the authorities and an open air channel is not accepted. All inhalers have a cap or a similar protection to prevent the ingress of foreign particles. Some inhalers, for example, described in U.S. Pat. No. 6,286,507B1 and U.S. Pat. No. 6,105,574, must have a cap at each end of the air channel, or a sealed bag that is torn up right before inhalation. The cap or the bag is an additional cost which in this context is of certain importance. It also requires an additional operation which the user has to perform.
[0006] The present invention has at least one closed air channel, a single tape that seals the intake holes, vent holes, at least one air channel and at least one recess for the medical powder. Everything is sealed by means of one tape. Foreign particles cannot enter the inhaler and consequently there is no need for protective caps or bags at the same time as the operation of the inhaler will be easier.
[0007] US20130025593 Describes a single dose inhaler wherein a capsule is to be positioned and then punctured prior to inhalation. The design consists of several parts, and the user must perform several steps to be able to take the intended dose. Contamination of the dose is also an obvious risk in this construction.
[0008] WO2012/004485 describes a single dose inhaler where a dose of drug in a blister pack is placed in an injection molded inhaler which is then sealed. The blister is opened by having a strip from the same blister protruding a bit from the inhaler after the inhaler is loaded with one dose. By pulling the strip the dose inside the blister is opened into the inhaler and can then be inhaled. This solution involves an increase in the cost of production compared with the present invention because an injection molded inhaler must be used. In addition, the end user performs more steps than in the use of the present invention before the patient/user can take the dose. This is because the inhaler must be opened, a blister capsule has to be added, the inhaler must be closed, the dose exposed by dragging the protruding part of the blister and then to be brought to the mouth for inhalation.
SUMMARY OF THE INVENTION
[0009] For the purpose of simplicity the following summary of the invention will describe a disposable inhaler with at least two separate recesses for medical powder. The same concept can be used with just one recess which is described in the “Description of embodiments” section, FIGS. 6A to 10B .
[0010] The disposable inhaler consists of, according to the invention, a body with a lower part/shaped body comprising at least one powder chamber in form of recesses. The recesses are also the disposable inhaler air channels and can simultaneously be its powder chambers. The air channels are covered by a foil provided with at least one hole. The holes allow air to pass through the air channels and the medical powder is emptied when the user inhales. The first series of holes thus represents the inlet holes and a second series of holes are the outlet holes. The foil can preferably be transparent. The powder in the air channels hence becomes visible to the user. After inhalation, the user can visually inspect that all the powder has been used. The foil is covered by a sealing tape. The tape is equipped with adhesive or warm formed material in the area between the holes and around them. One of the ends of the tape is devoid of adhesive material. The users can, with their fingers grasp this part of the tape and pull it off in its entirety thus freeing the inlet and outlet holes from their in-closure. The users should keep the one-time inhaler substantially horizontally when the tape is pulled away so that the powder in the powder chambers does not run the risk of being spilled out. The inhalers' predominantly horizontal position should also be used when inhaling. An instruction for the handling of the one-time-inhaler is appended or indicated on the inhaler. The user inserts the inhalers' allotted end in his mouth, takes a deep breath through the inhaler and inhalation is thus completed after which the exhausted inhaler can be disposed.
[0011] The purpose of the invention is to provide an as cheap disposable inhaler, as possible, which also has at least one powder chamber. The use of two or more powder chambers is necessary since sometimes the active ingredients to be used might react with each other if mixed in one chamber and hence loses the medical effect for the patient i.e. the ingredients may only be mixed with each other when in the body of the patient i.e. at inhalation in this case. The innovative inhaler is preferably constructed as a blister, a technique which is common for packing various products, toys, etc. It is also common that medical tablets are packaged in blisters. A blister is a thermoformed transparent or molded part, a lower part, which, for example, forms the space for tablets. The upper part is mostly quite flat and generally has a descriptive text printed on the surface. There are blisters where both the lower-and upper parts are thermoformed, however, that means that the cost increases. The process of pressing the text is complicated and more costly. The technology to produce blister is proven since decades, the cost is very low in this context. Blisters with a thermoformed transparent or molded underside and a flat top dominate the packaging market for objects under 20 cm in size. The large industrial base with gigantic volumes and competition between many vendors with very trimmed production processes, provide very low costs. Another purpose of the invention is that it is designed in such a way that the user can conveniently store a number of disposable inhalers in their purse or pocket. A disposable inhaler in the form of a blister might for example have a width 18 mm and a length of 75 mm (when two separate chambers are used per inhaler). It is usual for blisters to be attached to each other and being able to be torn apart in a perforation. Similarly, the disposable inhalers under the invention can be put together in a map of e.g. three one-time-inhalers with an overall dimension 54×75 mm (again if two separate chambers are used per inhaler). The user can tear off one inhaler at a time. The three disposable inhalers may, with a suggested dimension of 60×75 mm, comfortably be stored, for example in a breast pocket. The thickness is only 4-5 mm which is an advantage in terms of comfort. Length and width are about the credit-card size, also a comfort factor for the customers.
[0012] Another purpose of the invention is that the handling of the disposable inhaler should be simple and user-friendly. When the user has pulled off the tape the powder in the powder chambers can be made visible, given that the foil is transparent. The powder is usually of a light color or white and preferably, the lower part of the inhaler can be designed, in part, with a dark color to create contrast. After inhalation, the user can visually check that the powder has been consumed and that it therefore followed with the inhaled-airflow. Hence, the user can visually see that the inhalation of all of the powder has been successful. The construction also entails that the user does not need to open a protective bag around the disposable inhaler. Other designs have an open air channel which could cause contamination from the handbag or pocket interior into the air channel and by inhalation, down in the lungs. This is medically unacceptable; a protective bag must protect the air channel from contamination. A protective bag is an additional cost and brings additional steps that the user must carry out. The inventive disposable inhaler is its own protective bag. The tape seals the air channels off at both ends, no contamination can occur and no foreign particles can get into the same. After the doses are inhaled the inhaler is discarded.
[0013] A unique feature is hence achieved through letting the inhaler have at least two separate powder chambers whose content is inhaled simultaneously.
[0014] Yet another unique feature is to let the inlet and outlet holes for the air that will flow through the inhaler and the air channels, which also constitutes the powder chambers and contains preloaded dose(s) of powder, be sealed by the same tape. Thus, when the tape is removed, all the features of the disposable inhaler are made accessible; the inlet and outlet holes and the air channels containing the powder. Since the freeing of air channels are performed in this unique way the number of parts are reduced to a minimum while maintaining safety and good usability. The design eliminates the risk of contamination of the air channels and thus the disposable inhaler does not need a protective bag or similar around it, thereby reducing costs while maintaining a simple way of using the disposable inhaler.
[0015] A further advantage is the upward oriented outlet holes. The user inserts the inhaler until it reaches or is near the tongue. At this position, the outlet holes are correctly positioned to make the air flowing from the outlet holes will miss the tongue and instead pass into the space that exists between the tongue and the palate. The airflow direction out of the outlet holes are affected, among other things, by the placement of the holes, upwardly, combined with that the air hits a canted end walls. But through the momentum of the airflow, the airstream is essentially directed horizontally and streams into the oral cavity. The exact angle from the outlet holes is of less significance. The crucial part is that the air, when it comes out of the inhaler nozzle, does not hit the tongue directly. The upward outlet holes then allows the initial airstream, to not hit the tongue which happens to inhalers having an outlet directed straight backwards and into the user's mouth. The air channel formed by the tongue and palate in the mouth is essentially targeted about 45 degrees upward in its first part, which is about 20 mm long. The airflow speed is at its greatest when it leaves the inhaler nozzle. The nozzles' narrow section provides high air velocity since, the many times larger cross-section in the oral cavity, reduces the speed. For inhalers with straight outlet nozzles, the tongue meets the air flow when the speed is at its greatest. By inhalation of medicinal powder, which has a much higher density than the air, the powder will, because of its mass inertia, partially continue straight ahead and get caught on the mucous membrane. This happens with inhalers that have an outlet directed straight backwards and into the user's mouth. The powder that gets stuck in the oral cavity follows the saliva down to the stomach. The therapeutic effect is thereby lost for the percentage of the powder that follows the saliva down into the stomach. The present invention directs the air approximately 45 degrees upward. Hence the upward angled outlet holes reduce the amount of powder that sticks to the tongue. Two of the patents mentioned in the chapter “technical background” display other ways of addressing this problem. For example, you can increase the amount of powder. The driving force to avoid spills onto the tongue is that the medical powder is expensive; if you can reduce the amount of powder the product becomes cheaper.
[0016] An alternative construction would be for the outlet holes to be punched or cut in the shape of a semi-circle and form flaps that affects the direction of the airflow. When inhalation is ongoing the air stream forces the flaps upward and the foils balanced combination of thickness and stiffness can be chosen so that it affects the airflow angle upward within normal inhalation speeds. The flaps will allow for a more accurate directed air stream to a 30 to 60 degree angle, preferably 45 degrees, that is, in a direction that is consistent with the gap formed between the tongue and palate.
[0017] Another optional construction is to arrange a flap having two or more parts at the exit hole i.e. one first part that extends out over approximately half of the hole from the side of the hole that is closest to the intake hole and another second part that extends out over the exit hole from the opposite side of said hole and hence meets the other flap about half way over the hole. In this scenario the second flap part will, when inhalation is ongoing be forced to flap upwards by the air stream. The foils balanced combination of thickness and stiffness can be chosen so that it affects the airflow angle, within normal inhalation speeds, to an even more upward angle then given with just one flap part at the exit hole. Various other ways of designing said flap can be made. The flap can have its fastening point at the far end of the exit hole i.e. closest to the inside of the mouth. The flap over the exit hole can be punched out as an X or similar. Another optional construction is that a flap is arranged at the inlet hole. The purpose of this flap is to prevent powder from falling out if the user is incorrectly positioning the disposable inhaler, for example vertically or upside-down. The flap forces the powder to remain left in the single dos disposable inhalers air channel. When the user inhales a negative pressure is created in the air channel, the flap at the inlet hole is folded down and an opening for the airstream is created.
[0018] Another option is to arrange a text on the top of the inhaler, which instructs the user to “place the index finger at a specific point for inhalation”. This will then help the user to insert the inhaler in the oral cavity to a correct and favorable position. When the index finger touches the upper lip the outlet holes are in a suitable position to let the escaping air from the outlet holes to pass into the space that exists between the tongue and palate in an optimal manner.
[0019] Yet another option is to arrange an elevation or evisceration on the top of the inhaler and instruct the user to position the index finger at the said elevation/evisceration. The elevation/evisceration may for example consist of two parts that are so arranged that there is room for the width of an index finger between them. When the index finger touches the upper lip the outlet holes are in a suitable position to let the escaping air from the outlet holes to pass into the space that exists between the tongue and palate in an optimal manner.
[0020] Yet another option is to arrange an elevation/evisceration on top or on the underside of the inhaler and instruct the user to put the teeth in the said elevation/evisceration. The teeth have the advantage that they are arranged in a precise location in relation to the space that exists between the tongue and palate. The elevation/evisceration may for example consist of two upward pointing elevations on top of the inhaler with some space between them to fit against the maxillary incisors. When the front teeth are located between the two humps the outlet holes are precisely positioned to let the escaping air from the outlet holes to pass into the space that exists between the tongue and palate in an optimal manner.
[0021] Of course it is also possible to arrange only one elevation as indication on where the upper teeth should be placed. The inhaler is then passed into the mouth so far that elevation reaches the upper teeth, after which the user can inhale the doses of powder.
[0022] Alternatively, the elevations, or only one elevation can be arranged on the under-side of the inhaler to indicate where in the under teeth must be placed at inhalation.
[0023] It is also possible that instead of elevations arrange eviscerations in the inhaler to indicate where the index finger, thumb, upper teeth or the lower teeth shall be positioned at inhalation.
[0024] Another alternative form is that the covering foil is provided with an inlet hole and an outlet hole per air channel instead of a larger hole covering both air channels in the two channel variant of the invention.
[0025] The medical powder must be protected against moisture. Moisture-absorption makes the powder stick together in clumps that can cause coughing. The powder can get stuck together so that inhalation is made difficult or impossible. The present invention is built like a blister. Several multidose-inhalers are based on the principle that a blister in the form of a band with for example 60 doses are fed one on one to an opening mechanism rips or punctures the depressions containing the powder.
[0026] For moisture protection for the inventive inhaler is a thermoformed transparent mold-body in a plastic wrap, with a 0.3 mm thick aluminum layer, 6-8 microns, or a pressed frame completely in aluminum with a material thickness approximately 0.15 mm. The mold-body can alternatively be manufactured as a solid unit where the air channels are formed to a cavity, for example by means of mechanical machining, injection molding, cold pressing, hot pressing or die-casting. In the area of the cavity the mold-body is covered with a foil with inlet and outlet holes. The material is selected preferably for low permeation; COC (Cyclic Olefin Copolymer) is a material with good performance. The foil is covered by an adhesive tape in the area of the air channel. The tape consists of a plastic wrap with an aluminum layer, 6-8 microns. Aluminum is the main moisture barrier in construction. The three parts are joined together with heat. Binders are PVC and the joints should not be thicker than 30 microns, the seal length should be at least 3 mm. the tape may be self-adhesive as an alternative to heat-adhesive. With these conditions the regulatory requirements for moisture protection are met. It is an advantage that the innovative disposable inhaler can be constructed in this manner since the efficiency of the moisture protection is always a difficult issue for inhalers. The said construction is a well proven technology for moisture protection which reduces development and testing costs. In the present invention the mold-body is placed on the underside of the inhaler but it is of course also possible to organize form the body on top of the inhaler.
[0027] The described disposable inhaler is considerably cheaper, smaller and thinner than the famous disposable inhalers including the one variant of the invention that has at one powder chamber. The present invention consists of cheaper parts than the known disposable inhalers and accomplishes this with no loss of safety combined with an easy operation as well as displaying a variant that can store at least two different medical powders separately until inhalation.
[0028] The above mentioned and more purposes and benefits are achieved by the invention using a disposable inhaler in accordance with, in the characteristic part of the patent claim 1 specified features.
BRIEF LIST OF THE DRAWINGS
[0029] The invention is described in more detail below in a few preferred design examples with use of the attached drawings.
[0030] FIG. 1 displays an inventive disposable inhaler in an exploded view.
[0031] FIG. 2A-2B displays an inventive disposable inhaler, and how a tape is withdrawn and how that exposes the inlet and outlet holes.
[0032] FIG. 3A-3B displays an inventive disposable inhaler and how the airstream transports the substance in powder form via the air channel.
[0033] FIG. 4 displays an inventive disposable inhaler and that the inlet holes are shaped as flaps.
[0034] FIG. 5A displays an inventive disposable inhaler and two elevations for positioning of the index finger at inhalation.
[0035] FIG. 5B displays an inventive disposable inhaler and two elevations for the placing of the incisors at inhalation.
[0036] FIG. 6A, 6B and 6C displays an inventive single dose disposable inhaler in an exploded view.
[0037] FIG. 7A and 7B displays an inventive single dose disposable inhaler, how a tape is withdrawn and how that exposes the inlet and outlet holes.
[0038] FIG. 8A and 8B displays an inventive single dose disposable inhaler and how the airstream transports the substance in powder form via the air channel.
[0039] FIG. 9 displays an inventive single dose disposable inhaler and that the inlet hole is shaped as a flap.
[0040] FIG. 10A displays an inventive single dose disposable inhaler and two elevations for positioning of the index finger at inhalation.
[0041] FIG. 10B displays an inventive single dose disposable inhaler and two elevations for the placing of the incisors at inhalation.
[0042] FIG. 11 illustrates a disposable inhaler with two flap parts at the exit hole helping the airflow and hence the powder to exit the disposable inhaler into a steeper angle than given with only one flap.
[0043] FIG. 12A, 12B and 12C illustrates different ways of designing the flap of the exit hole to help increasing the angle of the airstream.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0044] FIG. 1 Displays in an exploded view an inventive disposable inhaler consisting of a mold-body 1 made of a rigid or semi-rigid material fitted with recesses which forms a first and second air channel 2 a,b containing, for example, a preloaded amount of medical substance in powder form. The mold-body 1 is covered by a foil 3 which can be transparent. The foil 3 is equipped with inlet holes 4 a,b and outlet holes 5 a,b at each end of the air channels 2 a ,and b . A tape 6 seals the inlet and outlet holes as well as it seals the air channels 2 a,b . One end of the tape 7 has no adhesive agent, in order to facilitate the user to take hold of the tape when it shall be removed.
[0045] The mold-body can alternatively be manufactured as a solid unit where the air channels are cavities, for example by injection molding, cold pressing, hot pressing or die-casting.
[0046] FIG. 2A and 2B displays how the tape 6 can be removed and how the inlet holes 4 a,b and outlet holes 5 a,b are exposed when the tape is fully removed. The air channels 2 a,b are protected from foreign particles as long as the tape has not been removed. The air channels are also moisture protected until the tape is removed.
[0047] FIG. 3A is a cross section from the side of the air channel 2 a and displays how the air stream passes through the inlet hole 4 a, through the recess that, at inhalation, forms the air channel 2 a and out through the outlet hole 5 a. The air stream is driven by the under-pressure formed by the user's inhalation. The direction of the airflow out of the outlet hole 5 a is a combination placement of the hole and its direction upwards, with a canted end-wall 8 in the air channel 2 a and combined with the momentum/current direction of the air which is directed horizontally inward toward the oral cavity.
[0048] FIG. 3B displays how the outlet holes 5 a,b form flaps 9 a,b which affects the airflow direction. When the inhalation is started the air flow forces the flaps to open upwards and the property of the foil, a combination of thickness and stiffness, is selected so that upward-angle of the airflows are affected by normal flows of inhalation. The flaps will allow a more accurate direction of the airstreams preferably in 30 to 60 degrees, especially about 45 degrees, a direction that is consistent with the initial gap formed between the tongue and palate of a user.
[0049] FIG. 4 displays an inventive disposable inhaler and that the inlet holes 4 a,b is designed as flaps 10 a,b in order to prevent the powder from falling out if the user positions the disposable inhaler incorrectly.
[0050] When the user inhales an under-pressure is created at the inlet holes 10 a,b and the flaps folds downwards, an opening for the airstreams are created.
[0051] FIG. 5A displays an inventive disposable inhaler with two elevations 11 a,b on the top of the inhaler. The elevations 11 a,b indicates where an index finger should be placed at inhalation. The inhaler is then inserted into the mouth with the index finger positioned between the two elevations 11 a,b . When the index finger 12 touches the upper lip 13 the outlet holes 5 a,b are optimally positioned to let the escaping air from the outlet holes 5 a,b to pass into the space that exists between the tongue 14 and palate 15 .
[0052] Of course it is also possible to arrange one or several elevations on the underside of the inhaler. The elevations (not shown) indicate, for example, where a thumb is to be positioned at inhalation. The thumb is naturally placed on the underside of the inhaler in line with the index finger on the top. The inhaler is then inserted into the mouth until the thumb reaches the lower lip, after which the user can inhale the powder doses.
[0053] FIG. 5B displays an inventive disposable inhaler and that two elevations 16 a,b indicates where the front teeth 17 , shall be positioned at inhalation. The inhaler is inserted in the mouth until the front teeth are positioned between the two elevations. In this position, the discharge holes 5 a,b are optimally positioned to let the escaping air from the outlet holes to pass into the space that exists between the tongue 14 and palate 15 .
[0054] Of course it is also possible to arrange only one elevation 11 a. The inhaler is then inserted into the mouth so that the elevation 11 a reaches the front teeth, after which the user can inhale the powder doses.
[0055] It is also possible to instead of elevations arrange one or several eviscerations/recesses in the inhaler to indicate where the index finger, thumb, incisors or the teeth in the lower jaw shall be placed on the inhaler at inhalation (not shown).
[0056] As described earlier another embodiment can be a single dose disposable inhaler i.e. the same concept as described in FIGS. 1-5 but with only one recess instead of two (or more).
[0057] FIG. 6 A- 6 C displays in an exploded view of an inventive single dose disposable inhaler consisting of a mold-body 18 made of a rigid or semi-rigid material fitted with a recess which forms an air channel 19 containing, for example, a preloaded amount of medical substance in powder form. The mold-body 1 is covered by a foil 20 which can be transparent. The foil 20 is equipped with an inlet 21 and an outlet hole 22 at each end of the air channel 19 . A tape 23 seals the inlet and outlet holes as well as it seals air channel 19 . One end of the tape 24 has no adhesive agent, in order to facilitate the user to take hold of the tape when it shall be removed.
[0058] The mold-body can alternatively be manufactured as a solid unit where the air channel is a cavity, for example by injection molding, cold pressing, hot pressing or die-casting.
[0059] FIG. 7A and 7B displays how the tape 23 is initially removed and how the inlet 21 and outlet 22 holes are exposed when the tape is fully removed. The air channel 19 is protected from foreign particles as long as the tape has not been removed. The air channel is also moisture protected until the tape is removed.
[0060] FIG. 8A is a cross section from the side of the air channel and displays how the air stream passes through the inlet hole 21 , through the recess that, at inhalation, forms the air channel 19 and out through the outlet hole 5 . The air stream is driven by the under-pressure formed by the user's inhalation. The direction of the airflow out of the outlet hole is a combination placement of the hole and its direction upwards, with a canted end-wall 25 in the air channel and combined with the momentum/current direction of the air which is directed horizontally inward toward the oral cavity.
[0061] FIG. 8B displays how the outlet hole 22 forms flap 26 which affects the airflow direction. When the inhalation is started the air flow forces the flap to open upwards and the property of the foil, a combination of thickness and stiffness, is selected so that upward-angle of the airflow is affected by normal flows of inhalation. The flap will allow a more accurate direction of the airstream preferably in 30 to 60 degrees, especially about 45 degrees, a direction that is consistent with the initial gap formed between the tongue and palate of a user.
[0062] FIG. 9 displays an inventive single dose disposable inhaler and that the inlet hole 21 is designed as a flap 27 in order to prevent the powder from falling out if the user positions single dose disposable inhaler incorrectly. When the user inhales an under-pressure is created at the inlet hole and the flap folds downwards, an opening for the airstream is created.
[0063] FIG. 10A displays an inventive single dos disposable inhaler with two elevations 28 on the top of the inhaler. The elevations indicate where an index finger should be placed at inhalation. The inhaler is inserted with the index finger positioned between the two elevations. When the index finger 29 touches the upper lip 30 the outlet hole 22 is optimally positioned to let the escaping air from the outlet hole 22 to pass into the space that exists between the tongue 31 and palate 32 .
[0064] Of course it is also possible to arrange an elevation on the underside of the inhaler. The elevation indicates, for example, where a thumb is to be positioned at inhalation. The thumb is naturally placed at the elevation on the underside of the inhaler in line with the index finger on the top. The inhaler is then inserted into the mouth until the thumb reaches the lower lip, after which the user can inhale the powder dose.
[0065] FIG. 108 displays an inventive single dos disposable inhaler and two elevations 28 that indicates where the front teeth 16 , shall be positioned at inhalation. The inhaler is inserted in the mouth until the front teeth are positioned between the two elevations. In this position, the discharge hole 5 is optimally positioned to let the escaping air from the outlet hole 5 to pass into the space that exists between the tongue 31 and palate 32 .
[0066] Of course it is also possible to arrange only one elevation 28 . The inhaler is then inserted into the mouth so that the elevation 28 reaches the front teeth, after which the user can inhale the dose of powder.
[0067] Alternatively, the elevations, or only one elevation be arranged on the underside of the inhaler to indicate where in the teeth must be placed at inhalation.
[0068] It is also possible to instead of elevations arrange eviscerations in the inhaler to indicate where the index finger, thumb, incisors or the teeth in the lower jaw shall be placed on the inhaler at inhalation.
[0069] FIG. 11 is a cross section from the side of the air channel 25 and illustrates how the air stream passes through the inlet hole 21 , through the recess that, at inhalation, forms the air channel 19 and out through the outlet hole 22 . The air stream is driven by the under-pressure formed by the user's inhalation. The direction of the airflow out of the outlet hole 22 is a combination placement of the hole and its direction upwards, with a canted end-wall 25 in end of the air channel 19 and combined with the momentum/current direction of the air which is directed horizontally inward toward the oral cavity. The outlet hole is here covered by a split flap 35 a,b . The second flap part 35 b seen in this figure will further help to angle the airstream upwards.
[0070] FIG. 12A to C illustrates different possible ways to design or punch the flap 35 and locate it in different positions at the outlet hole. The direction of the airflow is from left to right in the FIGS. 11 and 12A to C.
[0071] The flap 35 at the outlet hole can advantageously be designed as a split flap as illustrated in FIGS. 11, 12A and C, The flap 35 and 37 consists here of two or more parts which all will fold upwards upon inhalation but where at least one part 35 b, 37 b is located at the far edge of the outlet hole 5 a,b , 22 , downstream the outlet hole 5 a,b , 22 seen in the air flow direction and again arranged to influence the air stream to flow substantially straight upwards from the air channel 19 and into the user's mouth.
[0072] The flap parts 35 a,b may be of similar size as illustrated in FIG. 12A , i.e. the division line 38 can be located in the middle of the flap 35 but the division line can of course also be located closer to the front or distal edge of the outlet hole 5 a,b , 22 , seen in the direction of the air flow so that one flap part 35 a,b is larger than the other, in order to influence the air to flow in a desired manner, i.e. straight upwards or askew up from the air channel 19 and the outlet hole 5 a,b , 22 .
[0073] FIG. 12B shows how the flap 35 so-called hinge 39 or bend line, about which the flap 35 is folded up, is located on the opposite side, i.e. downstream of the outlet hole 5 a,b , 22 , i.e. to the right of the air channel 19 thereby forcing the flap 35 b to bend upwards by the air stream. Then the air flow even more is affected to flow upward at a steeper angle at inhalation whereby the quantities of medical powder that risk to meet and adhere to the tongues front/outer portion substantially is reduced.
[0074] The flaps 35 , 36 and 37 and their parts may have different shapes as shown e.g. in FIG. 12C where the flap 37 consists of four parts 37 a - d cut or punched out in a shape of a cross.
[0075] The material of the flaps 35 , 36 and 37 or their flap parts are selected or designed to have such rigidity that it/they fold up enough but no more in order to control the air flow substantially upwards or in a steep askew desired direction.
[0076] These optional designs of the flap described in FIGS. 11 and 12A to C, covering the outlet hole 5 a,b , 22 , can be made regardless of the amount of outlet holes 5 a,b , 22 i.e. thus also it could be used in the earlier described double dose (or more) disposable inhaler.
[0077] The description above is primarily intended to facilitate the understanding of the invention, and is of course not limited to the presented embodiments, also other embodiments of the invention are possible and conceivable within the framework of the innovative thought and the subsequent claims and scope of protection. Hence the disposable inhaler can be fitted, as described earlier, with one or more air channels with associated inlet and outlet holes.
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The invention relates to a disposable inhaler intended for single use and for substances in powder form which comprises a preferably elongated shape body arranged to, at least partially be inserted in the user's mouth, including one or more air channels arranged in the shape of the body, that a foil is arranged with inlet holes and an outlet holes in connection with the air channels, that a substance in powder form is placed in the air channels, that the foil is arranged to, in the inhaler storage mode, cover the inlet and outlet holes and thus prevent the substance in powder form to fall out of the inhaler air channels, and that tape is removable to be able to use the inhaler and when it is removed exposes the inhaler in-and outlet holes and thus facilitates that the substance in powder form, which is placed in the air channel, can leave the air channel using the airflow that occurs when the user inhales, through the inhaler. The invention is achieved through that the air channel is arranged with a canted end-wall near the outlet hole, the canted end-wall is helping to angle the airstream out of the air channel obliquely upward at its outlet.
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CROSS-REFERENCE TO RELATED APPLICATION
This is a continuation-in-part of application Ser. No. 330,260, filed Dec. 14, 1981, now U.S. Pat. No. 4,502,193.
BACKGROUND OF THE INVENTION
This application is directed toward fasteners and in particular those that are useful for selectively locking two objects to each other in a predetermined relationship.
For numerous reasons it is often useful to provide a mechanism which is able to secure or lock two objects or structures to each other in a fixed relationship and provide for a defined space between the objects. This is often desirable in electrical applications where spacing is critical in order to prevent interference between the electrical components mounted on adjacent circuit boards or between the electrical components on a circuit board and the chassis.
In the case of circuit boards, it is oftentimes necessary to mount a circuit board to a chassis. In other instances, it may be necessary to mount a series of boards in a stacked relationship. When mounting a board to a chassis the board is placed onto mounts or supports which have means for affixing the board immovably to the chassis.
Various mounts or supports in the past have been used to affix a circuit board to a chassis where a predetermined distance is intended to exist between the circuit board and the chassis. For example, a steel screw may be placed into an aperture of a circuit board with a non-conductive washer disposed between the head of the screw and the circuit board. On the other side of the circuit board from the washer a non-conductive hollow spacer is fitted over the threads of the screw. The threaded end of the screw passes through an aperture, another circuit board or a chassis and receives a second non-conductive washer and a nut. The screw and nut assembly is then tightened to secure the circuit board to the chassis or second circuit board. This screw and nut assembly is advantageous because it provides for a good mechanical fit and will not ordinarily vibrate loose. In addition, because the washers and spacer each extend a full 360° about the screw, good support is provided on both sides of the circuit board or both sides of the chassis. However, there are several disadvantages associated with this type of assembly, which requires several separate pieces and multi-step installation, including high material and stocking costs and high labor cost.
Alternatively, single-piece supports exist such as those marketed by FASTEX, a division of Illinois Tool Works, Inc. These supports have one end which snaps into an aperture of a circuit board and another end which is received by an aperture in the chassis. These supports have pronged or barbed ends or are barbed at one end and have a canoe clip at the other end. These supports are advantageous because of lower product and labor installation costs. However, they do not provide for a positive mechanical fit between the ends of the support and the circuit board or chassis and as a result they can vibrate loose of the circuit board or chassis. Furthermore, the prongs or barbs offer only limited contact between the support and the circuit board which can be insufficient when certain pressure is applied to the circuit board. Lastly, these type supports are less suitable for automated installation.
It is also known that a NYLATCH fastener may be used which has an extended length grommet. The grommet is fitted through an aperture in the circuit board and a plunger is partially actuated to connect the fastener to the circuit board by partially expanding the grommet. A plurality of washers may then be fitted over a portion of the grommet that extends beyond the underside surface of the circuit card. The grommet is then placed through an aperture in a chassis and is further expanded by the plunger to secure the grommet to the chassis and thereby fasten the circuit board and chassis together with the washers acting as a spacer to maintain the circuit board and chassis a predetermined distance apart. The use of a NYLATCH fastener is advantageous because it provides for a positive mechanical fit or lock between the fastener and the circuit board or chassis. However, the NYLATCH fastener is generally secured to the circuit board before the electrical components are added to the circuit board to prevent damage thereto during installation of the fastener because of the force required to activate the plunger. Thus, the fasteners must travel with the circuit boards during production and shipping of the circuit boards which may be undesirable because, in part, larger shipping containers are required to accommodate the extending portions of the fasteners. Furthermore, the addition of the washers slows installation and results in increased product and inventory costs.
SUMMARY OF THE INVENTION
The present invention is intended to satisfy an existing need for a fastener which overcomes the problems and disadvantages associated with the various prior art fasteners and supports discussed above. Such a fastener must be capable of securing or locking a first object or structure, such as a chassis or circuit board, to a second object or structure, such as another circuit board, and establishing and maintaining a predetermined distance between the two objects or structures. In the case of electrical applications, it is important that the fastener be easily opened to permit removal of a previously secured circuit board from the chassis or a first circuit board to which it is mounted, yet designed so that the fastener remains affixed to the chassis or the first circuit board for further use. The fastener of the present invention satisfies each of these requirements.
The fastener of the present invention has a fastener body with a captive plunger and includes a base member or spacer and locking elements. On one side of the spacer and attached thereto is a first locking element, which is adapted to engage a first structure, such as in the case of electrical applications, a chassis or a circuit board.
Attached to the other side of the spacer is a second locking element, which is adapted to engage a second structure, as for example a circuit board, and maintain the second structure in a fixed relationship with respect to the first structure.
The plunger is sized so that a portion of it will fit through both locking elements. The first locking element of the fastener is adapted to be inserted into an aperture in the first structure. The head of the plunger and the second locking element are adapted to extend through an aperture in the second structure. When the plunger is actuated, it will cause the first locking element to be fixably secured to the first structure. The plunger is adapted to also cause the second locking element to be fixably secured to the second structure. The spacer acts so that a defined distance exists between the first and second structures. Upon a reversal of the plunger action, the plunger will cause the release of the second structure from the second locking element thereby permitting removal of the second structure from the fastener. However, the plunger remains captive with respect to the fastener body and the fastener remains captive with respect to the first structure.
In the preferred embodiment of the invention, actuation of the plunger is a two step procedure. In the first step the plunger is pushed fully into the fastener body thereby expanding the first locking element to affix the fastener to the first structure. The second step involves turning the plunger through a controlled angle thereby expanding the second locking element to affix the fastener to the second structure.
In another form of the invention, actuation of the plunger is a single step procedure. When the plunger is pushed fully into the fastener body both the first and second locking elements are expanded to thereby rigidly affix the fastener to both the first and second structures.
In either form of the invention, prior to full actuation of the plunger, alignment of the first and second structures is facilitated by a free-float effect where at least one of the structures is allowed to move radially with respect to the locking element before the structure is affixed to the fastener. When the plunger has been fully actuated relative movement between the fastener and the first and second structures is substantially eliminated which thereby prevents wear or damage due to vibration.
The present invention includes several features and advantages not present in the prior art fasteners or supports. For example, the fastener of the present invention provides for a positive mechanical fit between the fastener and the object or structure to eliminate problems due to vibration. The fastener of the present invention is molded in a one-piece configuration. However, it is stored and shipped as a one-piece item consisting of two individual preassembled pieces to minimize inventory, shipping and installation. These and other features and advantages of the present invention will become more apparent from a review of the detailed description of the invention and the accompanying drawings.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view illustrating a preferred embodiment of the present invention in an unlocked position.
FIG. 2 is a side view illustrating the FIG. 1 embodiment of the present invention in a partially locked position.
FIG. 3 is a side view illustrating the FIG. 1 embodiment of the present invention in a fully locked position.
FIG. 4 is a side view illustrating the FIG. 1 embodiment of the present invention in an as molded configuration.
FIG. 5 is a side view turned 90° from FIG. 4 illustrating the FIG. 1 embodiment of the present invention in a molded configuration.
FIG. 6 is a cross-section taken substantially along section line 6--6 of FIG. 5.
FIG. 7 is a cross-section taken substantially along section line 7--7 of FIG. 5.
FIG. 8 is a cross-section taken substantially along section line 8--8 of FIG. 5.
FIG. 9 is a cross-section taken substantially along section line 9--9 of FIG. 5.
FIG. 10 is a cross-section taken substantially along section line 10--10 of FIG. 5.
FIG. 11 is a cross-section taken substantially along section line 11--11 of FIG. 5.
FIG. 12 is a side view illustrating a second embodiment of the present invention in a fully locked position.
FIG. 13 is a cross-section taken substantially along section line 13--13 of FIG. 12.
FIG. 14 is a cross-section taken substantially along section line 14--14 of FIG. 12.
FIG. 15 is a cross-section taken substantially along section line 15--15 of FIG. 12.
FIG. 16 is a side view illustrating another embodiment of the present invention in an as molded configuration.
FIG. 17 is a side view illustrating the FIG. 16 embodiment of the present invention in a fully locked configuration.
FIG. 18 is a side view illustrating still another embodiment of the present invention in an unlocked position.
FIG. 19 is a side view illustrating the FIG. 18 embodiment of the present invention in a fully locked position.
FIG. 20 is a side view illustrating the FIG. 18 embodiment of the present invention in an as molded configuration.
FIG. 21 is a bottom view taken substantially along view line 21--21 of FIG. 20.
FIG. 22 is a cross-section taken substantially along section line 22--22 of FIG. 20.
FIG. 23 is a cross-section taken substantially along section line 23--23 of FIG. 20.
FIG. 24 is a cross-section taken substantially along section line 24--24 of FIG. 20.
FIG. 25 is a cross-section taken substantially along section line 25--25 of FIG. 20.
FIG. 26 is a cross-section taken substantially along section line 26--26 of FIG. 20.
FIG. 27 is a cross-section taken substantially along section line 27--27 of FIG. 20.
FIG. 28 is a cross-section taken substantially along section line 28--28 of FIG. 20.
FIG. 29 is a cross-section taken substantially along section line 29--29 of FIG. 20.
FIG. 30 is a cross-section taken substantially along section line 30--30 of FIG. 20.
FIG. 31 is a side view illustrating the first locking element of the FIG. 18 embodiment of the fastener of the present invention.
FIG. 32 is a cross-section taken substantially along section line 32--32 of FIG. 31.
FIG. 33 is a cross-section taken substantially along section line 33--33 of FIG. 20.
FIG. 34 is a side view illustrating still another embodiment of the present invention in a fully locked position.
FIG. 35 is a side view illustrating the FIG. 34 embodiment of the present invention in an unlocked position.
FIG. 36 is a bottom view taken substantially along view line 36--36 of FIG. 34 illustrating the first locking element of the FIG. 34 embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A preferred embodiment of the present invention is shown in FIGS. 1 through 11, and comprises a fastener, generally designated as 10, which is preferably made of a non-conductive material, such as plastic. Briefly, the fastener 10, as shown in FIG. 1, is operative to affix a structure, such as a circuit board 12 to another structure, such as chassis 14, wherein a predetermined distance A is intended to exist between the board 12 and the chassis 14.
Circuit boards typically have a plurality of spaced apertures, such as aperture 16, extending entirely through the body of the circuit board 12. Similarly, a chassis, such as the type used in computers or other electronic equipment wherein circuit boards are to be mounted, also includes a plurality of spaced apertures, such as aperture 18, defined therein. The apertures 16 and apertures 18 are uniformly spaced to permit their alignment when the circuit board 12 is to be mounted to the chassis 14.
A chassis is normally constructed of metal, which may act as an electrical conductor. Circuit boards are normally made of a non-conductive material, however, a plurality of raised logic lines are present on the boards and contain conductive material which connect the various electronic components mounted on the boards. These boards normally have a plurality of leads (not shown) at one end thereof which are aligned with leads (not shown) integral within the mounts of the chassis. When the boards are properly mounted within the chassis, the leads of both are aligned and in contact for electrical connection.
As shown in FIG. 1, the fastener 10 includes a fastener body, generally designated as 19. An integral part of the fastener body 19 is a generally cylindrical base member or spacer, generally designated as 20. For molding purposes, the spacer 20 includes a plurality of voids 21 which also provide for material reduction. The spacer 20 by reason of its circular surfaces 20a and 20b provides 360° of support about the aperture of the circuit board or the chassis. Disposed substantially centrally within the fastener body 19 is a channel 22, which extends entirely through the fastener body 19. A plurality of webs 23 extend between opposite portions of the spacer 20. The webs 23 add structural integrity to the fastener 20 and guide the plunger as will be discussed hereinafter.
Extending from one end of the spacer 20 and integral therewith is a first locking element, generally designated as 30, which in this preferred embodiment has two oppositely positioned captivating tabs 32, which are pivotably attached to the spacer 20 at the hinge portions 34. These captivating tabs 32 have chamfered portions 35 which facilitate placement of the first locking element 30 into and through the aperture 18. Each tab 32 is provided with an internal ridge 36 which extends into the channel 22 to captivate a plunger as will be discussed hereinafter. Each tab 32 is also provided with an angled inner cam surface 38 which causes the spreading of the tabs 32 into the locked position when the plunger is fully extended into the fastener body 19. At the lowermost portion of each angled inner surface 38 a protrusion 39 is provided to premanently captivate the plunger as shown in FIG. 2, and discussed in more detail later.
In the position shown in FIG. 1, the fastener 10 is capable of rotational movement with respect to the chassis 14. However, once the plunger has been fully extended into the fastener body 19, the tabs 32 are operative to provide a positive interface or mechanical lock to rigidly affix the fastener 10 to the chassis 14 and restrict any rotational movement of the fastener.
In this preferred embodiment, there are two captivating tabs 32. However, it should be apparent that additional captivating tabs (not shown) of various configurations could also be utilized.
Extending from the other end of the spacer 20 and integral therewith is a second locking element, generally designated as 40. The second locking element 40 has oppositely positioned tabs 42 which are pivotably secured to the spacer 20 at hinge portions 44. Each of the tabs 42 has a chamfered upper surface 46 and a recessed portion 48, as best shown in FIG. 7, on each side of the channel 22. The tabs 42 define an upper portion 49 of the channel 22 and each of the tabs 42 has an aligning piece 50 which extends partially into the upper portion 49 of the channel 22 as illustrated in FIGS. 1 and 8. The aligning pieces 50 are useful to align the plunger within the fastener body 19 and provide additional surface area to affix the circuit board 12 to the fastener 10.
A plunger, generally designated as 60, is designed to fit into the channel 22. The plunger 60 has a head portion 62 which is integral with a downwardly extending first plunger portion 64. A slot 66 is formed in the top of the head portion 62 and the head portion 62 is made hexagonal to permit rotation of the plunger 60 by the use of various tools. Below the head portion 62 and extending outwardly from the first plunger portion 64 are dual projections 68, as shown in FIGS. 1, 6, and 7. The projections 68 are adapted to fit within the recessed portions 48 of the second locking element 40 when the plunger 60 is fully extended into the fastener body 19 and is rotated to expand the second locking element 40.
As shown in FIG. 2, the plunger 60 has a second plunger portion 70 which has a taper 72 formed within its lowermost portion. The taper 72 extends toward a lower head 74 which has a chamfered lower surface 76. The chamfered lower surface 76 is provided to ease movement of the lower head 74 into a position past the internal ridges 36 and the captivating protrusions 39, as shown in FIG. 2 and 3.
As the plunger 60 is pushed fully into the fastener body 19, the lower head 74 will pass over the ridges 36 defined on the inner walls of the tabs 32 and will engage the angled inner surfaces 38 of the tabs 32 to cause outward movement of the tabs 32 to rigidly affix the fastener 10 to the chasis 14. An upper surface 82 of the lower head 74 will fit underneath the protrusions 39 to captivate the plunger 60 at its fully extended position within the fastener body 19.
Rotation of the plunger 60 when it is pushed fully into the fastener will cause the first plunger portion 64 to engage the inner surfaces of the tabs 42 and cause their pivotal movement about the hinge portions 44 to affix a circuit board 12 to the fastener 10. The projections 68 eventually rest along the walls 69, as shown in FIG. 7, provided along the inner surface of each tab 42 to terminate rotation of the plunger 60. Thus, there is a positive rotational stop within the second locking element 40 to prevent over-rotation of the plunger 60.
The design of the fastener is such that it may be molded and thereby produced efficiently and economically in large numbers. In FIG. 4, the fastener 10 of the present invention is shown in the molded configuration before a frangible connection 90 between the plunger 60 and the second locking element 40 has been severed. The frangible connection 90 is illustrated in greater detail in FIG. 5, which illustrates the same molded configuration as FIG. 4 except turned 90°. Thus, in the as molded condition the fastener is a one-piece item.
In FIG. 1, the fastener 10 is shown in a shipped condition prior to actuation of the plunger. In this condition the fastener is a one-piece item consisting of two individual preassembled pieces which minimizes inventory, shipping and installation costs. In this configuration, the tabs 32 are normal to the spacer 20, thus the first locking element 30 may be placed into the aperture 18 of the chassis 14. The chamfered lower portions 35 of the tabs 32 permit easy insertion of the first locking element 30 along a vertical axis into the aperture 18. This is important because a straight-in insertion is desirable if the fastener is to be automatically installed by a machine to the chassis or a circuit board.
In FIG. 2, the fastener 10 is shown in the partially locked position, wherein the first locking element 30 is operative to maintain the fastener 10 affixed to the chassis 14. In this configuration the plunger 60 has been fully extended into the channel 22, such that the lower head 74 is disposed below the protrusions 39. As the lower head 74 moves into the position below the protrusions 39, the tabs 32 will pivot outwardly such that they engage the material of the chassis 14 which forms the aperture 18. Thus, the fastener 10 will be immovably fixed and captivated with respect to the chassis 14. As illustrated in FIG. 2, the lower head 74 is captivated by the protrusions 39 to maintain the plunger 60 within the channel 22 and to secure the first locking element 30 within the aperture 18. Such a connection facilitates subsequent mounting or removal of a circuit board which is received by the second locking element of the fastener.
The aperture 16 in the circuit board 12 has a diameter slightly greater than the effective circumference of the second locking element 40, as defined by the outside surfaces of the tabs 42 when in the normal position. In the normal position the circuit board 12 may be moved axially with respect to the plunger 60 and the second locking element 40 to mount or remove the circuit board 12, as shown in FIG. 2. In addition, because the outer diameter defined by the outside surface of tabs 42 when the tabs 42 are not expanded is less than the diameter of the aperture 16 limited lateral or radial movement of the circuit board with respect to the fastener is available for alignment adjustment.
In FIG. 3, the fastener 10 is shown in the fully locked position wherein the circuit board 12 has been mounted to the chassis 14 with the spacer 20 providing a predetermined distance A between the circuit board 12 and the chassis 14. As indicated previously, there may be a plurality of apertures 16 in the circuit board 12 to permit the affixation of the circuit board 12 to the chassis 14 at numerous locations.
When the circuit board 12 contacts the top of the spacer 20, the plunger 60 may be rotated to cause the first plunger portion 64 to engage the inner surfaces of the tabs 42 to cause their outward pivotal movement to engage the material of the circuit board 12 which forms the aperture 16. At this point, the circuit board 12 will be rigidly affixed to the fastener 10 and thus to the chassis 14. The plunger 60 locks over center to provide for added security by providing a positive locking moment.
The pivotal hinged movement and compression of the tabs 32 and the tabs 42 is such that it provides a variable grip range and thereby allows the fastener 10 to function when there is a variation in the aperture size of the circuit board 12 or chassis 14 or when there is a variation in the thickness of the circuit board 12 or chassis 14.
Since the plunger 60 must be fully extended into the fastener body 19 before the second locking element 40 is operative to engage the circuit board 12, the fastener 10 presents a small profile. In addition, it may be advantageous to rotate the plunger 60 into a locked position instead of pushing it into such a position because this avoids applying a pushing force on the circuit board 12 or chassis 14. Also the two step operation is advantageous because when unlocking the fastener 10 it is easier to overcome the frictional resistance which maintains the plunger 60 in the fully locked position.
To manufacture the present fastener 10, a mold is made which is capable of producing a single integral unit. The as molded configuration of the present invention is shown in FIGS. 4 and 5. As indicated previously, a frangible connection 90 exists between the bottom of the plunger 60 and the top of the second locking element 40. After the frangible connection 90 has been severed, the plunger 60 may be partially inserted into the channel 22 of the fastener body 19 and remain captivated by the fastener body 19. The fastener is then secured to a chassis or circuit board by an initial actuation or first locking step of the plunger whereby the plunger is pushed in the same direction as the axis of the aperture which receives the first locking element. This first step forever secures the first locking element and thus the fastener to the chassis or circuit board.
A second embodiment of the present invention is shown in FIGS. 12-15, and is generally designated at 110. The configuration of the second embodiment is similar to the preferred embodiment, except for the shape of the inner portion of the first locking element, generally designated as 130, and the shape of the lower portion of the plunger, generally designated as 160.
Briefly, the first locking element 130 has two oppositely positioned tabs 132 which are pivotably attached to the spacer 120 at hinge portions 134. Each of the tabs 132 have chamfered lower surfaces 135 to facilitate easier insertion of the first locking element 130 into the aperture 118 of the chassis or circuit board 114. Along the inner wall of each tab 132 a ridge 136 extends into the channel 122. Each tab 132 has an angled inner cam surface 138 which is provided to ease movement of the plunger 160 into the fully extended position in the first locking element 130 and expand the tabs 132 within the aperture 118.
At the lower end of the plunger 160 dual reduced portions 170, 172 are present which define a first lower head 174 and a second lower head 176. The first lower head 174 has a chamfered lower surface 175 which engages the angled inner cam surfaces 138 of the captivating tabs 132. As the first lower head 174 is pushed between the tabs 132, the tabs 132 will pivot about the hinged portions 134 to rigidly affix the fastener 110 to the chassis 114.
When the plunger 160 is fully extended into the channel 122 the second lower head 176 will be positioned below the ridges 136 such that the upper surface 178 of the second lower head 176 will rest below the ridges 136 to captivate the plunger 160 within the fastener 110.
In FIG. 12, the fastener 110 is shown in the fully locked position wherein the fastener 110 is rigidly affixed to the chassis 114 and the circuit board 112 is rigidly affixed to the fastener 110. The plunger 160 has been rotated to cause the first plunger portion 164 to expand the tabs 142 to affix the circuit board 112 to the fastener 110. As in the preferred embodiment, once the plunger 160 has been fully extended into the fastener 110 the fastener 110 is rigidly affixed to the chassis 114 and the plunger 160 may not be removed because it is captivated in the fastener body 119.
A third embodiment of the present invention is shown in FIGS. 16 and 17, and is generally designated as 210. Briefly, the fastener 210, as shown in FIG. 16, is operative to maintain a plate 212 flush with a body 214. It should be apparent, however, that the fastener 210 of the third embodiment may be constructed to provide for a predetermined distance between the plate 212 and the body 214.
As shown in FIG. 17, the plate 212 is provided with an aperture 216 and the body 214 is provided with a blind hole 218 to which the aperture 216 is aligned.
As shown in FIG. 16, the fastener 210 includes a fastener body, generally designated as 219. A part of the fastener body 219 is a base member or washer, generally designated as 220. Disposed substantially centrally within the fastener body 219 is a channel 222, which extends entirely through the fastener body 219.
Attached to one end of the washer 220 and integral therewith is a first locking element, generally designated as 230, which in the third embodiment consists of two oppositely positioned captivating tabs 232, which are pivotally attached to the washer 220 at the hinge portions 234. These captivating tabs 232 have chamfered portions 235 which are provided to facilitate placement of the first locking element 230 into a blind hole 218 as shown in FIG. 17.
Each captivating tab 232 is provided with a ridge 236 which extends into the channel 222 to captivate a plunger as discussed hereinafter. Each tab 232 is also provided with an angled inner cam surface 238 to facilitate movement of a plunger into the fully extended position between the tabs 232 of the first locking element 230.
Extending outwardly from tabs 232 are a plurality of serrations 239, which are clearly shown in FIGS. 16 and 17, and which are operative to engage the material which forms the blind hole 218. The protruding serrations 239 are designed to resist movement of the fastener 210 out of the blind hole 218 once the plunger has been fully extended into the fastener body 219.
As in the first two embodiments, there are two captivating tabs 232. However, it should be apparent that additional captivating tabs (not shown) of various configurations could be utilized.
Attached to the other end of the washer 220 and integral therewith is a second locking element, generally designated as 240. The second locking element 240 consists of oppositely positioned tabs 242 which are pivotally secured to the washer 220 at hinge portions 244, as shown in FIG. 16. Each of the tabs 242 has a chamfered upper surface 246 and a hollowed inner portion 248. The tabs 242 define an upper portion 249 of the channel 222. Each of the tabs 242 has an aligning piece 250 which extends partially into the upper portion 249 as illustrated in FIG. 16.
A difference between the fastener 110 of the second embodiment and the fastener 210 of the third embodiment is the size of the spacer 120 with respect to the size of the washer 220. The reduced width of the washer 220 compared to the spacer 120 allows for the flush affixation of the plate 212 to the surface of the body 214. In this instance, the washer 220 is placed within a groove or recess 215 in the body 214, as shown in FIG. 17. This permits the plate 212 to be mounted flush to the surface of the body 214. It may be desirable to provide space between the plate 212 and the surface of the body 214 and this may be accomplished by increasing the width of the washer 220.
To use the fastener 210 of the third embodiment, the first locking element 230 is placed into the blind hole 218. The fastener 210 is pushed toward the blind hole 218 such that washer 220 will fit within the groove or recess 215. When this has been accomplished, the plunger 260 is fully extended into the channel 222. Movement of the plunger 260 into the channel 222 will cause the first lower head 274 to engage the angled inner surfaces 238 of the captivating tabs 232. This will cause the tabs 232 to pivot outwardly and engage the surface of the blind hole 218. When the plunger 260 has been fully extended into the channel 222, the captivating tabs 232 will be pivoted outwardly to their maximum distance thus rigidly affixing the fastener 210 to the body 214. The second lower head 276 will rest below the ridges 236 of the tabs 232 and will captivate the plunger 260 in the fastener body 219.
After the fastener 210 has been rigidly affixed to the body 214, the plate 212 may be mounted against the surface of the body 214. The aperture 216 of the plate 212 has a diameter slightly larger than the circumference of the second locking element 240, as defined by the outside surfaces of the tabs 242, when in the unactuated position. When the tabs 242 are in the unactuated position, the plate 212 may be moved axially with respect to the plunger 260 and the second locking element 240 to mount or remove the plate 212.
In FIG. 17, the fastener 210 is shown in the fully locked position. The plate 212 is placed over the plunger 260 and locking element 240 and in contact with the surface of the body 214 and the top of the washer 220. When the plate 212 contacts the top of the washer 220 and the surface of the body 214, the plunger 260 may be rotated to affix the plate 212 to the body 214.
As the plunger 260 is rotated the first plunger portion 264 will engage the inner surfaces of the tabs 242 causing outward pivotal movement of the tabs 242 to rigidly affix the plate 212 to the body 214. In this respect the operation of the third embodiment of the fastener 210 is essentially the same as the operation of the second embodiment of the fastener 110.
When it is desired to remove the plate 212 from the body 214, the plunger is reverse rotated, thus the first plunger portion 264 will move from its engagement with the inner surfaces of the tabs 242 causing the tabs 242 to pivot inwardly to their normal position with respect to the washer 220. When this occurs, the plate 212 may be moved axially with respect to the plunger 260 and locking element 240 to remove the plate 212 from the surface of the body 214.
To manufacture the fastener 210, a mold is made which is capable of producing one complete fastener. The partial molded configuration of the present fastener 210 is shown in FIG. 16. A frangible connection 290 exists between the bottom of the plunger 260 and the top of the second locking element 240. After the frangible connection 290 has been severed, the plunger 260 may be inserted into the channel 222 of the fastener body 219 for the purposes set forth hereinabove.
A fourth embodiment of the present invention is shown in FIGS. 18 through 33, and is generally designated as 310. Briefly, the fastener 310, as shown in FIG. 18, is operative to affix an object such as a circuit board 312 to a chassis 314 wherein a predetermined distance A is intended to exist between the board 312 and the chassis 314.
Circuit boards 312 of the type used are referred to previously and these circuit boards 312 may have a plurality of spaced apertures 316 extending entirely through the body of the circuit boards 312. Similarly, the chassis 314 is of the type referred to previously and these chassis 314 may have a plurality of spaced apertures 318 defined therein. The apertures 316 and apertures 318 are uniformly spaced to permit their alignment when the circuit board 312 is to be mounted to the chassis 314.
As shown in FIG. 18, the fastener 310 includes a fastener body, generally designated as 319. A part of the fastener body 319 is a base member or spacer, generally designated as 320, which is preferably made of an non-conductive material, such as plastic. For purposes of weight reduction and material use reduction, the spacer 320 may have a plurality of voids 321 located therein, as best shown in FIGS. 18 and 29. Disposed substantially centrally within the fastener body 319 is a channel 322, which extends entirely through the fastener body 319.
Attached to one end of the spacer 320 and integral therewith is a first locking element, generally designated as 330, which in this embodiment consists of two oppositely positioned captivating tabs 332, which are pivotably attached to the spacer 320 at the hinge portions 334. These captivating tabs 332 have chamfered portions 336 which are provided to facilitate placement of the first locking element 330 into and through the aperture 318. Extending outwardly from the tabs 332 are a plurality of raised portions 338, which are also shown in FIGS. 19, 20, 21, 30, 31 and 32. The raised portions 338 are positioned along the tabs 332 to permit a portion of the chassis 314 to fit between the top of the raised portions 338 and the bottom of the spacer 320, as shown in FIG. 19.
In the unlocked position as shown in FIG. 18, the fastener 310 is capable of rotational movement with respect to the chassis 314. However, once the first locking element 330 has been placed into and through the aperture 318, the raised portions 338 are operative to maintain the chassis 314 in contact with the spacer 320 to captivate the fastener 310.
Attached to the other end of the spacer 320 and integral therewith is a second locking element, generally designated as 340. The second locking element 340 consists of oppositely positioned tabs 342 which are pivotably secured to the spacer 320 at hinge portions 344. Each of the tabs 342 has a chamfered upper surface 346 and a semi-circular recess 348, which adds flexibility to the tabs 342. The tabs 342 define an upper portion 349 of the channel 322. Each of the tabs 342 has an aligning piece 350 which extends partially into the upper portion 349 as illustrated in FIGS. 18 and 27.
The aligning pieces 350 each have an upper surface 352 which may also act as a stop for the plunger when it is pushed downward into the channel 322 as discussed hereinafter. The lower surface 354 of each of the tabs 350 is operative to captivate the plunger within the channel 322 and thus define the maximum outward movement of the plunger.
A plunger, generally designated as 360, is designed to fit into the channel 322. The plunger 360 has a head portion 362 which is integral with a downwardly extending first rod portion 364. The cross-section of the head portion 360 is shown in FIG. 22 and the cross-section of the first rod portion is shown in FIG. 23. The first rod portion 364 is adapted to extend downardly into the second locking element 340 and is integral with a second rod portion 366 which is of less width. A cross-section of the second rod portion is shown in FIG. 25. Because of the difference in widths between the first rod portion 364 and the second rod portion 366 a cam shoulder 368 is formed.
Defined within each side of the plunger 360 is a guide recess 369, reference to which is made in FIGS. 18 and 24. The guide recesses 369 extend through part of the first rod portion 364 and entirely through the second rod portion 366 as shown in FIG. 18, 24, 25 and 26. The guide recesses 369 are adapted to receive the aligning pieces 350 to maintain the plunger 360 in proper position when moved axially within the channel 322.
A stop 370 is integral with the second rod portion 366, and is placed within each of the guide recesses 369. Each stop 370 has an upper surface 372 as shown in FIG. 20, which will contact the lower surface 354 of an associated aligning piece 350 to captivate the plunger 360 within the fastener body 319 and resist further retraction of the plunger 360.
As shown in FIG. 18, an upper surface 374 of the guide recess 369 and the upper surface 352 define a distance B which is the maximum travel of the plunger 360, when captivated within the fastener body 319. The lower edge 376 of the second rod portion 366 is chamfered to ease movement of the plunger 360 into the first locking element 330.
In FIG. 20 the fastener 310 of the present invention is shown in the as molded configuration before the frangible connection between the plunger 360 and the second locking element 340 has been severed. The frangible connection 380 is illustrated in greater detail in FIG. 33.
In FIG. 18 the fastener 310 is shown in the unlocked configuration. In this position the tabs 332 of the first locking element 330 have been pushed through the aperture 318 into the chassis 314. Thus, the fastener 310 is captivated with respect to the chassis 314. When the fastener 310 is in the unlocked configuration, the first rod portion 364 is disposed outside of the second locking element 340, thus, the unbiased tabs 342 of the second locking element 340 are positioned normal to the circuit board 312. The aperture 316 in the circuit board 312 has a diameter slightly greater than the effective circumference of the second locking element 340, as defined by the outside surfaces of the tabs 342, when the unlocked position. In the unlocked position the circuit board 312 may be moved axially with respect to the plunger 360 and the second locking element 340 to mount or remove the circuit board 312.
In FIG. 19, the fastener 310 is shown in the locked position. The circuit board 312 is placed over the plunger 360 and in contact with the spacer 320. As indicated previously, there may be a plurality of apertures 316 in the circuit board 312 to permit the affixation of the circuit board 312 at numerous locations. When the circuit board 312 contacts the top of the spacer 320, the plunger 360 may be pushed into the channel 322 of the fastener body 319 to affix the circuit board 312 to the chassis 314.
As the plunger 360 moves into the channel 322, cam shoulder 368 will contact the upper portion of each tab 342 of the second locking element 340, and the first rod portion 364 will cause outward movement of the tabs 342 until the tabs 342 contact the portion of the circuit board 312 which forms the aperture 316. When the first rod portion 364 has been pushed a certain distance into the channel 322, the cam shoulder 368 will contact the lowermost portion of the second locking element 340 to terminate downward movement of the plunger 360. At this point the circuit board 312 will be rigidly affixed to the fastener 310 and the chassis 314.
Simultaneous with the movement of the tabs 342 outward, the second rod portion 366 will cause the normally positioned tabs 332 to move outwardly. In turn, this will cause the raised portions 338 to move outwardly and affix the chassis 314 between the spacer 320 and the upper surface of the raised portions 338, as shown in FIG. 19.
As the plunger 360 is retracted to unlock the circuit board 312 from the chassis 314, the first locking element 330 will loosen its grip on the chassis 314 to permit limited radial movement or float of the fastener 310. The second locking element 340 will also loosen its grip on the circuit board 312 to permit the circuit board 312 to be removed over the plunger 360 and second locking element 340. As the plunger 360 is retracted to unlock the circuit board 312 from the chassis 314, the upper surface of the stop 370 will contact the lower surface 354 of the aligning piece 350 to resist further retraction of the plunger 360. Thus, the plunger 360 may not be totally retracted from the fastener body 319. The placement of the stop 370 thus defines the maximum position that the plunger 360 may be retracted from the fastener body 319 in the unlocked position.
To manufacture the present fastener 310, a mold is made which is capable of producing one complete fastener. The molded configuration of the present invention is shown in FIG. 20. A frangible connection 380 exists between the bottom of the plunger 360 and the top of the second locking element 340. After the frangible connection has been severed, the plunger 360 may be inserted into the channel 322 of the fastener body 319 for the purposes set forth hereinabove.
A final embodiment of the present invention is shown in FIGS. 34-36. In FIG. 34 a side perspective view of the fastener of the present invention is shown. Briefly, the fastener, generally designated 410, is operative to affix an object such as a circuit board 412 to a chassis 414 or another circuit board wherein a predetermined distance A is intended to exist between the board 412 and the chassis 414. The distance A is dependent upon the type of electrical circuit boards 412 that may be used. The circuit board includes an aperture 416. The chassis 414 includes an aperture 418.
The fastener 410 includes a fastener body, generally designated 419. An integral part of the fastener body 419 is a base member or spacer, generally designated 420, which is preferably made of a non-conductive material. For purposes of weight reduction the spacer 420 may have a plurality of voids 421 located therein. The fastener body 419 has an internal channel 422 substantially in the center, which runs entirely through the fastener body 419. A ridge 424 extends into the channel 422 from each side thereof.
Attached to one end of the spacer 420 and integral therewith is a first locking element, generally designated 430, which in the first embodiment consists of two oppositely positioned captivating tabs 432 which are pivotally attached to the spacer 420 at the recessed portions 434. These captivating tabs 432 have wall sections 436 which are integral with angled ribs 438 attached to the wall sections 436. The ribs 438 extend toward the spacer 420 and are capable of limited pivotal movement with respect to the wall sections 436. The ribs 438 are connected to the wall sections 436 such that pivotal movement away from the wall sections is resisted.
A protrusion 439 extends outwardly from each wall section 436 and is adapted to fit within the aperture 418 of the chassis 414. The size of the protrusions 439 will determine the range of movement or radial float of the first locking element 430 with respect to the chassis 414.
Attached to the other end of the spacer 420 and integral therewith is a second locking element, generally designated 440. The element 440 consists of oppositely positioned tabs 442 which are pivotally secured to the spacer 420 at pivots 444. The tabs 442 define an upper portion 446 of the channel 422 which has at its centermost portion a hollowed area 448 extending into each of the tabs 442. The hollowed area 448 provides for flexibility of the tabs 442 and may receive a detent (not shown) on the plunger to further secure the plunger in the locked position. Disposed into the upper portion 446 of the channel 422 from each of the tabs 442 is an aligning piece 450.
On each side of the second rod portion 466 is a recess 470. The recesses 470 are adapted to receive the ridges 424 which guide the plunger 460 and captivate it with respect to the fastener body 419. At the lower end of each recess 470 is a surface 472 which engages the lower surface 478 of the ridge 424 when the plunger 460 is retracted. At the lower end of the plunger 460 are chamfered surfaces 476 which facilitate downward movement of the plunger into the fastener body 419.
In FIG. 35 the fastener 410 is shown in the unlocked configuration. In this position, the tabs 432 of the first locking element 430 are biased inwardly and, thus, the angled ribs 438 do not contact the lower surface of the chassis 414.
When the fastener 410 is in the unlocked position, the first rod portion 464 is disposed outside of the second locking element 440, thus, the unbiased tabs 442 of the second locking element 440 are positioned normal to the plane of the circuit board 412. The aperture 416 in the board 412 has a diameter greater than the effective circumference of the second locking element 440, as defined by the outside surface of the tabs 442, when in the unlocked position. Thus, the board 412 may be moved axially with respect to the plunger 460 and the second locking element 440 to either mount or remove the board 412.
As the plunger 460 is retracted to unlock the board 412 from the chassis 414, the surfaces 472 of the recesses 470 come in contact with the inwardly extending bottom surfaces 478 of the ridges 424. Thus, the plunger 460 may not be totally retracted from the fastener body 419. The ridges 424 thus define the maximum position that the plunger 460 may be retracted in the unlocked position.
Briefly, in FIG. 36, the position of the angled ribs 438 is shown with respect to the lower surface of the chassis 414 when the circuit board 412 is locked to the fastener 410. The ribs 438 are permitted limited pivotable movement toward the wall section 436 to permit the first locking element 430 to be inserted into the aperture 18 of the chassis 14.
To manufacture the fastener 410 of the present invention a mold is made which is capable of producing one complete fastener. In the molded state, the plunger 460 is integral with the uppermost portion of the second locking element 440, whereby a frangible connection exists. After the frangible connection has been severed, the plunger 460 may be inserted into the channel 422 of the fastener body 419.
To use the fastener 410 of the present invention, first locking element 430 of the molded fastener 410 is inserted into and through the aperture 418. When the plunger 460 is in the retracted position, as shown in FIG. 35, the circuit board 412 may be mounted by passing the plunger 460 and second locking element 440 through the aperture 416. As indicated previously, there may be a plurality of apertures 416 in the circuit board to permit the affixation of the board 412 at numerous locations. When the board 412 contacts the top of the spacer 420, the plunger 460 may be pushed into the channel 422 of the fastener body 419 for the purposes stated herein.
As the plunger 460 moves into the channel 422, the first rod portion 464 will cause outward movement of the tabs 424 until the tabs 424 contact the portion of the board 412 which forms the aperture 416. At this point, the board 412 will be rigidly affixed to the fastener 410. Simultaneous with the movement of the tabs 424 outward, the second rod portion 466 will cause the tabs 432 to move outwardly. In turn, this will cause the ends of the ribs 438 to engage the bottom surface of the chassis 414 thus clamping the fastener 410 to the chassis 414.
Although the present invention has been described in great detail herein, it should be apparent to those of ordinary skill in the art that various modifications could be made to the fasteners 10, 110, 210, 310, 410 to perform in a similar manner, without departing from the spirit and scope of the following claims.
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A fastener for securing two objects or structures together in a predetermined relationship. The fastener has a fastener body including a spacer which defines a predetermined distance between the two objects. A first locking element is attached to one side of the spacer and a second locking element is attached to the other side of the spacer. The fastener body is adapted to receive a plunger which when actuated will cause the locking elements to secure the first object and second object a predetermined distance apart.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a vertical heat-treating apparatus used in the thermal diffusion step or film-forming step in the process of manufacturing a semiconductor device.
2. Description of the Related Art
Researches on a vertical heat-treating apparatus used in the thermal diffusion step or film-forming step in the process of manufacturing a semiconductor device are being made vigorously in recent years in an effort to save the required space and required energy. The vertical heat-treating apparatus is also effective for dealing with the tendency toward enlargement in diameter of the semiconductor wafer and with tendency toward automation of the process for manufacturing a semiconductor device.
The conventional vertical heat-treating apparatus comprises a vertical heat-treating furnace consisting of a cylindrical reaction vessel made of, for example, quartz and a heater, a heat insulating material, etc. arranged about the outer surface of the reaction vessel. A wafer boat made of, for example, quartz and having a number of semiconductor wafers housed therein is loaded into a lower part of the vertical heat-treating furnace and moved upward by a lift mechanism to reach a predetermined position for applying a predetermined heat treatment to the wafers. In general, semiconductor wafers are put in a wafer carrier made of resin for transporting the wafers, making it necessary to transfer the wafers between the wafer boat and the wafer carrier. Thus, the vertical heat-treating apparatus is provided in general with a wafer transfer mechanism positioned between the wafer boat and the wafer carrier.
It is desirable to use a plurality of wafer boats such that, during the heat treatment applied to semiconductor wafers held by a wafer boat within a heat-treating furnace, other wafers are transferred onto another wafer boat and the wafer boat supporting said wafers is put in a waiting position so as to suppress the reduction in the heat-treating efficiency cause by the wafer transfer time between the wafer boat and the wafer carrier. It is also desirable to provide a section in which the wafer boat supporting the wafers is disposed in preparation for the heat treatment of the wafers and to arrange a plurality of vertical heat-treating furnaces in parallel so as to permit a single wafer transfer mechanism to be commonly used for the plural heat-treating furnaces and, thus, to improve the heat-treating efficiency.
As described above, it is desirable to put a wafer boat having semiconductor wafers mounted thereon in a waiting position so as to improve the treating efficiency. It should be noted, however, that an increase in the waiting time of the semiconductor wafer leads to an increase in the formation of a natural oxide film on the wafer surface. Presently, the semiconductor element is made finer and finer with increase in the integration density, with the result that a defective wiring is brought about by the presence of a natural oxide film as thin as only several nanometers. In addition, the natural oxide film is nonuniform in thickness, with the result that the defective wiring is likely to be brought about more easily. Naturally, it is of high importance to eliminate the natural oxide film on a semiconductor wafer.
As described above, it is very important to improve the heat-treating efficiency and to suppress formation of a natural oxide film on a semiconductor wafer. It is also important to eliminate the natural oxide film formed on a wafer before the wafer is subjected to a heat treatment.
What should also be noted is that a heat-treating apparatus used in the manufacture of a semiconductor device is disposed in general in a clean room. Naturally, a clean air is supplied to each equipment included in the heat-treating device in an attempt to prevent dust being attached to the wafer. However, it is impossible to completely prevent the dust attachment because of convection of the air. It follows that an increase in the waiting time of the semiconductor wafer enhances the possibility of the dust attachment to the wafer. Naturally, it is very important to take measures for preventing the dust attachment to the wafer during the waiting time of the wafer.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a vertical heat-treating apparatus comprising a waiting mechanism of the workpiece so as to improve the heat-treating efficiency. The waiting mechanism permits applying a pre-treatment to the workpiece, e.g., a semiconductor wafer, so as to prevent oxidation of the workpiece or to remove the natural oxide film formed in advance on the workpiece. The pre-treatment makes it possible to maintain a high quality of the workpiece after the heat treatment.
According to the present invention, there is provided a vertical heat-treating apparatus, comprising:
a vertical heat-treating furnace for applying a predetermined heat treatment to a workpiece housed therein;
a workpiece stocker provided with a vessel capable of surrounding an untreated workpiece and serving to temporarily store the workpiece;
gas inlet means communicating with the inner space of said surrounding vessel; and
a transport mechanism for transporting the workpiece between the vertical heat-treating furnace and the workpiece stocker.
It is desirable for the vertical heat-treating apparatus of the present invention to comprise further:
a stocker for housing a transporting vessel having the workpiece housed therein; and
a transfer mechanism for transferring the workpiece between said transporting vessel and a treating vessel.
The vertical heat-treating apparatus of the present invention comprises a stocker for housing a workpiece in preparation for the heat treatment applied to the workpiece, making it possible to suppress the reduction in the treating efficiency caused by the transfer operation, which takes a long time, of the workpiece between the transporting vessel and the treating vessel. Further, the workpiece stocker is constructed to be capable of applying a pre-treatment to the workpiece, making it possible to suppress the defect occurrence in the workpiece after the heat treatment, said defect occurrence accompanying the increase in the waiting time of the workpiece. It follows that it is possible to further improve the quality of the workpiece after the heat treatment.
Further, a series of devices including the transporting vessel stocker, the transfer mechanism, the workpiece stocker, the transport mechanism and the vertical heat-treating furnace are incorporated in the vertical heat-treating apparatus of the present invention, making it possible to carry out effectively each step of the heat treatment including the transfer of the workpiece and the transport of the vessel.
Additional objects and advantages of the invention will be set forth in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. The objects and advantages of the invention may be realized and obtained by means of the instrumentalities and combinations particularly pointed out in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate presently preferred embodiments of the invention, and together with the general description given above and the detailed description of the preferred embodiments given below, serve to explain the principles of the invention.
FIG. 1 is an oblique view showing a vertical heat-treating apparatus according to one embodiment of the present invention;
FIG. 2 is a plan view showing the apparatus of FIG. 1;
FIG. 3 is a front view, partly broken away, showing in a magnified fashion a gist portion of the vertical heat-treating apparatus shown in FIG. 1;
FIG. 4 is a cross sectional view showing in a magnified fashion the workpiece stocker included in the vertical heat-treating apparatus shown in FIG. 1; and
FIG. 5 is a plan view showing in a magnified fashion the transfer arm included in the vertical heat-treating apparatus shown in FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Let us describe a vertical heat-treating apparatus 1 according to one embodiment of the present invention with reference to the accompanying drawings. As shown in FIGS. 1 and 2, the vertical heat-treating apparatus 1 comprises a carrier stocker 10 capable of storing a number of wafer carriers 3 each housing semiconductor wafers 2 which are to be subjected to heat treatment. The wafer 2 housed in the wafer carrier 3 is transferred onto a wafer boat 4 made of, for example, quartz by a transfer mechanism 20. The wafer boat 4 having the wafer 2 mounted thereon is moved into any one of a plurality of vertical heat-treating furnaces 30 arranged in parallel such that a predetermined heat treatment is applied to the wafer 2. A boat transport mechanism 40 is provided in front of the array of the vertical heat-treating furnaces 30 so as to transport the wafer boat 4 standing upright. Further, a boat stocker 50 is disposed along the boat transport mechanism 40. An untreated semiconductor wafer 2 is held in the boat stocker 50. Also, a pre-treatment is applied to the untreated wafer 2 within the boat stocker 50. Still further, the vertical heat-treating apparatus comprises a boat transfer mechanism 60 serving to transfer the wafer boat 4 between the wafer transfer mechanism 20 and the boat transport mechanism 40 while performing a horizontal-to-vertical conversion.
A plurality of carrier racks 11 each having a plurality of wafer carriers 3 disposed thereon are arranged in a vertical direction within the carrier stocker 10. The wafer carrier 3 is transferred between the carrier stocker 10 and the wafer transfer mechanism 20 by a carrier transport mechanism 70. The carrier stocker 10 also comprises a mechanism 12 for holding and transferring the carrier. The mechanism 12, which is movable both in the lateral and vertical directions, serves to transfer the wafer carrier 3 from the carrier rack 11 onto the carrier transport mechanism 70.
The wafer transfer mechanism 20 comprises a wafer handling section 21 serving to collectively hold a plurality of semiconductor wafers 2. The wafers 2 are transferred by the handling section 21 between the wafer boat 4 disposed on a boat support member 22 in the horizontal direction by the boat transfer mechanism 60 and the plural wafer carriers 3 transported toward the wafer transfer mechanism 20 by the carrier transport mechanism 70.
The boat transfer mechanism 60, which comprises a boat handling section 61 serving to hold the upper and lower end portions of the wafer boat 4 and a transfer section 62 of the boat handling section 61, serves to hold the wafer boat 4 in the horizontal position, said wafer boat 4 having the semiconductor wafer mounted thereon by the wafer transfer mechanism 20. Then, the boat transfer mechanism 60 converts the wafer boat 4 from the horizontal position into the vertical position. Further, the wafer boat 4 is transferred by the boat transfer mechanism 60 onto the boat supporting section 41 of the boat transport mechanism 40.
The boat transport mechanism 40 comprises the boat supporting section 41 having the wafer boat 4 supported thereon upright, a rail 42 for transporting the boat supporting section 41 to any one of the boat stocker 50 and the vertical heat-treating furnace 30 on the basis of a treating program, and a driving means (not shown) for driving the boat supporting section 41 along the rail 42, in the lateral direction perpendicular to the rail 42, and in the vertical direction. It is possible to use an optional driving means known to the art.
As shown in FIG. 3, each of the vertical heat-treating furnaces 30 comprises a furnace body 33 consisting of a reaction vessel 31 made of, for example, quartz, a heater 32 arranged to surround the circumferential outer surface of the reaction vessel 31, and a heat insulating member (not shown). The furnace body 33 is fixed to a base plate 34 extending in a direction substantially perpendicular to the axis of the reaction vessel 31.
The wafer boat 4 having the wafers 2 mounted thereon is transferred by a boat transfer arm 37 from the boat transport mechanism 40 onto a region above a heat insulating cylinder 36 disposed on a turntable 35 which is rotatable. Then, the wafer boat 4 is loaded into the reaction vessel 31 by a lift mechanism 38. The open portion of the reaction vessel 31 is hermetically closed by a disk-shaped cap portion 39 which can be moved up and down together with the turntable 35 by the lift mechanism 38.
As shown in FIG. 5, the transfer arm 37 is rotatably pivoted to a shaft 37a such that the arm 37 is rotatable in a horizontal direction as denoted by an arrow a and is vertically movable in the longitudinal direction of the shaft 37a. The arm 37 supports the lower end portion of the wafer boat 4 and transfers the wafer boat 4 onto the turntable 35. Reference numeral 37b denotes rotary position sensors, and 37c represents a length adjusting hole. The boat stocker 50, which will be described later, also comprises a boat transfer arm 55 which is substantially equal in construction and function to the transfer arm 37 described above.
A gas inlet device 301 for introducing a clean gas or a nitrogen gas is provided in a side wall of the vertical heat-treating furnace 30.
Two boat stockers 50 are disposed in parallel such that the wafer boat 4 having untreated semiconductor wafers 2 disposed thereon is positioned within one of the two boat stockers in preparation for the succeeding heat treatment so as to suppress the reduction in the treating efficiency caused by the wafer transfer time. Also, pre-treatments such as an anti-oxidizing treatment and an oxide film removing treatment are applied to the wafer 2 during the waiting time so as to improve the quality of the wafer after the heat treatment.
As shown in FIG. 4, each boat stocker 50 comprises a turntable 53 fixed to a rotary shaft 52 joined to a rotary driving mechanism 51. A support plate 54 made of, for example, quartz and having the wafer boat 4 supported thereon is disposed on the turntable 53. The boat stocker 50 also comprises a boat transfer arm 55 serving to transfer the wafer boat 4 transported by the boat transport mechanism 40 onto the support plate 54.
A cylindrical surrounding vessel, e.g., a reaction tube 56 made of quartz, is disposed above the turntable 53 at a position at which the reaction tube 56 does not provide an obstacle in the stage of transferring the wafer boat 3. The reaction tube 56 is fixed to a lifting portion 72a of a lift mechanism, e.g., a ball bearing 57, by a frame 58 such that the reaction tube covers the wafer boat 4 disposed on the support plate 54.
A treating gas inlet pipe 59 is connected to the reaction tube 56. A desired pre-treating gas such as a nitrogen gas is supplied through the treating gas inlet pipe 59 into the reaction tube 56 so as to apply a desired pre-treatment to the untreated semiconductor wafer 2. In the case of using, for example, a nitrogen gas as the pre-treating gas, it is possible to prevent a natural oxide film from being formed on the semiconductor wafer 2. It is also possible to prevent dust from being attached to the wafer 2. In the case of using an etching gas, it is possible to remove the natural oxide film formed in the previous step immediately before the wafer is subjected to a heat treatment.
In the embodiment shown in the drawings, four vertical heat-treating furnaces 30 are arranged in parallel so as to make it possible to apply simultaneously a plurality of different heat treatments, e.g., epitaxial growth of silicon and thermal diffusion of an impurity. In order to prevent a cross contamination caused by the different heat treatments which are applied simultaneously, two sets of members are arranged with respect to those portions of the vertical heat-treating device 1 which are in contact with the wafer boat 4, i.e., the boat support portion 41 of the boat transport mechanism 40, the boat holding portion 61 of the boat transfer mechanism 60, the boat support member 22 of the wafer transfer mechanism 20, etc. These two sets of members can be selected appropriately depending on the specific heat treatments applied to the wafers 2.
The apparatus 1 shown in the drawings comprises four vertical heat-treating furnaces 30. However, the number of furnaces 30 need not be restricted to four. It is of course possible for the apparatus 1 to comprise five or more vertical heat-treating furnaces. Also, the number of boat stockers 50 need not be restricted to two. Desirably, the number of boat stockers 50 should be equal to that of vertical heat-treating furnaces.
The vertical heat-treating apparatus 1 of the construction described above is operated as follows. In the first step, the wafer carrier 3 is transferred from the carrier rack 11 of the carrier stocker 10 onto the carrier plate 71 of the carrier transport mechanism 70 and, then, transported toward the wafer transfer mechanism 20. On the other hand, the wafer boat 4 is transferred onto the boat support member 22 by the boat transfer mechanism 60, and the semiconductor wafer 2 housed in the wafer carrier 3 is transferred onto the wafer boat 4. Then, the wafer boat 4 is converted from the horizontal to vertical positions by the boat transfer mechanism 60 and is transferred onto the boat transport mechanism 40. Further, the wafer boat 4 is transported by the boat transport mechanism 40 into any of the boat stocker 50 and the vertical heat-treating furnace 30 on the basis of the processing program.
For example, the wafer boat 4 transported into the vertical heat-treating furnace 30 is disposed on the heat insulating cylinder 36 and, then, loaded by the lift mechanism 38 into the reaction vessel 38 which is preliminarily heated to, for example, about 800° C. After the wafer boat 4 is loaded into the reaction vessel 31, the reaction vessel 31 is closed by the cap portion 39. Then, a treating gas, e.g., SiH 2 Cl 2 , HCl or H 2 , is introduced through a gas inlet pipe (not shown) into the reaction vessel 31 kept at a predetermined vacuum, e.g., about 10 Torr, so as to apply a heat treatment, e.g., Si epitaxial growth, to the semiconductor wafer 2.
On the other hand, the wafer 2 transported into the boat stocker 50 is disposed on the turntable 52 and covered with the descending reaction tube 54. Under this condition, a pre-treating gas, e.g., nitrogen gas or etching gas, is supplied through the treating gas inlet pipe 56 into the reaction tube 54 so as to apply a desired pre-treatment for preventing oxidation or removing a natural oxide film to the wafer 2 before a desired heat treatment is applied to the wafer 2 within the heat-treating furnace 30.
Transfer of the semiconductor wafer 2 and transport of the wafer boat 4 into the vertical heat-treating furnace 30 or the boat stocker 50 are carried out in succession. Also, the wafer boat 4 transported into the boat stocker 50 is transported into the vertical heat-treating furnace 30 on the basis of the processing program.
After completion of the heat treatment within the vertical heat-treating furnace 30, the semiconductor wafer 2 is transferred together with the wafer boat 4 onto the boat supporting member 22 of the wafer transfer mechanism 20 by the boat transport mechanism 40 and the boat transfer mechanism 60 and, then, onto the wafer carrier 3. The wafer carrier 3 housing the semiconductor wafer 2 after the heat treatment is brought back to the carrier stocker 10 and, then, transported to the next processing step.
As described above, the vertical heat-treating apparatus 1 of the present invention comprises a plurality of boat stockers 50 providing the waiting positions of the wafer boat 4 having the semiconductor wafers 2 mounted thereon. The particular construction permits suppressing the reduction in the treating efficiency accompanying the transfer of the semiconductor wafer 2 regardless of the kind of the heat treatment applied to the wafer 2. The apparatus 1 also comprises the carrier stocker 10 housing the wafer carrier 3 transported from the previous step, the transfer mechanism 20 of the semiconductor wafer 2, and the mechanisms 40 and 60 for transferring and transporting the wafer boat 4. It follows that it is possible to carry out with a high flexibility and consecutively a series of treating steps relating to the heat treatment leading to further improvement in the treating efficiency. Naturally, it is possible to lower the manufacturing cost accompanying the heat treatment of the semiconductor wafer 2.
It should also be noted that the boat stocker 50 is provided with the reaction tube 54 movable in the vertical direction, making it possible to apply a pre-treatment such as a treatment with an inert gas or an etching treatment to the semiconductor wafer 2. Thus, a natural oxide film is prevented from being formed on the wafer 2 in the waiting position. It is also possible to remove a natural oxide film formed previously on the wafer 2. Further, since the wafer 2 is positioned within the reaction tube during the waiting period, it is possible to suppress the defect occurrence caused by, for example, dust attachment to the wafer 2.
To reiterate, the boat stocker 50 included in the vertical heat-treating apparatus of the present invention makes it possible to apply a pre-treatment to the semiconductor wafer 2 mounted on the wafer boat 4. It follows that the defect occurrence during the waiting period can be suppressed, leading to an improvement in the quality of the wafer after the heat treatment and to an improved heat-treating efficiency.
Additional advantages and modifications will readily occur to those skilled in the art. Therefore, the invention in its broader aspects is not limited to the specific details, and representative devices, shown and described herein. Accordingly, various modifications may be made without departing from the spirit or scope of the general inventive concept as defined by the appended claims and their equivalents.
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A vertical heat-treating apparatus to be used for a thermal diffusion step or film-forming step in the manufacture of a semiconductor device is proposed. This vertical heat-treating apparatus is characterized in that a work piece-waiting mechanism is incorporated in the apparatus for applying a pre-treatment to workpieces such as semiconductor wafers so as to prevent oxidation of the workpiece, or to remove the natural oxide film formed on the surface of the workpiece.
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FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0001] This invention was made with government support under Contract No. W-7405-ENG-36 awarded by the U.S. Department of Energy. The government has certain rights in the invention.
TECHNICAL FIELD OF THE INVENTION
[0002] The present invention relates to separation membranes, more particularly to gas separation membranes, and especially to meniscus-shaped membranes for gas separations as well as the use of such meniscus-shaped membranes for applications such as thermal gas valves, pre-concentration of a gas stream, and selective pre-screening of a gas stream.
BACKGROUND OF THE INVENTION
[0003] The last decade has seen a dramatic increase in the use of polymer membranes as an effective, economical and flexible tool for many gas separations. The processability, gas solubility, and selectivity of several classes of polymers (such as polyimides, polysulfones, polyesters and the like) have led to their use in a number of successful gas separation applications. A drawback to the use of polymer membranes for gas separation can be their low permeability. In most instances, the success of a given membrane rests on achieving adequate fluxes.
[0004] The commercial use of polymer membranes for air separation, the recovery of hydrogen from mixtures of nitrogen, carbon monoxide and methane, and the removal of carbon dioxide from natural gas has been reported. In each of these applications, high fluxes and excellent selectivities have relied upon glassy polymer membranes which rely on gas size differences for separation of species. Yet, this technology has focused on optimizing separation materials for near ambient conditions. The development of polymeric materials that achieve good combinations of high selectivity, high permeability, mechanical stability and processability at temperatures above about 25° C. and pressures above about 10 bar has been needed.
[0005] Separation of carbon dioxide (CO 2 ) from mixed gas streams is of major industrial interest. Continued improvements in such separations are sought. Commercially viable membrane-based approaches to industrial CO 2 separations require reduction in costly drops in operating temperatures and pressures while maintaining high fluxes. The need for higher flux CO 2 separation approaches remains.
[0006] Other research efforts have been directed to the development of polymer membranes that operate at elevated temperatures and pressures.
[0007] Through the efforts of the present inventors, a polymer membrane design has now been achieved which can operate under high fluxes. Such a polymer membrane design involves a meniscus-shaped polymer membrane within one or more small pore or opening. That polymer membrane design allows for a number of varying applications described herein.
[0008] It is an object of this invention to provide a polymer membrane capable of operation under high fluxes.
[0009] It is another object of this invention to provide a meniscus-shaped polymer membrane within one or more small pore or opening, the meniscus-shaped polymer membrane contained substantially completely within such small pores or openings.
[0010] Still another object of the present invention is a process for rapidly screening polymers for membranes in non-ambient gas separations by use of such a meniscus-shaped polymer membrane.
[0011] Still another object of the present invention is the use of a meniscus-shaped polymer membrane as a selective pre-screen, e.g., for a sensor system including a sensor element where the meniscus-shaped polymer membrane can serve to screen out molecules that would contaminate the sensor element.
[0012] Still another object of the present invention is the use of a meniscus-shaped polymer as a pressure/temperature sensor element.
[0013] Still another object of the present invention is the use of a meniscus-shaped polymer as a pre-concentrator for a gas stream prior to entry into, e.g., a mass spectrometer.
[0014] Still another object of the present invention is the use of a meniscus-shaped polymer as a temperature controlled valve in a gas separation system.
SUMMARY OF THE INVENTION
[0015] To achieve the foregoing and other objects, and in accordance with the purposes of the present invention, as embodied and broadly described herein, provides a process for simultaneously screening a multiplicity of polymer materials for comparative effectiveness in gas separation, the process including preparing an array of individual testing ports on a substrate, each individual port including a pore passing through said substrate, a gas inlet to said pore at a first location of said substrate and a gas outlet from said pore at a second location of said substrate, placing said multiplicity of polymer materials, each within a pore of at least one individual port in an amount sufficient to form a meniscus-shaped polymer membrane within said pore, passing a pre-selected gas flow to said gas inlet, analyzing gas flow from said gas outlet, and, comparing gas separation properties for said multiplicity of polymer materials.
[0016] The present invention further provides a screening system for simultaneously screening polymer materials for effectiveness in gas separation including a substrate containing an array of individual ports, each port including a pore passing through said substrate, a gas inlet to said pore at a first location of said substrate and a gas outlet from said pore at a second location of said substrate, a meniscus-shaped polymer membrane situated within said pore with each meniscus-shaped polymer membrane formed of a pre-selected polymer material, and, a gas analyzer controllable attached to said outlet gas flows.
[0017] The present invention further provides the improvement in a gas separation process using a solid polymer membrane as a gas separator, wherein said solid polymer membrane is selected through the above-described screening process.
[0018] The present invention further provides a gas separation module including a substrate containing at least one opening therein, and, a polymer material contained within the opening of said substrate, said polymer material characterized as forming a meniscus-shaped separator within said opening.
[0019] The present invention further provides a temperature gas valve including a gas separation module including a substrate containing at least one opening therein and a polymer material contained within the opening of said substrate, said polymer material characterized as forming a meniscus-shaped separator within said opening, said temperature gas valve characterized as preventing a pre-selected gas to pass through said polymer material at a first temperature, but allowing said pre-selected gas to pass through said polymer material at a second temperature.
[0020] The present invention further provides an improvement in a detector including a sensing element responsive to the presence of a pre-selected species, said sensing element characterized as subject to deactivation in the presence of selected volatile organic materials, the improvement being location of a polymer membrane between said sensing element and any ambient atmosphere, said polymer membrane capable of allowing said pre-selected species to pass therethrough to said sensing element and said polymer membrane capable of preventing sufficient selected volatile organic materials to pass therethrough to said sensing element whereby said sensing element is deactivated.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] [0021]FIG. 1 shows a schematic drawing illustrating preparation of a meniscus-shaped membrane within a small pore or opening in accordance with the present invention.
[0022] [0022]FIG. 2 shows a sideview of the meniscus-shaped membrane in accordance with the present invention.
[0023] FIGS. 3 ( a )-( e ) show embodiments of meniscus-shaped membranes in accordance with the present invention.
[0024] FIGS. 4 ( a )-( c ) show additional embodiments of meniscus-shaped membranes with alternative pore or opening structures in accordance with the present invention.
[0025] [0025]FIG. 5 shows operation of a meniscus-shaped membrane for selective separation in accordance with the present invention.
[0026] [0026]FIG. 6 shows a graph of temperature versus helium flux for a meniscus-shaped membrane of polybenzimidazole in accordance with the present invention.
[0027] [0027]FIG. 7 shows a graph of temperature versus hydrogen flux and carbon dioxide flux for a meniscus-shaped membrane of polybenzimidazole in accordance with the present invention.
[0028] [0028]FIG. 8 shows a graph of temperature versus carbon dioxide flux and methane flux for a meniscus-shaped membrane of polybenzimidazole in accordance with the present invention.
DETAILED DESCRIPTION
[0029] The present invention is concerned with solid polymer membranes for gas separation. Additionally, the present invention is concerned with a system and process for determining and optimizing the operating temperature ranges of solid polymer membranes for gas separation.
[0030] By the term “solid” is meant that the membranes are substantially non-porous and do not contain a liquid element as would be the case in a liquid supported membrane system.
[0031] The present invention involves a gas separation membrane formed by the self-assembly of a solid polymer membrane or film into a thin meniscus that spans a small hole, pore or opening. The solid polymer membrane is formed by a process driven by capillary forces, viscosity, and surface adhesion effects. The result is a thin polymeric membrane or film that is strongly bound to the edges of a hole, pore or opening in a substrate. The seal between the solid polymer membrane and the substrate material defining the pore, hole or opening can be gas tight at pressures in excess of 100 pounds per square inch (psig). An important feature of the resulting solid polymer membrane is its non-uniform thickness throughout the span of the film. The meniscus that forms when the polymer dries in the hole is characterized by a thick structure at the point of attachment to the support material (the sides of the hole) and a minimum thickness at the center of the membrane (FIG. 1). The result is a solid polymer membrane that self-assembles into a concave “lens.”
[0032] The shape of the membrane resulting from this invention leads to separation properties well suited to several applications. The desirability of high fluxes in gas separation makes thin membranes attractive. The typical problem with thin polymer films is their fragility, even in composite structures. In capitalizing on the natural formation of a structurally optimized meniscus, this process yields membranes that are both thin and strong. FIG. 2 shows the reduced thickness 22 at the center of the film acting to enhance flux while maintaining a large contact area 24 with the metal support to improve strength. The inherent strength of the concave arch structure can surpass the strength of flat sheet membrane geometry.
[0033] In general, the meniscus membrane can range in thickness of from about 5 microns to about 100 microns with greater thickness at the edges of from about 7 microns to about 100 microns, tapering to as thin as from about 5 microns to about 50 microns at the center. The size of the meniscus membrane is limited only by the particular physical properties of the polymer material and the size of the hole, pore or opening. Generally, the size of any individual hole, pore or opening can be from about 0.003 inches in diameter to about 0.25 inches in diameter, preferably from about 0.03 inches in diameter to about 0.1 inches in diameter. A polymer meniscus membrane formed with a concave structure that affords a thin membrane thickness in the center will maximize permeability.
[0034] In one embodiment of the present invention, the substrate containing the holes, pores or openings can be a porous metal or porous ceramic substrate. An example of a suitable substrate is a commercially available ceramic substrate element made from silicon carbide. Another preferred substrate can be formed of a porous metal medium such as sintered porous stainless steel. Such a porous metal medium is available from Pall Corporation of East Hills, N.Y. under the trade names PSS (a sintered stainless steel powder metal medium), PMM (a porous sintered metal membrane including metal particles sintered to a foraminate support), PMF (a porous sintered fiber metal medium), Rigimesh (a sintered woven wire mesh medium), Supramesh (stainless steel powder sintered to a Rigimesh support), PMF II (a porous sintered fiber metal medium), and combinations of more than one of these materials. A sintered metal medium for use in the present invention may be formed from any of a variety of metal materials including alloys of various metals such as nickel, chromium, copper, molybdenum, tungsten, zinc, tin, gold, silver, platinum, aluminum, cobalt, iron, and magnesium, as well as combinations of metals and metal alloys, including boron-containing alloys. Brass, bronze, and nickel/chromium alloys, such as stainless steels, the Hastelloys, the Monels and the Inconels, as well as a 50 weight percent nickel/50 weight percent chromium alloy, may also be used. Examples of other suitable high temperature substrates include those formed of glass fibers.
[0035] In the present invention, the solid polymer material is- characterized as being substantially within the pores, holes or openings of the substrate. That is, the solid polymer material forming the meniscus-shaped membrane does not extend outside of the pores, holes or openings of the substrates to the outer surfaces of the substrate. This allows minimization of polymer material needed. In some instances, it may be desirable to apply a release material such as a polytetrafluoroethylene (PTFE) to selected surfaces of the substrate to prevent the polymer material from adhering at those locations. In some instances, a bonding agent such as a suitable silane material (e.g., a silane coupling agent such as, an alkyl siloxane or phenyl triethoxysilane) can be used to promote greater adhesion of the polymer material at certain locations.
[0036] In a process of preparation of such a meniscus membrane, a selected amount of polymer material can be placed into the pore, opening or hole in the substrate and the combination heated above the melting point of the polymer to allow it to form the meniscus-shaped membrane. Optionally, the selected amount of polymer material in conjunction with a suitable solvent for such material can be placed into the pore, opening or hole and the solvent evaporated from the system such that the polymer forms the meniscus-shaped membrane. In another embodiment, a substrate containing the openings, holes or pores can be dipped into an amount of the polymer material where the polymer material can penetrate the openings, holes or pores. Thereafter, the surfaces of the substrate can be wiped to remove excess polymer material. Selected regions can be pre-treated with a release material and/or bonding agent as well.
[0037] The simplicity of this meniscus membrane design is desirable as well. One sizeable hurdle to adopting polymer membranes in commercial devices is the difficulty in producing robust, inexpensive modules. The approach of the present invention can allow sealing and fixturing using a metal surface (the supporting disk) eliminating the need to seal the polymer in the membrane module. From a research standpoint this meniscus membrane design has several advantages. The ability to screen polymers rapidly by making a gas tight seal can expedite membrane testing. The versatility of the meniscus membrane structure is also an advantage. Control over the size and shape of the hole, pore or opening, the quantity of polymer loaded, and the chemical composition of the polymer can be useful in optimizing gas separation performance for particular applications. The ability to optimize the polymer performance and adjust the hole shape for increased strength is shown below. From FIG. 3( a ) to FIG. 3( b ) is shown an increase in polymer loading such that the mensicus-shaped membrane has a greater thickness. From FIG. 3( a ) to FIG. 3( c ) is shown a reduced hole size. The polymer chemistry of the mensicus-shaped membrane is shown represented by the darker membrane of FIG. 3( d ). An increase in gas flux rate can be obtained with the multiple pore/openings of the substrate in FIG. 3( e ).
[0038] By changing the shape of the hole or opening, particularly when such a hole or opening is within a supporting substrate (e.g., a metal or ceramic disk), the strength of the surface bonding between the meniscus shaped membrane and the surface of the substrate may be altered. Examples of such altered shapes of holes/openings are those shown in FIGS. 4 ( a )-( c ) where FIG. 4( a ) shows a typical shaped opening while FIG. 4( b ) shows tapered openings 42 and 44 , and FIG. 4( c ) shows other tapered openings 46 and 48 . Other modifications to the shapes of the holes or openings will be readily apparent to those skilled in the art.
[0039] In the present invention, the meniscus membranes are operated at high temperature ranges generally in excess of about 100° C., and often more preferably at high temperature ranges generally in excess of about 200° C. By use of such temperature ranges, the meniscus membranes can have different selectivity than found at more traditional ambient range temperatures.
[0040] Applications for small, selective membranes that can be easily integrated into commercial devices are numerous. For example, in the growing field of sensors and control switches it is often crucial to avoid the contamination of the sensor itself with non-innocent matrix constituents (FIG. 5). For example, carbon monoxide sensors are available with excellent selectivity for CO but their susceptibility to contamination by volatile organic compounds often limits their commercial use. A pre-filter (polymer membrane) that permeates CO selectively and at high flux provides a significant improvement to sensor designs. Such a pre-filter can be applied in any detector having a sensing element responsive to the presence of a pre-selected species, where the sensing element is characterized as subject to deactivation or a reduction in activity in the presence of selected volatile organic materials. By location of such a polymer membrane between such a sensing element and any ambient atmosphere (the polymer membrane capable of allowing the pre-selected species to pass through to the sensing element while the polymer membrane prevents sufficient selected volatile organic materials to pass through to the sensing element), the sensing element can be protected from deactivation or a reduction in activity.
[0041] Several properties of solid polymer membranes for gas separation also appear to have important potential for commercial application when in the meniscus form. The solubility selectivity of gases in polymer membranes can be changed by varying the backbone structure as well as the type and distribution of functional groups. Selectivity for certain gases can also be achieved by controlling the interchain spacing (i.e., free volume) in the matrix. Temperature can also be used to affect the separation performance of polymer membranes. As the temperature increases, thermal motion causes increased permeability of gases through the polymer. This behavior is shown in the graphs of FIG. 6, FIG. 7 and FIG. 8. Different gases (FIGS. 7 and 8) can have different flux rates at different temperatures yielding the opportunity for separation from one another.
[0042] Pressures of up to 100 psig have been withstood by the meniscus membranes of the present invention without failure, marking a significant improvement over the operating pressure of many freestanding polymer films. Advances in stability may be made with control of the hole geometry as well as the introduction of covalent interactions between the polymer and the metal support (silane coupling).
[0043] The gas separation performance of the meniscus-shaped membrane is highly dependent on the polymer structure. Preliminary data using PBI membranes in this configuration have shown that the performance is quite good and can be adjusted with temperature (FIG. 6).
[0044] Of particular interest are the following features of the meniscus membrane. The tunability of the gas separation performance is quite important for any application in which selectivity for a particular gas is desirable. The tradeoff between gas diffusivity and solubility in the polymer with the thickness of the membrane often makes optimization difficult in thin film membranes. Control over hole size as well as polymer loading (i.e., membrane thickness) and polymer structure (backbone structure, extent of crosslinking, functionalization with gas solubility functionality, and the formation if interpenetrating polymer networks) can give a valuable element of control in forming selective membranes for low flux applications (sensors).
[0045] The ability to form gas tight polymer films with high reproducibility that can be readily tested is seen as an important contribution to membrane gas separation technology. This invention allows the rapid screening of membranes consisting of different polymers in a variety of thicknesses.
[0046] The solid polymer membranes of the present invention can generally be formed of any solid polymer material capable of forming a meniscus-shaped membrane within a pore or opening of a substrate. Generally, glassy polymers are preferred. High gas separation factor materials are frequently glassy polymers. Representative examples of such polymers include polyesters, polyestercarbonates, sulfonated polysulfones and sulfonated poly(phenylene oxides), cellulosic derivative polymers, such as cellulose acetate or blends of cellulose acetate with poly(methyl methacrylate) to name a few. Also, the solid polymer material should be stable, both chemically and physically at high temperatures of above about 150° C.
[0047] The permeability of a gas or vapor through a membrane is a product of the diffusion coefficient, D, and the Henry's law sorption coefficient, k. D is a measure of the permeate's mobility in the polymer; k is a measure of the permeate's sorption into the polymer. The diffusion coefficient tends to decrease as the molecular size of the permeate increases, because large molecules interact with more segments of the polymer chains and are thus less mobile. The sorption coefficient depends, amongst other factors, on the condensability of the gas.
[0048] Depending on the nature of the polymer, either the diffusion or the sorption component of the permeability may dominate. In rigid, glassy polymer materials, the diffusion coefficient tends to be the controlling factor and the ability of molecules to permeate is very size dependent. As a result, glassy membranes tend to permeate small, low-boiling molecules, such as hydrogen and methane, faster than larger, more condensable molecules, such as C 2 + organic molecules. For rubbery or elastomeric polymers, the difference in size is much less critical, because the polymer chains can be flexed, and sorption effects generally dominate the permeability. Elastomeric materials, therefore, tend to permeate large, condensable molecules faster than small, low-boiling molecules.
[0049] Among the suitable solid polymer materials are included cellulose acetates, polyimides, polystyrenes, poly (alkyl methacrylate)s and copolymers of poly (alkyl methacrylate)s and other acrylates or blends thereof where alkyl can be methyl, ethyl and the like, poly(vinyl chloride)s, polysulfones, and polybenzimidazoles. Preferably, the solid polymer material is a polybenzimidazole that is thermally stable up to temperatures of at least about 450° C.
[0050] The solid polymer membranes of the present invention can also include semi-interpenetrating polymer networks such as blends of Thermid FA-700 thermosetting polyimide (commercially available from the National Starch and Chemical Corporation) and a thermoplastic polyimide heat treated at 250° C. to alter the polymer rigidity and inhibit interchain mobility so as to enhance control of diffusion pathways.
[0051] In one embodiment, the solid polymer membranes of the present invention may also surface functionalization, e.g., with CO 2 -philic groups (such as amines, sulfolenes, sullfolanes and carboxylates) so as to enhance selectivity of the solid polymer membranes for carbon dioxide.
[0052] The meniscus membranes of the present invention may be used as a thermal gas switch in a temperature valve approach. That is, a meniscus membrane may be positioned at a place within a system at which a particular gas is retained behind the meniscus membrane until the meniscus membrane reaches a selected temperature whereat the membrane allows the particular gas to pass through at some measurable flux. Thus, a thermal gas switch or temperature Valve is provided. Thus, at a first selected temperature the pre-selected gas can be retained while at a second selected temperature the pre-selected gas can pass. The first and second pre-selected temperatures are generally about 25° C. apart, preferably about 10° C. apart, more preferably as little as about 1° C. apart.
[0053] As a pre-concentration approach, the meniscus membranes of the present invention may be used for a mass spectrometry interface such that a semi-selective membrane may be used as the initial aperture of the machine.
[0054] The meniscus membrane design of the present invention would be valuable in fixtures ranging from thermal gas switches and flow controllers to gas purifiers in confined settings (such as, e.g., hydrogen gettering).
[0055] The present invention is more particularly described in the following example, which is intended as illustrative only, since numerous modifications and variations will be apparent to those skilled in the art.
EXAMPLE 1
[0056] A polybenzimidazole (PBI) meniscus-shaped membrane formed in an opening of size ( 0 . 005 inch) was exposed to a helium feed stream. At room temperature the permeance was negligible, but as the temperature was raised the flux increased significantly as shown in FIG. 6. Given the correct combination of selectivity and flux, selective separation of particular gas components may be achieved.
[0057] The formation of a leak tight (helium) seal between the metal edge and the polymer membrane. The holes range in size form 0.03 to 0.1 inches in diameter (drilled through a ¾ inch stainless steel disk, 0.0275 inch in thickness).
[0058] Additional data from polybenzimidazole (PBI) meniscus-shaped membrane formed in various openings is shown in Table 1.
[0059] Gas Separation Data fron PBI Meniscus Membranes
Single Gas Performance cm 3 (STP)cm/ (cm 2 s cmHg) × 10 10 Ideal Gas Mixed Gas Temp. (Barrer) Separation Separation Factor (° C.) He H 2 CO 2 He/H 2 H 2 /CO 2 H 2 /CO 2 CO 2 /CH 4 25 0.03 0.009 0.007 3.3 1.3 1.9 — 50 0.19 0.09 0.05 2.1 1.8 5.1 6.3 100 0.84 0.74 0.30 1.1 2.5 9.9 7.8 150 4.46 3.91 1.99 1.1 2.0 8.0 23.1 200 8.11 9.54 4.26 0.9 2.2 9.1 25.5 250 17.3 18.9 8.56 0.9 2.2 10.5 50.5
[0060] The process of the present invention should help overcome major economic and environmental challenges to gas separations.
[0061] Although the present invention has been described with reference to specific details, it is not intended that such details should be regarded as limitations upon the scope of the invention, except as and to the extent that they are included in the accompanying claims.
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Gas separation membranes, especially meniscus-shaped membranes for gas separations are disclosed together with the use of such meniscus-shaped membranes for applications such as thermal gas valves, pre-concentration of a gas stream, and selective pre-screening of a gas stream. In addition, a rapid screening system for simultaneously screening polymer materials for effectiveness in gas separation is provided.
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FIELD OF THE INVENTION
The present invention relates generally to analytical devices and micro-arrays containing integral fluidic input/output devices for sample application and washing steps. More particularly, the present invention relates to the input/output fluidic devices constructed from planar solid-phase hydrophilic matrix circuits containing dry chemical reagents for use in point of care diagnostics and other micro-scale analyses.
BACKGROUND OF THE INVENTION
Lateral flow diagnostic devices including a micro-porous element along which a sample fluid flows laterally and a capture region for binding an analyte of interest contained in the sample fluid are known in the art. A lateral flow diagnostic device of simple construction includes a rectangular micro-porous strip, which supports capillary fluid flow along its length. Generally, quantitative and sensitive detection using such devices is limited. More recently, devices that incorporate instrumentation that allow for quantitative determination of the amount of analyte in a sample have been disclosed.
The lateral flow diagnostic strip has become widely used in assay techniques. In its simplest form the prior-art lateral flow device comprises a microporous strip element, which supports capillary flow of a fluid along its length. The strip has one end for application of a sample containing an analyte to be measured, a first region along its length containing a mobile reporter conjugate (typically a visually observable reporter such as colloidal gold conjugated to a first antibody directed against the analyte) and a second region containing a capture reagent (typically a second antibody directed against the analyte), and an effluent end. Sample fluid applied to one end of the strip flows along the strip to the first region where a complex is formed between the analyte and the reporter conjugate. The sample, including the mobile reporter conjugate-analyte complex, flows to the second region where the reporter conjugate-analyte complex is captured, while uncomplexed mobile reporter conjugate flows beyond the capture region towards the effluent end of the strip. The amount of visually detectable signal at the capture region is a measure of the amount of analyte in the sample. Prior art lateral flow devices are used in the above described sandwich immunoassay format as well as in an inhibition or competitive binding format.
Because prior-art lateral flow devices are inexpensive, give rapid results and are easy to use, they have been used in non-laboratory applications in so-called field-able, on-site testing or point of care diagnostic applications. Devices of the prior art have been routinely used for non-instrumented, non-quantitative diagnostic applications at the point of care, the presence of an analyte at or above a threshold concentration being determined by observing the appearance of a visible signal at the capture region. However, devices of the prior art are not generally suitable for use in quantitative assays for two reasons. Firstly, they are usually formatted with visually observable reporters, which are suitable for threshold yes/no detection, but unsuitable for quantitative analysis. Secondly, both the concentration of the complex formed between the analyte and the reporter conjugate and the amount of binding at the capture site are flow rate dependent. The variability of device operation, particularly sample flow rate and sample evaporation, creates significant variability in the detected signal.
Recently workers in the field have disclosed quantitative lateral flow devices incorporating instrumentation to measure the amount of signal at the capture site when using a chromophore reporter, or to measure the light emitted upon laser excitation of the capture region when using a fluorescent reporter (U.S. Pat. Nos. 5,753,517 and 6,497,842). U.S. Pat. No. 5,753,517 517 and U.S. Pat. No. 6,194,222 disclose instrumented quantitative lateral flow methods using internal controls incorporated into the flow path for internal calibration of variable factors, in particular variable flow rates. However, even quantitative prior-art lateral flow devices, have not matched the sensitivity of more complex laboratory based assays. There are three primary reasons for lower sensitivity. The first reason is the absence of rigorous wash steps, which may be required to fully remove unbound reporter conjugate from the capture region. The second reason is the absence of an amplification step. The third reason is the absence of a high sensitivity detection technique such as chemiluminescent detection. Because they are less sensitive, lateral flow devices are only used in routine analysis of higher abundance analytes. Low abundance analytes must still be measured on laboratory equipment, which incorporates rigorous wash steps, enzymatic signal amplification and extremely sensitive chemiluminescent detection techniques.
Lateral flow devices that account for some of these shortcomings are known in the prior art. U.S. Pat. No. 6,306,642 discloses a device with a primary lateral flow element for formation and capture of an enzyme-conjugate/analyte complex, and a supplementary lateral flow element containing a chromogenic substrate and a means of delaying the delivery of a chromogenic substrate to the capture region. U.S. Pat. No. 6,316,205 discloses a two-step lateral flow device with improved wash-out of unbound conjugate using a lateral flow element to which sample fluid is applied and an absorption pad separated by a removable barrier with a supplementary manual second step application of a wash fluid.
High sensitivity assays for detection of analytes using multi-step procedures in conventional laboratory equipment are well known in the art. “Luminescence Biotechnology” eds. K. Van Dyke, C. Van Dyke and K. Woodfork, CRC Press, 2002, contains numerous examples of highly sensitive luminescence based assays. Enzyme immuno-assay kits based on membrane capture in a flow-through configuration (as opposed to lateral flow) are also known in the art. These kit-based devices typically require multiple reagent additions and wash steps and consequently are not well adapted to point-of care applications where a simple one-step procedure is preferable.
Flow-through type membrane based immunoenzymatic devices with a one-step format are now being developed. U.S. Pat. No. 5,783,401 discloses a device utilizing controlled transport membranes to provide the timed sequence of reaction steps in a multi-step enzyme immunoassay format.
Devices containing electro-osmotically pumped and pneumatically driven fluids in micro-channels (capillary dimensioned tubes, troughs and channels) are well known in the art. These devices are commonly referred to as ‘lab-on-a-chip’ devices (for example U.S. Pat. Nos. 4,908,112 and 5,180,480). Reactions, mixture separations or analyses can take place in such microstructures in liquids that are electrokinetically or pneumatically transported along conduits. However, generally in these prior art devices, reagents are stored off-chip and need to be introduced during use. Also, devices of these technologies have generally operated in a continuous flow format because valves have been difficult to construct.
Electro-osmotically pumped solid hydrophilic matrix transport paths have been disclosed in U.S. Pat. Appl. Publ. No. 2002/0179448. Self-contained devices with integral reagents featuring electro-osmotically pumped lateral flow injection into micro-reactors have been disclosed in co-pending U.S. Pat. Appl. Publ. No. 20030127333. U.S. Pat. Appl. Publ. No. 2002/0123059 discloses a self-contained assay device with chemiluminescence detection based on pressure driven flow in micro-channels. Lateral flow immunochromatographic devices with electrochemical detection using integral electrodes have been disclosed in U.S. Pat. No. 6,478,938.
In summary, one-step prior art lateral flow diagnostic devices lack the amplification, washing and high sensitivity detection steps needed for quantitative determination of analyte levels. Micro-channel devices in the prior art have not incorporated chemical entities in the channels and reagents storage within the device. The prior art does not teach a one-step assay device that is as easy to use and inexpensive to manufacture but which features the more advanced fluidic capability found in high sensitivity quantitative laboratory-based assay technologies and in which assay performance is largely independent of the fluidic components and reaction vessels in which the assay is performed. This invention addresses the need to adapt standard lateral flow elements to incorporate more advanced fluidic elements for use in conjugate label application, washing, amplification and enhanced sensitivity detection without sacrificing the speed, simplicity of use and low cost of standard lateral flow technologies.
SUMMARY OF THE INVENTION
It is now an object of the present invention to address the above described sensitivity and variability problems inherent in the prior-art one-step diagnostic assay technology and to provide a more general platform for one-step testing.
It is another object of the present invention to provide an instrument-controlled integrated, diagnostic assay device, which can be used for quantitative one-step diagnostic testing and analyte detection.
It is still another object of the invention to provide an injector pump for controlled pumping of a fluid to a receiving location of a fluid receiving device, preferably a lateral flow path element of a diagnostic assay device. In the most basic preferred embodiment, the injector pump includes an initially dry, preferably micro-porous, fluidic path with a fluid application end for accepting fluid and an effluent end for delivering fluid to the receiving location, which fluidic path automatically fills with fluid up to the effluent end upon fluid application to the application end. The injector pump further includes a driving means for electro-osmotically pumping fluid out of the effluent end of the fluidic path and across the isolator. The driving means is preferably a pair of spaced apart first and second electrodes for the generation of an electric field to force fluid in the fluidic path after wet-up past the isolation element. In another preferred embodiment, the injector pump further includes an integrated isolation element for fluidically isolating the fluidic path at the effluent end from the fluid receiving location. The preferred isolation element or isolator is an air gap preventing capillary flow past the effluent end.
In the injector pump with the air gap, the application of the electrical potential forces the fluid across the air gap by electroosmosis when the micro-porous fluidic path has a surface charge and a zeta potential.
The first electrode is preferably in contact with the fluid in the fluidic path at a first location and the second electrode is positioned at a second, spaced apart location for electrical contact with the fluid at the application end.
During use of an integrated diagnostic device comprising such an injector pump, a fluid is applied to the fluid application end of the pump's fluidic path (either a sample fluid or another fluid which is preferably contained in an integral reservoir and transported therefrom to the application end of the element during the use of the device). Fluid fills the fluidic path by lateral capillary flow from its first fluid application end to its second effluent end. A voltage is then applied to two spaced apart electrodes, which voltage powers electro-osmotic flow through the fluidic path.
It is yet another object of this invention to teach an injector pump which has chemical entities such as mobilizable reagents incorporated along the length of the micro-porous fluidic path. Such chemical entities may be reporter conjugates, for example, which can react with analytes in the sample applied to the lateral flow device or they can be wash reagents or enzyme substrates. Chemical entities in the fluidic path are mobilized upon application of fluid to the path's application end and then pumped under instrument control into the lateral flow device. Preferred mobilizable reagents are luminogenic, fluorogenic, electrogenic, and chemiluminescent substrates.
It is still another object of this invention to provide a micro-assay device into which is incorporated an injector pump in accordance with the invention. The injector pump can be used to control fluid entry into other fluidic flow paths and to provide for at least one of reagent addition, washing and amplification steps of chemical reactions within the device.
It is another object of this invention to provide a micro-assay device into which fluidic elements are incorporated so as to provide for advanced fluidic manipulations. The fluidic elements comprise lateral flow elements supporting passive capillary flow and elements under instrument powered electro-osmotic lateral flow. There can be any number of both types of fluidic elements so long as one element is for sample application and so long as at least one element is part of an injector pump.
It is another object of the invention to provide a micro-assay device with flow elements having integrated chemical entities (such as reporter conjugates or enzyme substrates). The integrated chemical entities can be mobilized by application of fluid to the element, thereby either binding to analytes within the fluid if the fluid applied is sample and the mobilizable chemical entity is a reporter conjugate, or being transported along the element to one or more micro-reactor regions contained along the elements. When the chemical entities incorporated into the flow elements are enzyme substrates, these substrates may be luminogenic, fluorogenic, chromogenic or electrogenic. It is also possible to use a non-enzymatic label incorporated into the flow elements.
It is still another object of this invention to provide a single, integrated, diagnostic assay device containing some or all of the reaction chemicals and fluidics required to perform solution-based chemical reactions such as analyte labelling, capture, post-capture wash steps, amplification and high sensitivity detection.
It is yet a further object to teach how such a device can be manufactured by micro-fabrication. The means for detection is dependant upon the choice of chemical entity either applied using the injector pump, or incorporated into the flow elements.
It is still a further object to teach how integrated, diagnostic devices can be used to generate a signal, which can be detected and quantified by an external apparatus to which the device can be connected. The devices could be in the form of a diagnostic card containing an electrode module such as found in smart cards, which can be inserted into an external apparatus. The external apparatus provides for power to control fluid transport from one or more fluidic elements into micro-reactors within the device. The external apparatus can be connected to the diagnostic card in such a way to allow the products of the reaction occurring within the micro-reactors to be detected.
In a preferred embodiment, the injector pump is part of a micro-assay device and can be used to control fluid entry into other micro-channels within the device and to provide for reagent addition, washing and amplification steps of chemical reactions within the device. The pump will also be referred to herein as a second flow path.
Another preferred embodiment is a diagnostic device comprising an injector pump and a lateral flow element with a capture region along its length for binding analyte molecules contained within a sample fluid flowing through the lateral flow element. The injector pump provides for supplement actively pumped integral fluidics by providing wash, conjugate label application, amplification and detection of the captured complex. The lateral flow element comprises a sample application end and contains a micro-reactor region along its length.
In the one-step operation of the device of the invention, the user introduces sample to the diagnostic device and connects the diagnostic device to an external control instrument. Sample fluid is understood to be any chemical or biological aqueous fluid containing an analyte which is a chemical of interest to be analyzed. Sample fluid flows by capillary lateral flow through a fluidic element to an integral micro-reactor region of the device. Other reagents and wash fluids are then actively pumped to the micro-reactor region under instrument control and in timed sequence through other integral flow elements containing reagents that are also integral to the diagnostic device. The resulting device still retains the simplicity of the prior-art lateral flow device because it still only requires a simple one-step procedure by the user (all other steps being performed automatically by the instrument), and it is still low cost, but will now enable the quantitative determination of low abundance analytes.
Devices according to this invention can be configured in many different fluidic arrangements and in many different formats depending on the nature of the assay performed. In preferred embodiments of the invented diagnostic devices directed to sandwich type ligand-binding assays there are two types of assay format. In a first assay format a labelled conjugate is first reacted with an analyte in a sample fluid to form a complex, then the analyte-conjugate complex is captured for subsequent detection, the amount of captured complex detected being proportionate to the concentration of analyte in the sample. In a second assay format, the analyte is first captured then the captured analyte is reacted with a labelled conjugate with subsequent detection of the labelled capture complex.
In one preferred embodiment of the diagnostic assay device of the invention directed to a sandwich type ligand-binding assays in the format where the labelled conjugate reacts with analyte before capture, the integral, instrument-controlled fluidics of the device comprises a first micro-porous lateral flow element for flow of a sample fluid and at least one other micro-porous flow path for supplying another fluid to a fluid-receiving region of the first lateral flow element under instrument control. The first lateral flow element has a first end for sample application, and a second effluent end. There is an optional sample application pad and optional reagent application pad in fluidic contact with the first lateral flow element at its sample application end, and an optional fluid collection pad at its effluent end. The first lateral flow element may contain mobilizable dry reagents. For example, when performing a sandwich type ligand-binding assay, the mobilizable reagent in the first lateral flow element (or in the reagent pad in fluidic contact with it) may be a conjugate comprising a first agent that binds to an analyte (for example an antibody in an immunoassay or a nucleic acid in a nucleic acid assay) that is coupled to a label or reporter molecule (for example an enzyme reporter). There is a reaction region along the length of the first micro-porous element located in a micro-reactor containment means. The reaction region of the first micro-porous element may, for example, comprise a capture region containing immobilized second binding agent (a second antibody to the analyte in an immunoassay or a second nucleic acid in the case of a nucleic acid assay) that. The first micro-porous flow path element is also connected by a second flow path at a fluid-receiving location for injecting a second fluid, the second flow path being actively pumped under instrument control and generally, being part of an injector pump. The second flow path is a micro-porous element with a first end for fluid application and a second effluent end. It may be initially dry and may contain mobilizable dry reagents (for example, a substrate for the enzyme label in the ligand-binding assay). There is an air gap separating the effluent end of the second path from the fluid-receiving region of the first lateral flow element, which constitutes an isolation means.
During use of this device, sample fluid is applied to the application end of the initially dry first lateral flow element. Another fluid, a low conductivity aqueous electrolyte solution preferably contained in a sealed fluid reservoir integral to the device, is introduced into the initially dry second flow element from its fluid application end. The fluids flow by capillary flow through the two elements, dissolving or mobilizing the dry reagents therein, and fill the elements up to their effluent ends. In the ligand-binding assay example the mobilizable reagents include an enzyme labeled conjugate which binds with the analyte in the sample fluid as it flows along the first lateral flow element. A capture complex comprising the enzyme labeled analyte is formed in the micro-reactor region of the first flow element as the sample fluid containing enzyme labeled analyte complex traverses the micro-reactor region and binds to the immobilized binding agent at the capture site. Mobilizable reagents including enzyme substrate in the second flow path are transported to its effluent end as it fills by capillary flow. The isolation means assures that the fluid and mobile reagents in the second flow path are fluidically isolated from fluids and reagents in the first lateral flow element until such time that they are injected into the first lateral flow element at its fluid receiving location and thence to the micro-reactor region in the first lateral flow element by pumping under instrument control.
Instrument controlled injection from the second flow path to the first lateral flow element is by electro-osmosis in which case the pore surfaces of the micro-porous second flow path have a surface charge and zeta potential. The preferred method of providing power to drive electro-osmosis in the second fluidic path is with integral electrodes. The preferred electrical contact of the integral electrodes to the second fluidic path is one in which there is a field free region at the effluent end of the path. When the instrument-controlled pump power is supplied to the second flow path, fluid, including mobilizable reagents contained therein, is supplied to the micro-reactor region of the first flow element where the fluid reacts with fluid and reagents contained therein. In the enzyme labeled sandwich assay example the enzyme substrate supplied by the second flow path reacts with the enzyme label contained in the micro-reactor region of the first flow element to produce a detectable signal. A detector proximal to the micro-reactor measures the course of the reaction taking place in the micro-reactor which determines the concentration of an analyte contained in the sample fluid.
There are several possible high sensitivity detection formats in the known art appropriate for use in a device according to the invention. The enzyme substrate supplied to the micro-reactor region by instrument-controlled injection may be luminogenic, fluorogenic, or chromogenic. A luminogenic substrate reacts with the enzyme emitting a light signal, a fluorogenic substrate also emits a light signal but upon irradiation, and a chromogenic substrate reacts to produce a change in absorbance or reflection of incident light. In these cases, the proximal detector is preferably a light detector. It is also possible to use an electrogenic substrate for the enzyme label in which case the proximal detector is preferably an integral electrochemical detection electrode in contact with the micro-reactor region. It is also possible to use a non-enzymatic label such as a chemiluminescent acridinium ester compound known in the art. In that case, the reagent supplied to the micro-reactor region by instrument controlled injection is a known chemiluminescence triggering reagent and a light detector is preferably used to detect the product of the reaction.
The preferred detection format of this invention uses luminescence and the proximal detector is a light detector. When enzyme label is used in a luminescence detection scheme, the enzyme is preferably alkaline phosphatase in which case high sensitivity luminogenic substrates such as the known dioxetanes (for example adamantyl methoxy phenyl phosphate dioxetanes, AMPPD) can be used. Another possible known high sensitivity alkaline phosphatase substrate is luciferin-ortho-phosphate which is supplied to the capture region together with luciferase and ATP and magnesium ions. In this case the alkaline phosphatase decomposition of the luciferin phosphate produces luciferin which is enzymatically converted to bioluminescent light upon action by luciferase. Also possible is a galactosidase enzyme label and its adamantine-dioxetane luminogenic substrate. Another known high sensitivity assay format uses acetate kinase enzyme label, in which case its substrate acetylphosphate, ADP, luciferase and magnesium ion are supplied to the capture region. In this case acetate kinase catalysed formation of ATP is detected by the bioluminescent luciferase reaction. In another example, the enzyme label may comprise horseradish peroxidase in which case enhanced luminol reagent known in the art may be used.
When an enzyme label is used in a fluorescence detection scheme, the enzyme is preferably alkaline phosphatase and the high sensitivity fluorogenic substrate methyl umbiferyl phosphate (MUBP) can be used. When an enzyme label is used in an electrochemical detection scheme, the enzyme is preferably alkaline phosphatase and the electrogenic substrate para amino phenyl phosphate can be used.
A preferred embodiment of the diagnostic device is a ligand-binding micro-assay device in which a labelled conjugate is first reacted with an analyte in a sample fluid to form a complex. The analyte-conjugate complex is captured for subsequent detection, the amount of captured complex detected being proportionate to the concentration of analyte in the sample. The first lateral flow element has enzyme-labelled conjugate as the mobilizable reagent. The enzyme-labelled conjugate binds with the analyte in the sample fluid as it flows along the first lateral flow element. A capture complex comprising the enzyme-labelled analyte is formed in the micro-reactor region of the first flow element as the sample fluid containing enzyme labelled analyte complex traverses the micro-reactor region and binds to the immobilized binding agent at the capture site. Mobilizable reagents including enzyme substrate in the second flow path are transported to its effluent end as it fills by capillary flow. The isolation means assures that the fluid and mobile reagents in the second flow path are fluidically isolated from fluids and reagents in the first lateral flow element until such time that they are injected into the first lateral flow element at its fluid-receiving location and thence to the micro-reactor region in the first lateral flow element by pumping under instrument control.
In the sandwich-type ligand-binding assay device, instrument-controlled fluid injection in the second flow path of such a device is by electro-osmosis. The pore surfaces of the micro-porous second flow path have a surface charge and zeta potential. When the instrument-controlled pump power is supplied to the second flow path, fluid, including mobilizable reagents contained therein, is injected into the first lateral flow element at its fluid receiving region. The fluid is transported to the first micro-reactor where it reacts with fluid and reagents contained within it. In a second step, instrument-controlled pump power is again supplied to the second flow path and the fluid in the first micro-reactor is transferred to the second micro-reactor where it reacts with reagents contained therein. A detector proximal to the second micro-reactor measures the course of the reaction taking place in the second micro-reactor which is a measure of the concentration of an analyte contained in the sample fluid.
An example of a two stage reaction that can be performed in the above device is the reaction using an enzyme substrate such as luciferin-ortho-phosphate. Luciferin-ortho-phosphate is supplied to the micro-reactor region of the first flow element containing a capture complex with an alkaline phosphatase enzyme label. After an incubation step, luciferin, the product of the reaction, is fluidically moved under instrument control to the second micro-reactor region containing luciferase, ATP and other assay reagents to produce a bioluminescent signal. Another possible two stage reaction uses an acetate kinase label and acetylphosphate substrate along with ADP and magnesium ions to produce ATP in a first incubation step. The ATP is then fluidically moved to a second micro-reactor containing luciferase and luciferin to produce the bioluminescent signal.
In an embodiment of the invention directed to analyte capture followed by labelling, the device preferably includes a first micro-porous lateral flow element containing a sample fluid application end and an effluent end and having a capture region along its length. The volume of the element is known and thence its fluid capacity. The device further includes multiple auxiliary fluidic paths for injection of fluids into the first lateral flow element. Each of the auxiliary flow path elements is capable of being independently actively pumped under instrument control. The auxiliary flow paths each comprise a micro-porous element with a first end for fluid application and a second effluent end. Each micro-porous element has a surface charge and a zeta potential and is contacted by integral electrodes for supplying instrument-controlled power to drive electro-osmosis. The preferred electrical contact location to each auxiliary fluid path is one in which there is a field free region at the effluent end of the path. Each auxiliary fluid path is initially dry and optionally contains mobilizable dry reagents. Each auxiliary fluid path has an air gap separating its effluent end from each of three fluid-receiving regions along the length of the first lateral flow element.
During use of this device, sample fluid is applied to the application end of the initially dry first lateral flow element. A second fluid, a low conductivity aqueous electrolyte solution preferably contained in an integral sealed fluid reservoir, is introduced into each initially dry auxiliary flow path element from its fluid application end. Sample fluid flows by capillary flow through the first lateral flow element. The second fluid fills each of the auxiliary flow path elements by capillary flow thereby mobilizing and transporting reagents to the effluent ends. The air gaps assure that the fluid and mobile reagents in the auxiliary flow paths are fluidically isolated from fluids and reagents in the first lateral flow path until such time that they are injected into the first flow element by pumping under instrument control. Subsequent instrument controlled fluid propulsion to the first flow element is by electro-osmosis. When instrument-controlled pump power is supplied to each of the auxiliary flow paths, fluid, including mobilizable reagents contained therein, is injected into the first lateral flow path.
In another embodiment of this device, there are three auxiliary actively pumped flow paths: a first for supplying a conjugate with an enzyme label, a second for providing a wash fluid and a third for providing an enzyme substrate to the capture region of the first fluidic element.
During use of this embodiment, sample fluid is applied to the fluid application end of the initially dry first lateral flow element and flows by capillary action along the element to the effluent end. The dissolved analyte to be assayed contained in the fluid is captured at the capture region along the length of the lateral flow element. The volume of fluid flowing over the capture region is known because the fluid fill volume of the element is known and controlled by the volume of the element downstream of the capture region.
In the next step, a first injection fluid containing enzyme labelled conjugate is injected from a first auxiliary flow path into the first lateral flow element at a first injection location along its length. The first injection fluid flows along the first lateral flow element towards the effluent end as well as towards the fluid application end. During this step sample fluid in the first lateral flow element is flushed out and replaced by the first injection fluid. The first injection fluid flows over the capture region and a sandwich complex is formed there when the labelled conjugate binds to the captured analyte.
In the next step, a second wash fluid is injected from a second auxiliary flow path into the first lateral flow element at a second injection location along its length. The second fluid flows along the first lateral flow path towards the effluent end. During this step the first injection fluid in the first lateral flow element is flushed out thereby removing excess unbound conjugate out of the capture region and replaced by the second wash fluid. Importantly, the first injection fluid containing excess unbound conjugate is flushed out of the capture region thus removing unbound label. In the next step performed under instrument control, a third injection fluid containing enzyme substrate is injected from a third auxiliary flow path into the first lateral flow element at a third injection location along its length. The third fluid flows along the first lateral flow path towards the effluent end as well as towards the fluid application end. During this step the wash fluid in the first lateral flow element is flushed out and replaced by the third injection fluid. When the third injection fluid containing enzyme substrate is moved so as to be located within the capture region, the instrument controlled injection stops. At this time the enzyme substrate reacts with the enzyme-labelled capture complex.
The reaction produces a detectable signal proportionate to the amount of captured complex which in turn is proportionate to the concentration of analyte in the sample. The signal is measured by a detection means located proximal to the capture region of the device. In an optional variant of the use of this device there is a wash step performed by instrument controlled injection of the wash fluid before injection of conjugate (to wash out sample fluid from the reaction region), as well as a wash step after injection of conjugate. Any of the above recited high sensitivity detection schemes can be used in this device.
Those skilled in the art will appreciate that there are numerous other fluidic arrangements and assay formats that can be contemplated using the inventive principles described in the above exemplar devices.
In general, an integral diagnostic device of this invention comprises a substrate with at least one signal generating micro-reactor (or micro-reactor array for multiplexed assays) and integral reagents and fluidics. A micro-reactor comprises a containment means for containment of an aqueous chemical reaction. The chemical reaction produces a detectable signal which determines the concentration of an analyte in a sample fluid. The micro-reactor may further comprise an optional capture region. Each micro-reactor has integral fluidics comprising a network of N fluidic input path elements and M fluidic effluent path elements. A fluidic path is an element through which fluid flows by capillary action. A fluidic path has a fluid input end through which fluid enters the element and a fluid effluent end through which it leaves the element. The N input fluidic paths and M effluent fluidic paths are initially dry elements and, during use of the device, are filled by lateral capillary flow when a fluid is applied to their fluid input end. In the array of micro-reactors each micro-reactor is connected to a fluidic network where the numbers N and M of input and output fluidic elements may be different for each micro-reactor.
In the first step during use of this diagnostic device, some or all of the initially dry N and M fluidic paths are filled with fluid by lateral capillary flow. At least one of the N and M paths is a injector. An injector is defined as a fluidic path element capable of being actively pumped under instrument control and which, after being filled by capillary flow from its fluid application end to its effluent end, is fluidically isolated at its effluent end from associated other fluidic elements (such as other fluidic paths and the micro-reactor) by an isolation means in the form of an air gap. The fluid does not flow beyond the effluent end of the path and the reagents in the path do not react with chemicals in other paths or in the micro-reactor until the fluid in the injector's flow path is actively pumped out (by instrument controlled means) beyond the isolation means at its effluent end to another fluidic element. Some of the N and M flow paths might also be active pump elements, that is, they are actively pumped by instrument-controlled pumping means, but they are non-injector elements, since they are not fluidically isolated. In actively pumped, non-injector elements, the effluent end of the fluid-filled element is in fluidic contact with other fluidic elements before applying instrument controlled pump power and there is no isolation means. Still other of the N and M flow paths might be passive pump elements that are not actively pumped by instrument controlled pumping means, but rather utilize non-instrument controlled passive pumping by a wicking device at their effluent ends. Still other paths are not pump elements at all: They fill from the dry state up to their effluent end and then the fluid does not move unless an external pressure is applied to drive fluid along the path. Some of the N and M flow paths may comprise micro-porous lateral flow materials, others may be empty channels or pipes as in conventional fluidic components.
Active pumping of pumped path elements is by electro-osmosis in which case the pumped path element should have at least a region with a charged capillary surfaces and a zeta potential. Power for active pumping is supplied by instrument controlled means and is preferably supplied through a pair of spaced apart integral electrodes, at least one of which contacts the pump's fluidic path along its length and the other contacts the path at another location along its length or contacts a fluid that is in electrical contact with the path's fluid at the application end.
Any or all of the initially dry fluidic path elements may contain dry reagents which are mobilized upon aqueous fluid introduction by capillary flow. If the path element is an actively pumped path element the mobilized reagents may then subsequently be transportable to another location under instrument control, in particular to a micro-reactor. Any or all of the paths may contain capture reagents which can capture and immobilize chemicals in the fluid contained therein.
In the above general embodiment at least one of the initially dry N fluid input paths is filled by capillary flow with sample fluid. Some or all of the other initially dry paths may be filled by capillary flow with sample fluid, or with a different aqueous fluid. When the fluid is different from sample fluid, the paths may be preferably filled with a fluid originating from at least one integral fluid source initially contained in at least one sealed reservoir which fluid is supplied to the input end of the paths during the use of the device.
Micro-reactors in various embodiments of the invention are reaction containment structures. A reaction containment structure assures that the contents of the reactor stay contained within a fixed location during the course of the reaction. A micro-reactor may be a region of a micro-porous flow path element, or a chamber or channel fluidically connected to a region of a flow path element. The chamber or channel may be enclosed or it may be vented to atmospheric pressure. A signal generating micro-reactor region contains a reaction which generates a signal proportionate to the concentration of an analyte to be determined. The location of the signal generating micro-reactor is proximal to a detector of the instrument used to monitor the course of the reaction.
In preferred embodiments of this invention for use in ligand-binding assay applications a lateral flow element for flow of a sample fluid comprises a micro-reactor region with a capture agent. In one embodiment of the invention a micro-reactor is a region of a micro-porous flow path element with an open-top reaction chamber. It comprises a planar slab element with an orifice mounted over a micro-porous flow path element, the slab's orifice being located over the flow path's reaction region. The side wall of the slab's hole forms the side wall of the micro-reaction well, and the planar substrate with the reaction region of the first flow path element forms the base of the micro-reaction well. The effluent end of at least one injector is located at the edge of the well with fluid being actively pumped into the well in a direction orthogonal to fluid flow within the first flow path element. As fluid fills the micro-reactor's containment-well, air is vented out through the open top. In another embodiment of a vented reaction chamber, the effluent end of the at least one injector is located outside the wall perimeter of the well, with an air gap between the effluent end of the injector's fluidic path and the well cavity. In another embodiment, the micro-reactor is a chamber or channel with a closed-top that intersects a reaction region of a micro-porous flow path. This intersecting chamber or channel may be enclosed or vented to atmospheric pressure. In another embodiment the micro-reactor is a region of a microporous fluidic path element, fluid being completely sealed at its perimeter.
There are various possible electrical contact locations. In one case the contacts are at two spaced apart locations along the length of the path. There is a first field-free region between the first fluid application end and the first contact, a region between the first and second contacts in which there is an electric field and a second field-free region between the second contact and the effluent end of the pump's path. In another case a first electrical contact is at the path's first application end (or even beyond it, making electrical contact outside of the path to the fluid which was applied to the first application end and in electrical contact with it), and a second contact is at a location along the length of the path, there being a region between the application end and the second contact in which there is an electric field and a field-free region between the second contact and the effluent end of the path. In a less desirable case, electrical contacts are located at each end of the element. In this case the fluid contained within the entire element is in the electric field.
It is often preferable to have a field-free space at the effluent end of the fluidic path. In this case, and when the initially dry path contains a mobilizable dry reagent, the dry reagent can be initially located anywhere along the length of the initially dry path. During use of a device with an injector with a field-free region at its effluent end, when fluid is applied to the pump path's first fluid application end, the initially dry path is filled by capillary flow and the mobilizable reagent is transported to the effluent end of the path stopping at the isolation means. When a voltage is applied to the path through its contact locations, the fluid in the path including the mobilizable reagent is pumped out of the effluent end. During the pumping process the mobilizable reagent is always located in the field-free region. In this arrangement, the reagent is not negatively influenced by the applied electrical power (it will not electrophorese if charged, and it will not react electrochemically at the electrodes).
An injector's electro-osmotic pump must propel fluid at useful speed independent of external perturbation and, if pumping a fluid load through a fluidically resistive element, often against a considerable back-pressure (for typical fluid load resistances of circuits of this invention the pressure at the effluent end of the pump can be of the order of 1 atmosphere above ambient pressure or even higher). To achieve this requirement it is necessary that the pump region of an injector (the region of the path between the electrode contact locations) should be micro-porous and have a zeta potential. A micro-porous flow path with pores smaller than a radius of 1 micron is typically required, preferably less than 0.2 microns. To operate efficiently and reproducibly, the micro-porous electro-osmotic pump region must be sealed by a perimetric sealing means. An unsealed micro-porous pump element or, in the limit, one that is a free standing micro-porous slab with perimetric air (an arrangement often encountered in lateral flow elements of the prior art) will not pump effectively against a back pressure because the fluid will be expelled from the pores of the slab in a perimetric direction as opposed to along the path and out of the effluent end.
There are two ways in which an injector may be configured relative to a fluid-receiving element at its effluent end. In both ways the injector's effluent end is initially separated from the fluid-receiving element of another fluidic element by an air gap. In a first configuration the effluent end of the injector, the air gap and the fluid-receiving region of another fluidic element are sealed into an enclosing chamber containing air. This chamber is not vented to the external atmosphere. Both the injector and the fluid-receiving element have been previously primed with fluid. As the injector is powered, its fluid is delivered out of its effluent end displacing the air in the air gap isolation region to elsewhere in the sealed chamber, allowing fluid to contact the receiving region of the fluid-receiving element. The air in the sealed chamber becomes pressurized, which pressure drives the injector fluid into the fluid-receiving element. When the pump is turned off, the compressed air in the non-vented chamber pushes the fluid both into the fluid-receiving element and back through the injector's flow path, returning the air gap to the region between the effluent end of the injector and the fluid-receiving element. This process can be accelerated by operating the injector's pump in reverse polarity, allowing the fluid in the chamber to withdraw more rapidly. After this process, the injector, now in its off-state, is again isolated (electrically and fluidically) from the fluid-receiving element. In this way there can be multiple injectors along the length of the sample fluidic element, each isolated when turned off, but fluidically connected when turned on. This allows for numerous individually pumped injectors being operated in sequence without crosstalk between pumps (which would be the case if they were permanently connected electrically and fluidically). Furthermore, an injector can be turned on under instrument control to pump fluid, then turned off returning it to its isolated off-state while other fluidic operations are performed in the device, and then turned on again to pump a second or even multiple subsequent times.
In a second configuration, the sealed enclosure is vented to the external atmosphere by an air vent channel. As the injector is powered, its fluid is pumped out of its effluent end displacing the air in the air gap isolation region out of the sealed chamber through the vent channel, allowing the injected fluid to contact the receiving region of the fluid-receiving element. The chamber remains at atmospheric pressure and the injected fluid is not pneumatically driven into the fluid-receiving element. Reagents in the injected fluid in contact with the fluid-receiving element can diffuse into the receiving element and react therein. After operation of an injection step performed in this configuration, the pumped fluid in the vented enclosure can be drawn back by the pump when it is operated in reverse polarity thus isolating the pump from the receiving fluidic element.
An air gap region at the effluent end of the flow path of an injector is a fluid isolation means. An air gap region is a space between the effluent end of the injector's flow path and another fluid-receiving element. When fluid is applied to the initially dry flow path of the injector at its fluid application end, the fluid flows by capillary flow to fill the path up to the effluent end, stopping at the air gap isolation means. The isolation means is effective in halting the capillary flow of fluid beyond the effluent end of the flow path. When the flow resistance of the injector's flow path (which is maximal when the pore size is small and flow path dimensions are long) is sufficiently large it impedes leakage flow through the injector in its off-state beyond the effluent end of the injector's path, even when there are pressure differences that may arise during the use of the diagnostic device across the input and effluent ends of the injector's path, or when there are capillary pumping forces that may arise during the use of the device created by the surfaces of other fluidic elements at the input and effluent end of the path. The air gap is preferably sized to ensure that any such incidental fluid leakage out of the injector during its off-state will not traverse the air gap thus removing the fluidic isolation. When the injector is in its on-state, a voltage is applied along the path of the fluid-filled injector, which path has a region with a surface charge and a zeta potential, fluid moves beyond the path's effluent end into the air gap region and beyond to the fluid-receiving element. The injector must then be capable of pumping at a useful speed (determined by the assay requirements) overcoming the back pressure created by the fluid-receiving element's flow resistance, and the air gap isolation means should be sized so that the injected fluid can traverse it in a useful time period.
A fluid-receiving element is an element connected to an injector's effluent end. It can be a micro-porous path or chamber element or a conventional open channel, pipe or chamber. The fluid-receiving element may be initially dry or filled with fluid at the time it receives fluid from the injector. If the fluid-receiving element is micro-porous and dry when it receives fluid from the injector, the received fluid will flow by capillary wicking along it. If the fluid-receiving element is already filled with fluid when it receives fluid from the injector, the received fluid will displace the existing fluid when the fluid-receiving region of the receiving element is connected to the injector at an enclosed air chamber. The fluid-receiving element may have a zeta potential and be connected by integral electrodes in which case the received fluid can be further electro-osmotically pumped along the receiving element or injected into another receiving element connected to it.
A micro-porous flow path of the invention may comprise a variety of different materials known in the art. Such materials have hydrophilic surfaces enabling capillary wicking of aqueous solutions. For example, micro-porous cellulose acetate, cellulose nitrate, polyethersulfone, nylon, polyethylene and the like may be used. The micro-porous flow path of an injector pump may be a single element or may contain more than one element in combination through which fluid can flow by capillary action. Micro-porous electro-osmotic injector elements should further comprise a material with a surface charge and a zeta potential. A preferred material is cellulose nitrate.
Sealing elements of the invention are electrically insulating materials which are capable of forming a fluidic seal around the perimeter of a flow path element. Die cut sealing elements for use in injectors of the invention may comprise any of the known pressure sensitive glue formulations available in sheet form such as siloxane or acrylic glues. These materials, when laminated around the injector form a seal upon re-flow under applied pressure. Many other insulating sealing materials which can be applied as a conformal coating when deposited from a solvent are appropriate for use in the invented devices.
Diagnostic devices with integral instrument controlled fluidics according to this invention can be manufactured in one of two ways. In a first way, the micro-porous flow path elements are formed from membrane sheets, for example by die cutting, and then assembled and sealed onto a planar substrate. In a second way, the flow path elements are produced in a thin film microfabrication process. In this technology a film of micro-porous material is formed on a planar substrate by a deposition technique such as spin coating from a solution of the membrane material dissolved in a solvent system appropriate to cause a phase inversion during the film's drying in the spin coating process. The phase inverted material is micro-porous. The resulting micro-porous dry film is then formed into flow path elements by a photolithographic process, which process includes the steps of coating with a photoresist, exposure and patterning of the photoresist and pattern transfer into the micro-porous film by a subtractive etch using a reactive gas plasma. Micro-fabrication materials and methods of forming micro-porous flow path elements and perimetric sealing means are disclosed in more detail in co-pending US Patent Application Publication No. 20030127333.
Dry reagents contained in specified locations of the micro-porous flow path elements can be deposited from a solution using nozzle micro-dispensing technology as is known in the art and practiced routinely in the manufacture of lateral flow devices and other membrane based dry reagent devices of the known art.
Another embodiment of the invention comprises an array of detection devices comprising an array of micro-reactors each having peripheral fluidics with at least one instrument controlled injector. In a preferred embodiment of this array the device is manufactured in micro-fabrication technology.
Other aspects and features of the present invention will become apparent to those ordinarily skilled in the art upon review of the following description of specific embodiments of the invention in conjunction with the accompanying figures.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the present invention will now be described, by way of example only, with reference to the attached Figures, wherein:
FIGS. 1A-C show a top view and cross-sectional view schematics of an instrument-controlled electro-osmotic injector comprising integral electrodes connected to a fluid-receiving element according to a preferred embodiment of the invention;
FIGS. 2A-H show top view schematics of instrument controlled electro-osmotic injectors comprising integral electrodes and their different modes of connection to single fluid-receiving elements;
FIGS. 2I-Q are top view schematics of instrument controlled electro-osmotic injectors comprising integral electrodes and their different modes of parallel connection to two fluid-receiving elements;
FIGS. 2R-S are top view schematics of multiple instrument controlled electro-osmotic injectors comprising integral electrodes and the different modes of connection to a single fluid-receiving element;
FIGS. 3A-G are top views of fluid flow schematics during the fluid injection operation of an injector connected to a fluid-receiving element;
FIGS. 4A-B are a top view schematic of an injector connected to a fluid-receiving element including dimensions in millimeters, and the device's fluid flow equivalent circuit respectively;
FIG. 5 shows flow characteristics of the device of FIG. 4A ;
FIG. 6 is a top view schematic of a one-step diagnostic card incorporating a sample flow path with a multi-injector manifold and an integral sealed reservoir containing injector priming fluid;
FIG. 6A show cross-sectional view schematics of the diagnostic card of FIG. 6 .
DETAILED DESCRIPTION
A schematic of an instrument controlled electro-osmotic injector as part of a diagnostic device of the invention is shown in FIG. 1 . Throughout this detailed description section, the terms injector and injector pump are interchangeable. The terms fluidic path, fluidic element and fluidic path element are also interchangeable, as are the terms isolation element and isolator and the terms fluid receiving region and fluid receiving location. The top view schematic of FIG. 1A shows a substrate 10 with two integral electrodes for making electrical contact to an initially dry micro-porous fluidic path element 1 . A first electrode has a contact pad 7 for connection to an electrical circuit and a contact location 8 for making electrical contact with the fluidic element 1 along its length. A second electrode has a contact pad 5 for connection to an external circuit and a contact location 6 near to the fluid application end 2 of element 1 for making electrical contact to the fluid applied to the fluid application end 2 of element 1 . There is a first sealing element 9 covering the substrate 10 under the injector's fluidic path element 1 and under the fluid-receiving region 13 of a fluid-receiving element 12 , but not covering the electrodes at contact locations 5 , 6 , 7 and 8 . There is a second sealing element 11 covering the injector's fluidic path element but not at its fluid application end 2 or its effluent end 3 . The second sealing element also covers a portion of the receiving element 12 but not at its fluid-receiving region 13 .
The first and second sealing elements 9 and 11 form a seal around the perimeter of the injector as shown in FIG. 1C which is a cross-sectional schematic through the section B-B′ of FIG. 1A . There is a cover element 23 located over the opening in sealing element 11 at the location of the effluent end of 3 of the injector and the receiving region 13 of the fluid-receiving element 12 . The cover element 22 is sealed to the second sealing element 11 forming an enclosed air chamber 15 surrounding the effluent end 3 of the injector and the receiving region 13 of the fluid-receiving element 12 . There is an air gap isolation element 14 fluidically separating the effluent end 3 of the injector and the receiving region 13 of the fluid-receiving element 12 . The fluid-receiving element is a micro-porous strip with one end connected to a fluidic circuit 21 and its other end connected to a fluidic circuit 22 comprising a sample fluid application region. There is a fluid injection location 13 along its length.
During use of a device comprising this injector, a sample fluid is applied to a sample fluid application region of the fluidic circuit 22 . An electrical connection is made to an external electrical control circuit through contact pads 5 and 7 . A fluid is applied to a fluid application region 20 of the device making electrical contact at contact location 6 of the electrode and making fluidic and electrical contact to the flow path element 1 at its fluid application end 2 . The fluid flows by capillary wicking into element 1 , filling it up to its effluent end 3 but not beyond. During this time, the fluid in the injector is fluidically isolated by air gap isolation element 14 from the fluid-receiving element 12 and all other fluidic circuits connected thereto and shown schematically as regions 21 and 22 in FIG. 1A . Instrument controlled power is applied to the electrodes. A voltage difference between the power electrode at contact location 8 and the grounded electrode at contact location 6 creates an electric field across the length of the fluidic element 1 between contact locations 6 and 8 . This field drives electro-osmotic flow when the micro-porous material of element 1 has a zeta potential. When its surface charge and zeta potential are negative a negative voltage at contact location 8 will propel fluid from the fluid application region 20 , through the injector's flow path and out of its effluent end 3 . As fluid flows out of the effluent end, it displaces the air gap 14 towards end 16 of air enclosure 15 and compresses it. Fluid is now in contact with receiving region 13 of fluid-receiving element 12 and it is pumped into the receiving element 12 and fluidic circuits 21 , 22 by pressurized chamber 15 . Reagents contained in the injected fluid may react with chemicals contained in the fluid-receiving element 12 or in the fluidic circuits connected thereto. Reagents in the injected fluid may be contained in the fluid introduced into the injector from the fluid application region 20 , or they may have been mobilized from dry reagent sources in the injector's path 1 when it was primed by capillary wicking of the fluid introduced from the application region 20 . Preferably the dry reagent is located in the field free location 4 . After instrument controlled pumping, the power on the electrode at contact location 8 is turned off or even reversed. Now the pressurized chamber 15 propels fluid back into pump element 1 and the pressurized air at end 16 of chamber 15 expands back to fill the chamber including the air gap region 14 , thus returning the injector to its initial isolated off-state.
In an alternative embodiment of an injector and fluid-receiving element, the air chamber 15 is vented to ambient at location 16 , for example through an orifice in cover 23 or along a conduit extending through sealing element 11 . In this case, when instrument controlled power is applied to the injector's electrodes, fluid flows out of the effluent end 3 of element 1 . The fluid displaces the air in the air gap region 14 to the vented end 16 of chamber 15 and fluid contacts the receiving region 13 of fluid-receiving element 12 . Because the chamber is vented to atmosphere it is not pressurized in this case, and fluid is not pumped into element 12 . However, there is diffusion of chemicals and reagents contained within the injector's pump fluid and the chemicals and reagents in the fluid-receiving region 13 of element 12 . After instrument controlled pumping the power on the electrode at contact location 8 is reversed until the injected fluid in the chamber has returned into the injector and drawn air back to the air gap region, thus returning the pump to its initial off state.
There are other possible configurations of an injector and fluid-receiving elements that utilize the above described injector. FIG. 2A-2S shows schematically some other ways of connecting an injector of the invention with fluid-receiving elements. In this figure there is shown a schematic injector comprising a sealed flow path, integral electrodes, a fluid application end and fluid application region and an effluent end with an air gap isolation member. These components are as described in FIG. 1 and are grouped in the dashed regions 100 , 101 and 102 of FIG. 2A-2S . There are four configurations of injector and fluid-receiving elements depicted in FIG. 2A-2H . An injector with an air chamber at its effluent may be connected to no fluid-receiving elements ( FIGS. 2A and 2E ), or it may be connected to an element of one of three types. It may be connected to a fluid-receiving element 118 which stands alone and is not fluidically connected to other fluidic circuitry ( FIGS. 2B and 2F ). It may be connected to a fluid-receiving element 110 , which is a flow path with one fluid-receiving end and another end connected to other fluidic circuitry 103 ( FIGS. 2C and 2G ). It may be connected to a fluid-receiving element 115 which is a flow path with both ends connected to fluidic circuitry ( 105 , 106 being connected at either end of 115 ) and a fluid-receiving location along its length. FIGS. 2A-2D show fluid-receiving elements connected to an injector at an enclosed air chamber 120 , while FIGS. 2E-2H show them connected at a vented air chamber 130 . FIG. 2D is identical to the configuration depicted in FIG. 1 .
An example of the configuration of FIG. 1 or 2 D is a device comprising a lateral flow strip for transport of sample and an injector for instrument controlled injection into the strip. In this case 115 is the lateral flow strip, 105 contains a sample application region and 106 contains a sample effluent region. Lateral flow strip 115 may contain a capture region along its length which region constitutes the signal generating micro-reactor, and injector 100 may be used to inject a wash fluid, a conjugate or an enzyme substrate into the strip and through the capture region, as required to perform a ligand-binding assay.
FIGS. 2I-Q show how two fluid-receiving elements can be connected to a single fluid injector. The schematics depict a connection of an injector to two fluid-receiving elements in parallel at an enclosed air chamber. Similar parallel connections of multiple receiving elements to an injector are also possible when the air chamber is vented but they are not shown in FIG. 2 .
FIGS. 2I , 2 J and 2 K show connection of an injector to a first stand-alone fluid-receiving element 118 and a second parallel connection to a fluid-receiving element of each of the three types. FIGS. 2L , 2 M and 2 N show connection to the receiving end of a first flow path element 110 there being a fluidic circuit 103 at its other end, and a parallel connection to a second fluid-receiving element of each of the three types. FIGS. 2O , 2 P and 2 Q show connection to a first flow path 115 whose two ends are connected to fluidic circuits 105 , 106 at a fluid-receiving location along its length, and a second parallel connection to a receiving element of each of the three types. It is clearly also possible to connect in parallel three or possibly more fluidic elements to a single injector, as might be necessary in some assay formats.
FIG. 2R depicts how multiple injectors may be connected to a single fluid-receiving element. In this schematic there is a fluid-receiving flow path 115 with fluidic circuitry 105 and 106 at its either end. There are three injectors 100 , 101 and 102 which inject fluids at three locations along the length of the element 115 . There is an enclosed air chamber at each of the injection locations 120 , 121 and 122 . The three ground electrodes of each of the three injectors may be connected independently from one another to each of three separate fluid application regions at the fluid application end of each injector element, as shown in FIG. 2R . More preferably, in FIG. 2S the three injector's ground electrodes are connected at one point to a single fluid application region that covers all three injectors' fluid application ends. This can be accomplished by a fluid application conduit.
An example of the configuration of FIGS. 2R and 2S is a device comprising a lateral flow strip for transport of sample and a multi-injector manifold for instrument controlled multiple fluid injections into the strip. In this case 115 is the lateral flow strip, 105 contains a sample application region and 106 contains a sample effluent region. Lateral flow strip 115 may contain a capture region along its length which capture region constitutes the signal generating micro-reactor. Injector 100 may be used to inject a fluid containing a reporter conjugate, injector 101 may be used to inject a wash fluid and injector 102 may be used to inject an enzyme substrate into the strip and through the micro-reactor region, as required to perform a sandwich type ligand-binding assay.
In general, a device of this invention comprises therefore at least one instrument controlled injector connected to a fluidic circuit through a fluid-receiving element according to any one of the configurations of FIG. 2 . The device further comprises a sample application region for introducing sample fluid into the device's fluidic circuit and at least one signal generating micro-reactor region. This micro-reactor region may be contained within the fluid-receiving element or the fluidic circuits connected thereto. A detector proximal to the signal generating micro-reactor measures the course of the reaction taking place in the micro-reactor which determines the concentration of an analyte contained in the sample fluid. During use, the device of any of the variants of FIG. 2 is inserted into a receiving orifice of a detection instrument comprising a planar slab with an embedded light detector connected to an instrument means. The slab also has embedded spring loaded electrical contacts with one end connected to an electrical circuit in an instrument means and the other end contacting the electrodes' contact pads when the device is inserted into the orifice of the detection instrument. The device in the receiving orifice of the detection instrument has the detector's slab co-planar with the device substrate 10 and in close proximity, with the light detector located proximal to the signal generating micro-reactor region of the device. The detector slab and the substrate 10 form part of a dark cavity which lets in no external light.
Devices such as the exemplar device of FIG. 1 and variants shown in FIG. 2A-2S were constructed on a standard circuit board supporting electrodes for supplying electrical power to the fluidic circuit. Devices were fabricated on planar insulating epoxy substrates 10 . The spaced apart electrodes were gold-plated copper electrodes which were 0.025 mm thickness copper plated with gold, fabricated in standard circuit board technology. Onto this was laminated a 0.025 mm thickness element 9 which was a silicone adhesive slab (Adhesives Research 8026) die cut from an adhesive sheet with openings over electrode contact locations 5 , 6 , 7 , 8 . The adhesive slab was assembled with its openings over the electrode contact locations resulting in a top surface that is approximately co-planar with the top surface of the metal of the electrode contact at each contact location. Micro-porous flow path elements 1 , 12 die cut from a sheet were each about 0.15 mm in thickness. Element 1 was about 1 mm wide at its effluent end. It could be a rectangle as shown in FIG. 1 in which case its fluid application end also was about 1 mm wide. It could be a trapezoid in which case its fluid application end would be wider.
We generally have preferred trapezoid pumps with input to effluent width ratio of about 4:1 because they are capable of delivering higher pump rates. When element 12 is used to transport fluid to adjacent fluidic circuits 21 , 22 , it could be a rectangular strip of about 1-2 mm in width as shown in FIG. 1 , although other shapes are possible depending on the specific performance requirement of the fluid-receiving element. When the fluid-receiving element is a micro-reactor, element 12 could be a square or a circular slab. Fluidic elements 1 , 12 were assembled over the adhesive slab 9 with an air gap 14 of about 0.5 to several millimetres separating the effluent end 3 of fluid injection element 1 from the fluid-receiving element 12 at location 13 . Depending on the type of experiment being performed, flow path element 1 , 12 may be a die-cut strip from a sheet of micro-porous material as received from the manufacturer, and may be pre-treated by soaking (for blocking or introduction of surface charge) or impregnated with reagents at specific locations along its length.
Numerous materials with different porosity and surface treatment for the receiving element were used as discussed further herein. For the fluid injector element, cellulose nitrate with 0.22 micrometer pore diameter as received from the manufacturer is preferred because it has a high surface charge as required for efficient electro-osmotic propulsion. Next, a second silicone adhesive slab 11 was assembled over the micro-porous flow path elements. The adhesive slab 11 was 0.15 mm thickness made by laminating three layers of 0.05 mm layers (Adhesives Research 7876) and was die-cut from a sheet. It covered element 1 along its length, (but did not cover its fluid application end 2 , the air gap region 14 or its effluent end 3 ), and it covered a portion of element 12 , (but not at its fluid-receiving region 13 or a region 16 adjacent to it). A mylar cover element 23 was die-cut from a sheet and assembled over the opening in second sealing element 11 defined by regions 3 , 4 , 13 and 16 of FIG. 1 , thus forming an enclosed air cavity 15
In the final assembly step, the planar composite of slabs was compressed (60 PSI, 50° C. for 2 minutes). In this step the adhesive in slab 11 sealed to the adhesive in slab 9 and the cover slab 23 , also sealing the elements 1 and 12 and importantly, with the sealant flowing around the element 1 and forming a perimeter seal in the region between the electrode contacts as is shown in the cross section BB′ of FIG. 1C .
Various configurations of devices of FIGS. 1 and 2 were used to study instrument-controlled fluid injection to a receiving element and fluidic circuitry connected thereto as is described below.
Electro-Osmotic Pumping of Fluid from an Injector
Different configurations of the components of the injector of FIG. 1 (and the equivalent injector 100 of FIG. 2 ) were investigated. To operate to the required specification the injector should have the following characteristics: 1. reproducible capillary fill from the dry state when a fluid is applied to its application end; 2. no flow beyond its effluent end when there is no power being applied to drive electro-osmosis; and 3. reproducible flow at a useful flow rate beyond its effluent end when power is applied to the integral electrodes. The injector's flow path element was investigated with respect to its composition: material, surface treatment, porosity and pore size and with respect to its shape and dimensions. Integral electrodes were investigated with respect to their contact location and contact area. The air chamber was investigated with respect to its cavity dimensions, air gap dimensions, venting configuration. The effect of the above design parameters on initial capillary fluid fill rate during pump priming, the effectiveness of the flow arrestment at the effluent end of the pump element during the priming step and the subsequent electro-osmotic pumping characteristics as they depend on the fluid flow resistance of the element they are pumping into was investigated.
Experiment 1: Injection into a Vented Channel
To investigate the injector's pumping characteristics with no fluidic load injectors with a vented air channel at their effluent end but with no other fluid-receiving elements were constructed. This configuration is depicted in the schematic FIG. 2E . The injector was first primed by applying an aqueous fluid to the fluid application end of the initially dry injector. Next, a voltage was applied between the integral electrodes and the volume flow rate was measured by measuring the length of fluid in the vent channel of known cross-sectional area at different times. From this the electro-osmotic mobility (EOM) was obtained.
Best performance was obtained with injector fluids comprising aqueous solutions of low conductivity: an electrolyte concentration of about 2 mM was preferred and 10 mM was the upper useful range. A micro-porous cellulose nitrate/acetate (Millipore MF membrane GSWP) having a porosity of 0.75 with 0.11 micrometer pore radius was used as the injector's flow path. There was an integral anode ground electrode in contact with the fluid application end of the injector and an integral cathode electrode along the length of the injector's micro-porous fluid path. Injection fluids were typically about 2 mM aqueous buffer solutions comprising N-[2-hydroxyethyl]piperazine-N′-[2-ethanesulfonic acid] (HEPES) or diethanolamine (DEA) buffers. At a fixed voltage in the range 0-60 volts the pump rate was stable to a few percent over hundreds of seconds. There was no visible gas bubble formation in the fluid stream. The effect of pH on pump rate was minimal in the range 7>pH>10. At higher concentration of electrolyte, the pump rate was lower. Above about 10 mM the injector drew too much electrical current and could not operate at elevated voltages because there was gas bubble evolution into the flowing fluid emanating from the cathode. The concentration of the injector fluid's electrolyte affects the pump in two ways. As the concentration is increased the ionic strength increases and the Debye screening length goes down. This in turn diminishes the zeta potential and thus the EOM as is known in the art. Also, a higher electrolyte concentration results in a higher electrical conductivity of the injector fluid. The result is that at a given applied pump voltage there is a higher current draw causing a larger electrode polarization. As the electrodes polarize, more of the applied voltage drops across the electrodes and less across the micro-porous flow path element, resulting in a lower pump rate. The addition of redox active molecules to the injector fluid to reduce electrode polarization was investigated, but these limit the generality of the pump because they can interfere with the biochemical reactions taking place in the downstream micro-reactor(s). There is no significant electrode polarization (or gas evolution at the electrodes) when the injector is operated with gold electrodes and an injector fluid containing less than about 10 mM buffer electrolyte and no redox additives.
Priming of Injector with Injector Fluid:
An initially dry micro-porous flow path element of an injector is primed when injector fluid is applied to the injector's fluid application end. The fluid fills the element to its effluent end by capillary wicking. Using the preferred flow path material, which is a micro-porous cellulose nitrate/acetate with 0.11 micrometers pore radius, in an injector with a 5 mm long flow path element the fill time is within about 50 seconds.
Integral Electrode Location:
Generally, acceptable performance was obtained whenever the anode was close to the fluid application end. The best performance was obtained when the anode was immersed in the fluid outside of the injector's micro-porous path beyond its fluid application end but in electrical contact with it. The cathode location could be anywhere along the length of the injector's micro-porous flow path up to its effluent end, but optimal was about half to three quarters along the length towards the effluent end. This left a field free region beyond the cathode at the effluent end for possible location of dry reagents. When the cathode was too close to the anode at the fluid application end the electrical current was too high, limiting the device to low voltage and low pump rate operation. The typical area of the electrode contacts was 0.5×5 mm for the anode and 0.5×1 mm wide for the cathode.
Flow Path Shape and Dimensions:
Both rectangular and trapezoidal injector flow paths were investigated. A typical rectangular flow path element was about 4.25 mm long by 1 mm wide and 150 micrometers thickness cellulose nitrate/acetate with 0.7 porosity and 0.11 micrometer pore radius. An injector constructed with this flow path with an anode beyond the fluid application end and a cathode 3 mm from the fluid application end (1.25 mm from the effluent end), was operated with 2 mM DEA injector fluid. The pump rate, which was linear with applied voltage, was 0.5 nanoliters/second/volt. At a nominal operating voltage of 40 volts the pump rate was 20 nanoliters/second. A typical trapezoidal flow path was about 4.25 mm long, 4 mm wide at its fluid application end and 1 to 1.5 mm wide at its effluent end. When operated with the same electrode location and injector fluid the pump rate, which was linear with voltage, was 1.1 nanoliter/second/volt. At a nominal operating voltage of 40 volts the pump rate was 45 nanoliters/second. We have preferred to use trapezoidal injectors because of their higher pump rate but with similar effluent end geometry as the rectangular injector. The size of the effluent end is constrained by the size of the receiving fluidic element.
Flow Path Material and Surface Treatment:
Micro-porous cellulose nitrate/acetate (Millipore MF membrane GSWP) with 0.11 micrometer pore radius was found to have a superior and consistent EOM of about 2.5×10−8 m2/volt-sec when used with 2 mM DEA injector fluid. This corresponds with the 1.1 (0.5) nanoliter/second/volt pump rate of the trapezoidal (rectangular) injector. Other investigated materials had lower or zero EOM. A surface pre-treatment of low EOM materials, for example a pre-soak in an anionic surfactant such as ammonium dodecylsulfonate followed by drying could introduce surface charge and enhance the EOM. However, it is preferred to avoid such treatments as the surfactant can be expelled along with the injected fluid into the fluid-receiving element and fluidic circuitry connected thereto, potentially causing a deleterious effect on biochemical reactions occurring therein. This was particularly noticeable with the luciferase reaction described later. Accordingly, because the cellulose nitrate/acetate cited above could be used as is, without surface modification, it was preferred for the injector's flow paths.
Experiment 2: Injection into an Enclosed Chamber
Injectors with an enclosed air chamber at their effluent end but with no other fluid-receiving elements were constructed to investigate the injector's pumping characteristics with infinite fluidic load. This configuration is depicted in the schematic FIG. 2A . First, the injector was primed by applying an aqueous fluid to the fluid application end of the initially dry injector. Next, a voltage was applied between the integral electrodes. Fluid was displaced from the injector's effluent end into the enclosed channel of initial volume V 1 and at P 1 =1 atmosphere. The air was compressed as the fluid filled the chamber until steady state when the fluid flow stopped. The new volume of air was V 2 <V 1 . The resulting pressure that stopped flow was calculated from Boyle's law to give P 2 =V 1 /V 2 . A micro-porous cellulose nitrate/acetate with 0.11 micrometer pore radius was used.
Pore Radius of Injector's Micro-Porous Flow Path:
Trapezoidal injectors (input end width 4 mm, effluent end width 1.5 mm, length 4.25 mm, thickness 0.15 mm) from micro-porous cellulose nitrate/acetate materials with 0.75-0.85 porosity and varying pore radii in the range 0.11 to 2.5 micrometers were constructed. Injectors were constructed with enclosed air chambers at their effluent ends. The pressure to stop flow at various pump voltages in the range 0-100 volts was measured. The pressure needed to stop flow increased approximately linearly with voltage. For small pore radius materials a larger back-pressure was required to stop flow as compared with the larger pore radius materials. An injector with a pore radius of 0.11 micrometers could pump against a back-pressure of 0.17 atmospheres/volt At a typical working voltage of 40 volts the back-pressure to stop injector flow was 7 atmospheres. For a 2.5 micrometer pore radius material the back-pressure to stop injector flow was 0.01 atmospheres/volt. At a typical working voltage of 40 volts the back-pressure to stop injector flow was now only 0.4 atmospheres.
Sealing of the Injector:
The quality of the perimeter seal of the injector is important in obtaining good injector flow rates. In the case of an improper seal an air channel at the perimeter of the injector's flow path along its length will result in back-flow through the channel driven by the pressure difference between the effluent end and the fluid application end of the injector during electro-osmotic pumping. The result is a less stable and lower than expected electro-osmotic pump rate.
Experiment 3: Injection into a Fluid-Receiving Element at an Enclosed Air Chamber
To investigate the pumping characteristics of an injector connected to a fluid-receiving element with a flow resistance injectors with an enclosed air chamber at their effluent end connected to a fluid-receiving strip element at a fluid-receiving location along its length were constructed. Both rectangular and trapezoidal injectors were investigated. The configuration of injector and fluid-receiving element is as depicted in the schematic FIG. 2D . The various steps in the operation of the injector of this configuration are depicted in FIG. 3A-3E . A first fluid was applied to the fluid application end of the initially dry strip ( FIG. 3A ). The strip was filled with the first fluid by lateral capillary flow ( FIG. 3B ). Next, the initially dry injector was primed by applying an aqueous fluid (2 mM DEA solution) to its fluid application end ( FIG. 3C ). The injector filled to its effluent end by capillary flow ( FIG. 3D ). A voltage was applied between the integral electrodes. Fluid was displaced from the injector's effluent end into the enclosed chamber of initial volume V 1 and at P 1 =1 atmosphere. The air in the enclosed chamber was compressed as the fluid filled the chamber until steady state when compression stopped ( FIG. 3E ). At this steady state there was flow of fluid along the fluid-receiving strip towards both of its ends, (fluid flowing towards regions 105 and 106 of FIG. 2C ), as shown in FIG. 3F . The new volume of air in the chamber was V 2 <V 1 . The resulting steady state pressure was calculated from Boyle's law to give the air chamber pressure P 2 =V 1 /V 2 . After the fluid injection step the voltage was switched off and the compressed air in the air chamber recovered to its position at the effluent end of the injector, thus fluidically and electrically isolating the injector fluid from the fluid in the fluid-receiving element ( FIG. 3G ).
For the configuration shown in FIG. 4 which shows a trapezoidal injector (inlet width 4 mm, effluent end width 1.5 mm, length 4.25 mm, thickness 0.15 mm) that used a micro-porous cellulose nitrate/acetate for the injector's fluidic path (porosity 0.7, pore radius 0.11 micrometer) and a micro-porous polyethersulfone fluid-receiving strip (1 mm wide by 9 mm long with a 1 mm long fluid-receiving region at a central location along its length and 4 mm length extending on either side of the fluid-receiving location, thickness 0.15 mm, with pore radius of 0.25 micrometers). The pressure at steady state flow increased linearly with applied voltage at 0.03 atmospheres/volt.
Injector's Specifications:
To better understand how the injector's performance depends on the injector's design parameters consider a model injector comprising an injector flow path that has been primed with fluid by capillary flow from its application end up to its effluent end. The injector flow path comprises a trapezoidal slab of length L, width w at its effluent end and W at its fluid application end, and height h of a micro-porous material of porosity ψ pore channel tortuosity τ and pore radius a. There is a first electrode at the injector's fluid application end (or in a fluid beyond the fluid application end but fluidically connected to it). There is a second electrode along the length of the injector's flow path at a distance l from the input and consequently there is a region whose length is L−l at the effluent end that is field-free. The flow rate Q of a fluid of viscosity η is given by
Q = ψ h ( W - w ) L τ ln ( W / w ) ( V μ eo - P a 2 8 η ) equation 1
which simplifies to equation 2 for a rectangular slab of width w
Q
=
ψ
hw
L
τ
(
V
μ
eo
-
P
a
2
8
η
)
equation
2
The first term is the electro-osmotic flow when V is the voltage applied along the length l and μ eo is the electro-osmotic mobility (EOM). The second term is the pressure driven flow when there is a pressure difference P across the length of the slab (positive P is a back-pressure that causes flow in the opposite direction to electro-osmotic flow). The electro-osmotic flow rate depends on the total slab length L and not on the electrode separation, but the electric current that the pump draws at the applied pump voltage increases as l decreases.
Pump Rate:
FIG. 5 shows the consolidated pump data for the trapezoidal injector and the rectangular fluid-receiving element of the FIG. 4 configuration and dimensions. The flow rate versus voltage with no load (vented operation) are shown as triangular data points. The pressure to stop flow versus voltage with infinite load (enclosed effluent chamber) are shown as rhombus data points. The pressure versus voltage during injection into a load are the square points.
The flow conductance of the injector GI and of the fluid-receiving load element GL was calculated using equations 3 and 4 respectively. These equations are obtained by differentiation of equation 1 and 2 for a trapezoidal injector and the rectangular load respectively.
G
I
=
ⅆ
Q
ⅆ
P
=
-
ψ
h
(
W
-
w
)
a
2
8
η
L
τ
ln
(
W
/
w
)
equation
3
G
L
=
-
ⅆ
Q
ⅆ
P
=
ψ
hwa
2
8
η
L
τ
equation
4
From these equations and the known porosity, pore radius and the element's dimensions shown in FIG. 4 an injector conductance of −6.4 nanoliters/second/atmosphere and the total load conductance of 27 nanoliters/second/atmosphere was determined. These calculated pump and load conductance lines are also shown in FIG. 5 . The fluidic equivalent circuit of the injector and fluid-receiving element is shown in FIG. 4 . From the graph of FIG. 5 it is possible to obtain the injection speed through any receiving fluidic element when connected to the injector, knowing its flow conductance. The location of intersection of the load conductance line with the injector conductance line at a given voltage indicates both the air pressure in the air chamber driving fluid flow through the receiving element and the rate of fluid flow through the element. The rate of flow through a load is given by the maximum pump rate at zero load (vented operation) multiplied by GL/(GL+GI). Whenever the injector's conductance is much smaller than the conductance of the fluid-receiving element (including the conductance of the fluidic circuits serially connected thereto), GI<<GL, the injector's pump rate will be close to the injector's maximal pump rate at zero load (vented operation) and the pump rate will be relatively independent of the value of the load conductance of the fluid-receiving element and fluidic circuitry connected thereto, particularly important in the case that the load conductance changes during the injection operation or from device to device. Preferred circuits of this invention therefore should be designed to operate close to this condition. To achieve this condition the injector's conductance, GI should be minimized by selecting a small pore radius material (symbol ‘a’ of equation 3), while the receiving element and fluidic circuits connected thereto should prefer a larger pore radius.
To further illustrate this point, consider the device of FIG. 4 and its equivalent circuit. The maximum pump rate with no load is reduced by a factor 27/(27+6.4)=0.81 with the load connected. Suppose the receiving fluidic element was initially filled by a sample fluid of variable viscosity in the range 0.001<η<0.002 Pa·s. The receiving element's conductance is 27 nanoliters/sec/atm. when η=0.001, while it is 13.5 nanoliters/sec/atm. when η=0.002. If the receiving element was initially filled with a sample of viscosity η=0.002 and it receives an injected fluid of viscosity η=0.001, the pump rate increases from 0.68 of its maximum rate to 0.81 of its maximum rate as the more viscous sample fluid is replaced by the less viscous injected fluid. The pump rate will similarly change from device to device as different sample fluids with differing viscosities are assayed. The reproducibility of the pump rate with variable load of a useful device will be determined by the requirements of a particular diagnostic assay format, but, typically for an injector connected to a receiving element which initially contains a sample fluid the injector's conductance should be less than about 0.05 of the receiving element's conductance. With GI=0.05GL the pump rate is 95% of the maximum pump rate in vented operation and quite invariant to changes in the load's conductance. For the injector of FIG. 4 with GI=6.4 the preferred minimum load conductance is therefore 128, the flow rate at the typical operating voltage of 40 volts is 44 nL/sec and the pressure in the air chamber driving flow through the load is 0.34 atmospheres above atmospheric pressure.
A useful injector pump speed is determined by the time to fill a fluid-receiving element in a diagnostic application of the device, being specified by the dimensions of the fluid-receiving element and on the time allowed to fill the receiving element as determined by the timing requirements for a particular assay format. The dimensions of a typical fluid-receiving element are 10 mm length×1 mm width×0.15 mm height and 0.7 porosity, for a volume of about 1000 nL. A representative useful pump speed is one at which the time to fill the typical fluid-receiving element is about 50 seconds or less i.e. a useful pump speed of at least 20 nL/s. Short path length pumps (L<3 mm) can operate to this specification at low voltage (V<12 volts). Longer path length pumps (3 mm<L<6 mm) require somewhat larger pump voltages (12<V<25 volts). Longer path lengths still (6 mm<L<12 mm) require even larger voltages (26<V<50 volts). A wider pump will deliver a higher flow rate, but if the dimensions of the effluent end of the pump are constrained by the dimensions of the fluid-receiving element then the optimal high speed pump is a trapezoid, being wide at its fluid application end and narrower at its effluent end.
Leakage Rate:
An injector of this invention can be characterized as being in one of two states: an off-state when no pump power is applied and an on-state when pump power is applied to the integral electrodes. In the initial off-state the injector is isolated from other fluidic elements by the air gap isolation means at its effluent end. In the ideal initial off-state there is no leakage flow across the air gap isolation means. In the on-state there is fluid flow beyond the injector's effluent end. In the ideal on-state the fluid flow rate should be dependent only on the applied pump power and not on the flow resistance of the fluid-receiving element to which the injector is connected, nor on the pressure difference across the input and effluent ends of the injector as may arise during the normal operation of the pump. In the ideal off-state after pumping there should be no further leakage-flow into or from the injector so that the position of the injected fluid in downstream fluidic elements such as the micro-reactor is stable for the duration of the off-state.
The magnitude of the injector's off-state leakage rate determines the effectiveness of the injector's air gap isolation means during the use of the fluidic circuit of the device before the injector is used, and the positional stability of the fluid after pumping by the injector. The air gap isolation means is sized so that the total amount of fluid that might leak in or out through the injector' effluent end during the time that the injector is in its initial off-state (during which time the injector is required to be isolated from neighbouring fluid-receiving elements) is insufficient to cause a fluid to traverse the air gap isolation means (and contact the neighbouring fluidic element). While it might be possible to isolate a very leaky pump by a large volume air gap, the negative consequence of this is that there is an extra amount of time taken to fill a large air gap volume when operating the injector in its on-state. An injector's leakage rate is determined by the injector's flow resistance and the pressure difference across the injector during its off-state as may arise during the normal operation of the fluidic circuit incorporating the injector. A pressure difference may be created during fluid flow through neighbouring fluidic devices (which may be typically of the order of 10,000 Pascal or 0.1 atmospheres above ambient when an injector is connected to fluid-receiving elements that are being driven by pressurized flow, for example by a neighbouring injector) or when there is a capillary wetting force due to interaction between the injector's fluid and active surfaces close to its effluent end (which are smaller, being typically 100 Pascal).
Using a diagnostic device of the invention incorporating an injector there is a period of time after the injector has been primed with fluid during which time it is isolated, this period being typically up to about 200 seconds but sometimes being as long as 500 seconds. During this time period it is required that the isolation means at the injector's effluent end does not fill when the injector's flow rate is its off-state leakage flow rate. It is further required that, during the subsequent pumping when the injector is in its on-state that the isolation means can be traversed in typically only about a few seconds or less by fluid being electro-osmotically injected to an adjacent fluid-receiving element. For example if it is required to inject 1000 nanoliters of fluid into a typically dimensioned fluid-receiving element in about 50 seconds or less, corresponding to a typical pump rate of 20 nanoliters/second, and when the air gap is about 10% of the fluid-receiving element's volume (also a typical value) the air gap is traversed in 5 seconds in the on-state. Thus, for a useful injector, the ratio of the on state flow to the off state leakage flow should be of the order of 200/5=40 or larger, but at a minimum it should be greater than 20. In the more general case the specification for the ratio of flow rate to leakage rate will be larger if the initial isolation time period is longer. For example for an isolation time of 500 seconds (say for example the time of an extended capture step taking place in a micro-reactor preceding a fluid injection step from an injector) the ratio of flow rate to leakage rate must be 100 for the same fluid-receiving element and air gap isolation means geometry. The off-state leakage after pumping can be determined in a similar fashion. If the volume of fluid in the fluid-receiving element that fills in 50 seconds during on-state pumping must be stable to about 10% over the duration of 200 seconds of an incubation step when the pump is in the off-state, the ratio of flow rate to leakage rate must be 40. For 5% stability the ratio should be 80. In conclusion, an injector of this invention must have a flow to leakage rate of at least 20 to be marginally useful and 40 for a typical application and 100 for an extreme case.
The ratio of the on state to off-state flow is derived from equation 1 and given by the equation below
Q
Q
V
=
0
+
1
=
8
η
V
μ
Pa
2
equation
5
This ratio depends on the pore radius a of the micro-porous injector flow path element, the pressure difference P across the injector that may arise during normal operation as well as on the normal operating pump voltage V. The injector's leakage was rated to a pressure difference of 100 Pa (10−3 atmospheres or about 1 cm head of water) when they are connected to a fluid-receiving element at a vented air chamber and 10,000 Pa (0.1 atmospheres) when they are connected to a fluid-receiving element at an enclosed air chamber and the receiving element supports pressure driven flow. In the table shown below we have calculated from equation 2 the critical pore radius and operating voltage required to achieve a flow rate ratio at its typical operation specification of 40 and at a value of 100 representing an extreme case specification requirement, for the two pressure ratings
η
Pa · s
0.001
μ eo
m 2 /V · s
2E−08
P = 100
V volts
1
5
9
12
40
100
20,000
50,000
Q/Q v=0 = 40
a μ m
0.20
0.45
0.60
0.69
1.3
2.0
28
45
Q/Q v=0 = 100
0.13
0.28
0.38
0.44
0.8
1.3
18
28
P = 10000
V volts
1
5
9
12
40
100
20,000
50,000
Q/Q v=0 = 40
a μ m
0.02
0.04
0.06
0.07
0.13
0.20
2.8
4.5
Q/Q v=0 = 100
0.01
0.03
0.04
0.04
0.08
0.13
1.8
2.8
This table indicates that an injector with a vented effluent, using a material with EOM=2×10−8 m2/volt-second operating with an aqueous injection fluid with viscosity 0.001 Pascal-seconds, when specified to operate at an on-state to off-state flow ratio of 40 (100) and operating against a 100 Pascal pressure difference, must have a pore radius of less than about 2.0 (1.3) micrometers to operate at a usefully low voltage of less than 100 volts, and preferably less than 0.7 (0.4) micrometers for 12 volts battery operation, and less than 0.4 (0.3) micrometers for 5 volts operation. An injector with an enclosed air chamber at its effluent experiencing 10,000 Pascals pressure difference and operating at a typical 40 volts requires a material with a pore radius of about 0.13 micrometers or less.
The small pore sizes required for injectors of this invention are typically not encountered in the micro-porous materials used in standard lateral flow diagnostic devices, nor in the open channel configuration of electro-osmotic pumps of the lab-on-a-chip technology. An injector constructed with a 28 micrometer radius open channel, as would be typical in a micro-fluidic device constructed in conventional lab-on-a-chip technology, would need to operate at 20,000 volts to achieve the typically required flow rate ratio of 40 and at 50,000 volts to achieve 100 . Thus, standard open-channel pumps of the lab-on-a-chip prior art, because they are susceptible to leakage flow in the off-state, cannot be valved by a passive valving means using an air gap as described in the current invention, rather they must be valved by an active closure means.
The experimental data generally support the model calculations shown above. There is consistently lowest leakage from small pore radius injector materials. Off-state isolation of injectors with pore radius larger than a few micrometers was poor, particularly when the air chamber's surfaces close to the effluent end of the injector were active or when there was a surfactant in the injector fluid.
Priming of Injector with Fluid from Integral Reservoir
The fluidic module of the invention comprising injectors with integral electrodes and fluidic circuits connected thereto can be incorporated into a plastic card-housing also comprising an integral sealed fluid reservoir containing an injector priming fluid. The card-housing with fluidic module and integral fluid reservoir now comprises a one-step device with all reagents required for the assay being contained within a single integral unit. The fluidic module of the invention can be constructed on a standard printed circuit board substrate as described in the schematic configurations of FIGS. 1-4 . In this case the integral electrodes' electrical contact locations to external contacting means are on the same side of the module's substrate as the fluidics. The fluidic module can also be constructed on a two sided flex circuit substrate, which substrate has through-substrate electrical connection vias, so that the fluidic circuitry can be constructed on the upper surface of the flex substrate and the contact locations to external contact means are on the lower surface. This is the preferred construction when incorporating the fluidic element into a card housing of the dimensions of a credit card, as shown schematically in FIGS. 6 and 6A .
The device of FIG. 6 is a top view schematic of a credit card sized diagnostic card with a fluidic module and a sealed fluid reservoir embedded therein. FIG. 6A shows side view schematics through sections AA′ and BB′ of FIG. 6 . The fluidic module has the same fluidic configuration as depicted in the schematic FIG. 2S , except the injectors are trapezoidal and the integral electrodes are connected through the substrate to external contacting means on the opposite side of the substrate to the fluidics. The diagnostic card comprises a molded plastic card housing 601 . The molded housing has a fluid reservoir cavity 604 which is lined with an upper and lower polyethylene film coated aluminum foil liner. The cavity contains an aqueous buffer of low conductivity. The reservoir fluid is hermetically sealed by fusing the polyethylene coatings of the aluminum liners. The card housing also comprises a trough 603 with an input end located at a valve means 606 and an effluent end 605 with an air vent 613 . The card housing further comprises a cavity 602 for accepting the fluidic module 600 .
The fluidic module 600 comprises a module substrate of epoxy foil 620 with gold coated copper metallization on both sides. On the upper fluidic side of the module's substrate the metal has been formed into integral electro-osmotic pumping electrodes 623 and 624 , 624 A, 624 B for contact to the injectors. On the lower side the metal has been formed into contact pads 621 and 622 , 622 A, 622 B for contacting to an external electrical contact means. There are four metal-plated holes (two of which are 625 , 626 shown in FIG. 6A ) through the epoxy substrate which electrically connect electrodes on the upper side with contact pads on the lower side. The epoxy module with formed electrodes is made using standard flex circuit technology known in the art. There is a first sealing means 627 which is a die-cut adhesive element located on the epoxy modules upper surface. Element 627 covers the module surface except at locations 623 , 624 , 624 A and 624 B where the integral electrodes contact the injector's fluidic elements. There is a micro-porous strip element 629 over the first sealing layer. Element 629 has a sample application end 640 and a fluid collection element 641 of known fluid fill volume at its effluent end. There are also three micro-porous injector path elements 628 , 628 A and 628 B whose effluent ends are separated from the strip element 629 by air gaps at three fluid-receiving locations along the length of the strip 629 . The injectors' path elements are trapezoidal with a wide fluid application end and a narrow effluent end. A second sealing element 630 covers the micro-porous fluidic elements except at their fluid application and effluent ends, and except at the air chambers including the air gaps and fluid-receiving regions of 629 at the effluent ends of the injectors. A perimeter seal is formed around the micro-porous elements when the sealing means 627 and 630 are compressed around them.
In the final assembly the fluidic module 600 is inserted into housing cavity 602 and sealed to it. The card is further sealed to an upper die-cut laminate 610 and a lower die-cut laminate 611 . In this step the housing element encloses the air chambers at the effluent ends of the injectors on the fluidic module and it encloses the molded trough 603 in the plastic card to form a fluidic channel.
During use a sample fluid is applied to the sample application end 640 of element 629 and it flows along the strip past a capture region 660 and into the fluid collection element 641 . An analyte in the sample fluid is captured at the capture location. Next, the card is inserted into the card orifice of an instrument means. The card orifice has a planar surface comprising a slab with elements for engaging with the card on the card's lower surface. Upon card insertion the card's lower surface is parallel to the slab surface of the instrument's card insertion orifice and separated from it. The slab has embedded spring loaded electrical contacts proximal to the module's electrical contact pads and two elevated regions proximal to the card's fluid reservoir 604 and valve 606 when the card is inserted into the card orifice. When in the orifice the card is next brought into contact with the slab. Spring-loaded contact electrical elements now make contact with the module's electrical contact pads. A first slab elevation makes contact with the card at location 650 and pushes the plug 606 through the hole 607 in the card housing, thus detaching the top lamination seal at locations 608 . A second slab elevation makes contact with the card at location 651 , depressing the fluid reservoir and displacing fluid through detached seal region 608 into the channel 603 . The fluid is displaced to the effluent end 605 of the channel filling the region 603 A of the channel. Region 603 A is the injectors' fluid application region. The fluid at this location now fills the injectors from their fluid application end to their effluent end by capillary wicking. Dry reagents in the injectors' effluent ends dissolve upon capillary filling. An instrument controlled voltage is applied to the first injector electrode 624 A relative to the common ground electrode 621 contacting the fluid application region 603 A, causing a first fluid containing a dissolved enzyme-labelled conjugate to be electro-osmotically injected along strip 629 including through capture region 660 to an effluent channel 670 . The labelled conjugate is captured by the analyte at 660 thus labelling the captured complex. A second instrument controlled voltage is applied to the second injector electrode 624 , causing a second wash fluid to be electro-osmotically injected along the strip including through the capture region. The wash fluid removes excess unbound conjugate. A third instrument controlled voltage is applied to the third injector electrode 624 B, causing a third fluid containing an enzyme substrate to be electro-osmotically injected along the strip including through the capture region. When the substrate is a luminogenic substrate the reaction of the substrate with the enzyme label at location 660 creates a light signal which is measured by a light detector in the instrument means which is proximal to location 660 of the card, which light signal is proportionate to the concentration of the analyte in the sample.
Experiment 4: Electro-Osmotic Injection of Luciferase Chemiluminescence Reagents
In this experiment an injector configuration similar to the one depicted in FIG. 2Q except with a vented air chamber was used. In this device the injector was a trapezoidal element with dimensions 1 mm at the effluent orifice, 4 mm at the input orifice and 4.25 mm long by 0.15 mm thick, comprising micro-porous cellulose nitrate/acetate with 0.7 porosity and 0.11 pore radius. There was a vented air chamber which was a 1 mm wide channel at the injector's effluent end including a 0.5 mm long air gap separating the effluent end from the first fluid-receiving element. The first fluid-receiving element was a lateral flow strip with a centrally located fluid-receiving region, a sample application end and an effluent end. This element was 0.15 mm thickness by 1 mm wide by 8 mm long micro-porous polyethersulfone with 0.7 porosity and 0.25 micrometer pore radius. There was a second fluid-receiving element separated from the first by another 0.5 mm air gap. The second fluid-receiving element was a reaction region comprising a polyethersulfone pad 0.15 mm in thickness by 2 mm square that had been impregnated with a solution comprising ATP, luciferase, magnesium ion and buffers and allowed to dry. Assay reagents were obtained from Sigma Corporation.
The device was inserted into the insertion orifice of the instrument means A sample fluid containing luciferin to be assayed was applied to the fluid-receiving end of the first fluid-receiving element, and a injector priming fluid comprising 2 mM aqueous DEA to the fluid application region of the injector. The fluids filled the two elements up to their effluent ends. When each element was filled with fluid an instrument controlled voltage (40 volts) was applied to the injector's integral electrodes and fluid was pumped out of the effluent end of the injector (at 45 nanoliters/second). In this first injection step the injected fluid flowed for a period of time (about 20 seconds) sufficient for it to flow over the fluid-receiving region of the first fluid-receiving element and cover it, but not as far as the second fluid-receiving element, at which time the injector voltage was turned off. At this time the luciferin in the fluid-receiving region of the first fluid-receiving element diffused into the injected fluid in contact with it. In a second injection step applying a voltage (40 volts) to the injector for a time period of 20 seconds caused the fluid to move further so that it was now located over the second fluid-receiving element. There was a reaction between the luciferin in the injected fluid with luciferase in the second fluid-receiving element to generate a light signal measured by a light detector (5 mm×5 mm area photodiode with an amplification of 109 volts output per amp of photocurrent: from EOS Corporation) proximal to the second fluid-receiving element. A batch of identical diagnostic devices was used to test luciferin samples at various concentrations prepared by serial dilution in buffer. The number of moles of luciferin in the assay reaction was the concentration multiplied by the fluid volume of the injector fluid-receiving region of the sample strip.
The dose response curve of moles of luciferin versus light signal was linear over the dose range 6×10 −14 to 6×10 −11 moles, with a sensitivity of 4 mV of detector output per picomole of luciferin. This exemplar experiment was used determine the detection sensitivity of the second step of a two step assay format. The two step assay format will use an alkaline phosphatase label in a sandwich assay in which the labelled analyte complex is formed in a capture region of the sample fluid strip and in a first step luciferin phosphate substrate is electro-osmotically injected into the capture region producing luciferin. In a second step the luciferin is transported to the second fluid-receiving element where it reacts with luciferase to produce a detectable light signal. Based on the detector baseline 2 SD variability of 8 microvolt a limit of detection of 2×10 −15 moles of luciferin can be estimated. For an alkaline phosphatase label producing 1000 moles/sec of luciferin from luciferin phosphate in excess we estimate a limit of detection of 2×10 20 moles of label with 100 seconds of incubation. A volume of 10 microliters of a sample fluid containing an analyte at a concentration of 2×10 −15 M when labelled with one alkaline phosphatase molecule per analyte molecule contains 2×10 −20 moles of label. When the analyte is completely captured at the capture site there will be 2×10 −20 moles of captured alkaline phosphatase. The limit of detection determined by the detector sensitivity for a 10 microliter sample volume is thence a concentration of about 2×10 −15 M.
Experiment 5: Electro-Osmotic Injection of Dioxetane Substrate for Alkaline Phosphatase Chemiluminescence
In this experiment, an injector configuration similar to the one depicted in FIG. 2I except with a vented air chamber, was used. In this device the injector was a trapezoidal element with dimensions 1 mm at the effluent orifice, 4 mm at the input orifice and 4.25 mm long by 0.15 mm thick, comprising micro-porous cellulose nitrate/acetate with 0.7 porosity and 0.11 pore radius. There was a vented air chamber which was a 1 mm wide channel at the injector's effluent end including a 0.5 mm long air gap separating the effluent end from the first fluid-receiving element. The first fluid-receiving element was a dry reagent application region containing a luminogenic dioxetane substrate for alkaline phosphatase (CDP-star obtained from Tropix Inc.). There was a second fluid-receiving element separated from the first by another 0.5 mm air gap. The second fluid-receiving element was a lateral flow strip with a centrally located fluid-receiving region, a sample application end and an effluent end. This element was 0.15 mm thickness by 1 mm wide by 8 mm long micro-porous nylon with 0.7 porosity and 0.25 micrometer pore radius. The element had been treated by blocking with BSA according to standard manufacturer's procedures prior to assembly in the device.
The device was inserted into the insertion orifice of the instrument means Sample fluid containing alkaline phosphatase to be assayed was applied to the fluid-receiving end of the second fluid-receiving element, and an injector priming fluid comprising 2 mM aqueous DEA to the fluid application region of the injector. The fluids filled the two elements up to their effluent ends. When each element was filled with fluid an instrument controlled voltage (40 volts) was applied to the injector's integral electrodes and fluid was pumped out of the effluent end of the injector at 45 nanoliters/second. In this injection step the injected fluid flowed for a period of time (15 seconds) sufficient for it to flow over the first fluid-receiving element and cover it, at which time the injector voltage was turned off. At this time, the luminogenic dioxetane substrate in the first fluid-receiving element dissolved into the injected fluid in contact with it. In a second injection step, applying a voltage (40 volts for 20 seconds) to the injector caused the fluid to move further so that it was now located over the second fluid-receiving element. There was a reaction between the dioxetane substrate in the injected fluid with alkaline phosphatase in the second fluid-receiving element generating a light signal measured by a light detector (5 mm×5 mm area photodiode with an amplification of 109 volts output per amp of photocurrent: device obtained from EOS Corporation) proximal to the second fluid-receiving element. A batch of identical diagnostic devices was used to test alkaline phosphatase samples at various concentrations prepared by serial dilution in buffer. The number of moles of alkaline phosphatase in the assay reaction was the concentration multiplied by the fluid volume of the injector fluid-receiving region of the sample strip.
The dose response curve of moles of alkaline phosphatase versus light signal was linear over the dose range 1×10 −14 to 1×10 −18 moles, with a sensitivity of 100 μV of detector output per attomole of alkaline phosphatase. This exemplar experiment was used determine the detection sensitivity of an alkaline phosphate label in a sandwich type ligand-binding assay. Based on the detector baseline 2SD variability of 5 microvolt we estimate a limit of detection of 5×10− 20 moles of alkaline phosphatase, or 5×10− 15 M in a 10 μL sample volume.
Experiment 6: Capture of Biotin-Conjugate to an Alkaline Phosphatase Label at a Streptavidin Capture Site and Signal Development Using an Electro-Osmotically Pumped Dioxetane Substrate.
This is an example of a ligand binding assay performed in a lateral flow strip with an injector for supplying luminogenic substrate. In this experiment the configuration of the device is similar to the one depicted in FIG. 2I . The injector was a trapezoidal element with dimensions 1 mm at the effluent orifice, 4 mm at the input orifice and 4.25 mm long by 0.15 mm thick, comprising micro-porous cellulose nitrate/acetate with 0.7 porosity and 0.11 pore radius. There was a vented air chamber which was a 1 mm wide channel at the injector's effluent end including a 0.5 mm long air gap separating the effluent end from the first fluid-receiving element. The first fluid-receiving element was a dry reagent application region containing a luminogenic dioxetane substrate for alkaline phosphatase (CDP-star obtained from Tropix Inc.). There was a second fluid-receiving element separated from the first by another 0.5 mm air gap. The second fluid-receiving element was a lateral flow strip with a centrally located fluid-receiving region, a sample application end and an effluent end. This element was 0.15 mm thickness by 1 mm wide by 8 mm long micro-porous nylon with 0.7 porosity and 0.25 micrometer pore radius. The element was first treated by applying streptavidin to a 1 mm long capture location centrally located along the length of the strip (by impregnating 600 nanoliters of a solution containing 10 mg/liter) then treated by blocking with SUPERBLOCK (Pierce Biotechnology Inc) according to manufacturer's recommended procedures prior to assembly in the device.
The device was inserted into the insertion orifice of the instrument means. 6 microliters of a sample fluid containing biotin conjugated with an alkaline phosphatase label at a concentration to be assayed (in the range 0.1 to 50 pM) were added to the fluid-receiving end of the second fluid-receiving element, and an injector priming fluid comprising 2 mM aqueous DEA was applied to the fluid application region of the injector. The fluids filled the two elements up to their effluent ends. When each element was filled with fluid an instrument controlled voltage (40 volts) was applied to the injector's integral electrodes and fluid was pumped out of the effluent end of the injector at 45 nanoliters/second. In this injection step the injected fluid flowed for a period of time (15 seconds) sufficient for it to flow over the first fluid-receiving element and cover it, at which time the injector voltage was turned off. At this time the luminogenic dioxetane substrate in the first fluid-receiving element dissolved into the injected fluid in contact with it. In a second injection step, applying a voltage (40 volts for 20 seconds) to the injector caused the fluid to move further so that it was now located over the second fluid-receiving element. There was a reaction between the dioxetane substrate in the injected fluid with alkaline phosphatase in the capture complex in the second fluid-receiving element generating a light signal measured by a light detector (5 mm×5 mm area photodiode with an amplification of 109 volts output per amp of photocurrent: device obtained from EOS Corporation) proximal to the second fluid-receiving element. A batch of identical diagnostic devices was used to test samples of biotin conjugated to alkaline phosphatase at various concentrations prepared by serial dilution in buffer. The assay gave a linear response with 100 microvolts of diode signal per picomolar concentration of biotin. The limit of detection determined by the detector's baseline 2 standard deviation variability of 5 microvolts was determined to be a concentration of 5×10 −14 M.
Experiment 7: Capture of Biotin Conjugated to an Alkaline Phosphatase Label at a Streptavidin Capture Site and Signal Development Using an Electro-Osmotically Pumped Dioxetane Substrate
This is a second configuration of an exemplar ligand binding assay performed in a lateral flow strip with an injector for supplying luminogenic substrate. In this experiment the configuration of the device is similar to the one depicted in FIG. 2I . In this device the injector was a trapezoidal element with dimensions 1 mm at the effluent orifice, 4 mm at the input orifice and 4.25 mm long by 0.15 mm thick, comprising micro-porous cellulose nitrate/acetate with 0.7 porosity and 0.11 pore radius. There was an enclosed air chamber at the injector's effluent end at the location of connection with the two fluid receiving elements. This air chamber was a 0.6 mm wide by 200 micrometers high channel connected at the injector's effluent end traversing the two fluid receiving elements and terminating in an enclosed chamber which was 2 mm wide by 10 mm long by 200 micrometers high. There was a 0.5 mm long air gap separating the injector's effluent end from a 0.6 mm wide by 1.5 mm long first fluid receiving element. The first fluid receiving element was a dry reagent application region containing a luminogenic dioxetane substrate for alkaline phosphatase (CDP-star obtained from Tropix Inc.). There was a second fluid receiving element separated from the first by another 0.5 mm air gap. The second fluid receiving element was a lateral flow strip with a centrally located fluid receiving region, a sample application end and an effluent end. This element was 0.15 mm thickness by 2 mm wide by 11 mm long micro-porous nylon with 0.7 porosity and 5 micrometer pore radius (Osmonics: Magna membrane). The element was first treated by applying streptavidin to a 2 mm wide by 1 mm long capture region located along the length of the strip at a location in the strip between its central fluid receiving region and its effluent end (by impregnating 600 nanoliters of a solution containing 10 mg/liter) then treated by blocking with Superblock (Pierce Biotechnology Inc) according to the manufacturer's recommended procedures prior to assembly in the device.
The device was inserted into the insertion orifice of the instrument means. 6 microliters of a sample fluid containing biotin conjugated with an alkaline phosphatase label at a concentration to be assayed (in the range 0.1 to 50 pM) were applied to the fluid receiving end of the second fluid receiving element, and an injector priming fluid comprising 2 mM aqueous DEA to the fluid application region of the injector. The fluids filled the two elements up to their effluent ends. As sample fluid filled the second fluid receiving element, the fluid flowed over the capture location of the strip and the biotin with alkaline phosphatase conjugate was captured at the capture location. When each element was filled with fluid an instrument controlled voltage (40 volts) was applied to the injector's integral electrodes and fluid was pumped out of the effluent end of the injector at 45 nanoliters/second. In this injection step the injected fluid flowed for a period of time (15 seconds) sufficient for it to flow over the first fluid receiving element and cover it, at which time the injector voltage was turned off. At this time the luminogenic dioxetane substrate in the first fluid receiving element dissolved into the injected fluid in contact with it. In a second injection step applying a voltage (40 volts for 20 seconds) to the injector caused the fluid to move into the second fluid receiving element and through it towards its effluent end so that it was now located in the capture region of the strip. There was a reaction between the dioxetane substrate in the injected fluid with alkaline phosphatase in the capture complex in the second fluid receiving element generating a light signal measured by a light detector (5 mm×5 mm area photodiode with an amplification of 1010 volts output per amp of photocurrent: device obtained from EOS Corporation) proximal to the second fluid receiving element. A batch of identical diagnostic devices was used to test samples of biotin conjugated to alkaline phosphatase at various concentrations prepared by serial dilution in buffer. The assay gave a linear response with 243 femtoamps of diode signal per picomolar concentration of biotin. The limit of detection determined by the detector's baseline 2 standard deviation variability of 1 femtoamp was determined to be a concentration of 4×10−15 M.
The above-described embodiments of the present invention are intended to be examples only. Alterations, modifications and variations may be effected to the particular embodiments by those of skill in the art without departing from the scope of the invention, which is defined solely by the claims appended hereto.
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Devices with lateral flow elements and integral fluidics are disclosed. The integral fluidics consist of injector pumps comprised of fluidic elements under instrument control. The fluidic element of an injector pump is fluidically connected to lateral flow elements and can be used to control fluid entry into containment chambers referred to as micro-reactors. The lateral flow elements comprise conductor elements that can be used for sample application and transport of analyte contained in the sample to the micro-reactor. Fluidic transport through the fluidic element of the injector pump is under instrument-control. Both the lateral flow element and the fluidic element may contain chemical entities incorporated along their length. The chemical reactions that can be used for analyte detection using the devices are described. Also described are methods of manufacture of these devices.
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